Irmhs Unit 5

Industrial Robotics and Material Handling System
Prabandh CHAKRABORTY
1
➢Unit-5: Applications of Robots in Manufacturing
➢Manufacturing Robots
❑Welding Robots
❑Casting Robots
❑Coating Robots
❑Painting Robots
❑Deburring Robots
➢Material Handling and Assembly Robots
❑Pick and place Robot
❑Palletizing Robot
❑Packaging Robot
❑Assembly Robot
➢ Robots For Inspection
❑ Robotic vision systems
❑ Image Processing and Analysis
❑ Object recognition and categorization
❑ Depth measurement
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Manufacturing Robots
3
➢ Welding Robots:
“As the name connotes, robotic welding is welding automation that
uses a welding robot arm to weld.”
❑ In this type of welding, the robot moves the torch along the joint
to weld the pieces together.
❑ Compared to manual welding, robotic welding is faster and has
higher productivity. This is because the robot doesn't need to
take breaks.
❑ The welding cost per piece also decreases since the welding
robot can produce more welded parts than its human
counterpart.
4
➢ Welding Robots:
❑ Based on level of automation used in robots:
1. Semi-automatic welding
2. Automatic welding
❑ Based on type of welding used in robots:
1. Arc welding robot
2. Spot welding robot
3. Laser welding robot
4. Plasma welding robot
5
➢ Welding Robots:
❑ Based on level of automation:
1. Semi-automatic welding robot:
❖ In a semi-automatic robotic welding system, an operator enters the
robot cell, and removes the completed weld.
❖ The operator then positions the next pieces for the robot to weld.
2. Automatic welding robot:
❖ In an automatic robotic welding system, parts are fed in either a
conveyor or a magazine.
❖ They are then clamped in position by an automated clamp.
❖ When the welding is over the part is passed on via material handling
system like conveyor or carrier monorail.
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➢ Welding Robots:
❑ Based on level
of automation:
1. Semi-automatic
welding robot:
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➢ Welding Robots:
❑ Based on level of
automation:
2. Automatic welding
robot:
8
➢ Welding Robots:
1. Arc Welding Robot:
❖ Principle of Arc Welding: Arc welding is a type of welding process using an electric arc to
create heat to melt and join metals. A power supply creates an electric arc between a
consumable or non-consumable electrode and the base material using either direct (DC)
or alternating (AC) currents.
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➢ Welding Robots:
❖ Principle of Robotic Arc Welding: robotic arc welding system is formed by two
subsystems: the welding equipment delivering the energy from the welding power source
to the workpiece, and the robot providing relative positioning of the heat source and the
workpiece.
❖ Equipment in arc welding using robots:
― A typical robot cell consists of a robot with its control equipment, a manipulator for the
workpiece, a welding power unit and other welding equipment.
― Normally six-axis industrial robots comprising a three-axis lower arm and a three-axis
manipulators are used, since they enable the welding torch mounted at the manipulator
to achieve all the positions necessary for three-dimensional welding. The manipulator not
only ensures that the robot can reach all the joints, but also to ensure that welds can be
carried out in the best position.
― The manipulator may be a two-station interchange type, so that the operator can load and
unload jigs while the robot is welding, as shown in next slide.
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➢ Welding Robots:
❖ Equipment in arc welding using robots:
❖ Many robot manufacturers have recently developed arc welding-specific robots, which are
smaller and less expensive. Another recent development in welding robotics has been the
introduction of seven-axis robots, which feature an additional axis in the lower arm
providing additional flexibility and saving floor space
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➢ Welding Robots:
❑ Based on type of
welding used in robots:
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➢ Welding Robots:
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➢ Welding Robots:
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➢ Welding Robots:
2. Spot Welding Robot:
❖ Principle of Spot Welding:
― Spot welding (also known as resistance spot welding) is a resistance welding process. This
welding process is used primarily for welding two or more metal sheets together by
applying pressure and heat from an electric current to the weld area.
― The process involves applying pressure and heat to the weld area using shaped alloy copper
electrodes which convey an electrical current through the weld pieces.
― The material melts, fusing the parts together at which point the current is turned off,
pressure from the electrodes is maintained and the molten “nugget” solidifies to form the
joint.
― The amount of heat depends on the thermal conductivity and electrical resistance of the
metal as well as the amount of time the current is applied.
― Due to its lower thermal conductivity and higher electrical resistance, steel is comparatively
easy to spot weld, with low carbon steel being most suited to spot welding.
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➢ Welding Robots:
16
➢ Welding Robots:
―Robotic spot welding system requires the welding spot
welding gun(welding equipment delivering the heat energy
via electrical resistance) to the workpiece, and a substantial
loom to carry the services to the welder like power supply
from the transformers, water and air for cooling purpose and
also the information from the sensors.
―For maintaining the consistency in the quality of welds, tip
dressing stations are also fitted in spot welding cells.
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➢ Welding Robots:
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➢ Welding Robots:
❖ Equipment of Spot Welding:
1. Spot welding gun:
― A welding gun having a pair of opposing welding electrodes either one of which ismovable
towards the other to apply a pressure onto a work and away from the other to release the
pressure is attached with the arm of the robot.
― Robots need linear motion control to close and open the weld tips at precise position with
exact pressure. Pneumatic actuators have been popularly used. But due to the problems
of consistency, weld quality and speed they have been replaced by electric servo
actuators.
― A servomotor is attached to the servo actuator for adjusting the pressure applied to the
work through movement of the movable welding electrode.
― It provides a better welding performance and quality, which is made possible by accurate
control of position and torque.
― Control instruction send by the servo controller, which is part of the robot controller,
drives the servo motor at a velocity and torque predefined by robotic programs. For
maintaining the consistency in the quality of welds, tip dressing stations are also fitted in
spot welding cells.
19
➢ Welding Robots:
2. Spot welding cabinet:
― The spot-welding cabinet contains the electric components and circuits needed for spot
welding application.
― It has the welding controller build in and is fully controlled from the robot controller via
the spot-welding software.
― The capacity and functionality depends on the choice of different options. The cabinet has
a large size to support maintainability.
3. Water and air unit:
― The water and air unit contains components for water and air distribution and control
within the spot welding gun.
― It has the welding controller build in and is fully controlled from the robot controller via
the spot-welding software.
― It is available for both robot carried guns as well as for stationary guns and is controlled
from the robot controller via the spot welding software.
― The capacity and functionality depends on the choice of different options.
20
➢ Welding Robots:
3. Spot welding software:
― The Spot welding software is simple and has complete
functionality, but is still flexible to adaption for specific needs.
― It contributes with reliability and quality in the production and is
available for robot carried welding guns.
4. Tip Dresser:
― The tip dresser makes dressing in one fast step with even and
preset cutting conditions.
― The same tip dresser can be bolted on the floor for robot carried
guns or put on a swing arm for tip dress of stationary welding guns.
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➢ Welding Robots:
22
➢ Welding Robots:
23
➢ Welding Robots:
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➢ Casting Robots:
“Robot with a mounted casting ladle for automated ladling and pouring of
molten metals.”
❑ During ladling, the desired melt quantity is measured precisely by accurate
tilt-positioning of the casting ladle using a position sensing system. This
results in high dosing accuracy.
❑ It is used in gravity die casting and pressure die casting
❑ Even at high traversing speeds, a robot control with programmable
acceleration and deceleration ramps ensures rapid but smooth conveyance
of the molten metal to the casting position. Following low-turbulence
pouring of the liquid metal into the gravity die or shot sleeve.
❑ the casting ladle is turned over (if necessary, by up to 360°) at a
programmable position to discharge any adhering oxide film.
❑ The casting cycle of the casting robot is freely programmable and can be
adjusted to the casting location and the casting process.
25
➢ Casting Robots:
26
➢ Casting Robots:
❑ Gravity Die Casting Robots:
❖ Gravity die casting is a casting process in which the melt is poured from
above into a permanent metal mold through a sprue. The mold is filled
through the effect of gravity alone.
❖ The high thermal conductivity of the mold provides for accelerated
cooling of the solidifying melt. This in turn results in a dense and fine-
grained structure with improved mechanical properties.
❖ The tilting gravity die casting robots with their innovative drive,
operating and control concept provide you with the basis you need for
high casting quality. The software function in the integrated with gravity
die casting robot synchronizes the pouring motion of the robot with the
tilting motion of the casting machine. These are the optimal
prerequisites for a precise filling process.
❖ The robots ensure a high pouring rate meeting the requirements of
each casting.
27
➢ Casting Robots:
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➢ Casting Robots:
29
➢ Casting Robots:
❑ Pressure Die Casting Robots:
❖ The pressure die casting process consists of injecting under
high pressure a molten metal alloy into a steel mold (or tool).
This gets solidified rapidly (from milliseconds to a few
seconds) to form a net shaped component. It is then
automatically extracted.
❖ The pressurized die casting robots are used to remove the
casted component from the molds and for the inspection
purpose.
❖ The robots ensure efficient handling of component at such
high temperature
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➢ Casting Robots:
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➢ Casting Robots:
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➢ Coating Robots:
“Coatings are usually solvent-based paints that might trigger a fire.
Coating robots must work safely in a volatile environment, and can
control all aspects of coating and painting by virtue of volume of paint
required as per the coating layer defined.”
❑ When maximum flexibility and perfect coating quality are required,
robots are the solution.
❑ Multi-axis robots specially developed for the coating industry are
equipped with modern powder application technology. Once
programmed, the robots efficiently coat parts to the highest quality.
❑ The advantages of uniform and reproducible coating results, cost
reduction through increased efficiency, optimization of labor costs,
optimized throughput, easy adjustment and storage of various
programs and safer as well as improved working conditions.
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➢ Coating Robots:
❑ Process of Coating:
❖ Once the motion sequence is tailored to the object to be coated and programmed
accordingly, robots ensure that the guns operate at the correct speed, inclination and
position to achieve the required surface qualities with minimum powder consumption.
❖ Once defined, the programs can be called up on demand and the coating result is
reproduced accordingly. Robots can be programmed in different ways. Depending on the
robot manufacturer, different technologies are available for this purpose.
❖ Many impressive, integrated robot solutions exist however in many cases these standard
parts that are high in volume but low in variation. In the case where high product variation
exists (typical of powder coating installations) then de
❖ A robot becomes a coating robot only with the integration of a coating device. The optimal
connection of the guns to the robot also includes a 3D file of the guns used in order to
provide the robot integrator with the information required to determine the Tool Center
Point (TCP).
❖ TCP in robotics refers to the last element of the kinematic chain (stringing together all
moving parts and joints of the robot). It is the decisive point for which the positioning
requirements apply; in the case of coating robots, therefore, the point at which the
powder emerges, the nozzle.
34
➢ Coating Robots:
Powder is typically applied using a type of sprayer to charge the powder

particles so that they will stick to a material, which is normally made out
of metal. Powder coatings contain no solvents and release little or no
amount of Volatile Organic Compounds (VOC) into the atmosphere.
35
➢ Coating Robots:
36
➢ Coating Robots:
❑ Communication interface of Coating:
❖ The primary task of a robot is to bring the coating device into
position. The necessary movements are performed by a robot
control. The coating technology with all its parameters and programs
is controlled by a separate gun control unit. Therefore, an interface
between the controls is necessary to synchronize movement and
spraying.
❖ In the simplest case, i.e. when there is a clear separation between
robot and gun tasks, the robot control coordinates both the robot-
side tasks and the timing of the coating start and stop commands, by
means of a simple digital signal at the gun control. The latter
manages the gun parameters and the stored gun-side program.
37
➢ Coating Robots:
38
➢ Painting Robots:
“Industrial paint robots are designed to help standardize the distance
and path the automatic sprayer takes, thus eliminating the risk of human
error caused by manual spraying and accuracy of layer of painting.”
❑ A typical application of painting robots is the painting of exterior
body panels of cars. The purpose of such painting processes is not
limited to design only.
❑ The process usually consists of electrodeposition or rotary
atomization((see slide 39).
❑ In most cases, the electrodeposition process uses dip coating
(immersion), but other painting processes adopt electrostatic
painting using a rotary atomization system by painting robots.
39
❑ Rotary Atomization:
❖ A rotary atomization system is a mechanism that broadens the coating pattern

while converting the paint into a fine mist.
❖ The air motor is rotated at a high speed to convert the air for turbine rotation into
a layer of air between the axis and the bearing.
❖ The bearing air is used to make this mechanism rotate at high speed without
contact.
❖ The paint is converted into a fine mist by the rotation and sent in the direction of
the target due to the air pressure of the shaping air.
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➢ Coating and painting Robots:

❑ Electrodeposition :
A grounded target is set on the positive side while the paint spraying
equipment is set on the negative side. When a high DC voltage (70 K to
100 KV) is applied, the mist of powder coat becomes negatively charged
and adheres to the positively-charged target.
43
➢ Coating and painting Robots:

❑ Electrodeposition :
44
➢ Deburring Robots:
❑ Principle of Deburring:
45
❑ Robotic deburring, using particular deburring tools, can mimic
the motions of a human worker with a hand deburring tool. This
makes them suitable for a wide range of deburring tasks, not
just the single task that conventional deburring machines
manage.
❑ This is the way is a way to achieve highly flexible deburring
automation quickly and easily.
❑ With the right robot platform, you can get deburring automation
up and running in your facility very quickly. And, with the right
programming tool, you can easily program the deburring task
even if you have no previous experience with robotics.
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Material Handling
and Assembly Robots
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➢ Pick and place Robot:
(See Slide No. 52-54 of Unit-III)
➢ Palletizing Robot:
❑ Definition of Palletization(See slide No. 5,6 and 7 of Unit-I)
❑ Palletizing refers to the operation of loading an object such as a
corrugated carton on a pallet or a similar device in a defined pattern.
Depalletizing refers to the operation of unloading the loaded object
in the reverse pattern.
❑ Robotic palletizing technology increases productivity and
profitability while allowing for more flexibility to run products for
longer periods of time.
❑ A robot control system with a built-in palletizing function makes it
possible to load and unload an object without spending a lot of time
on teaching.
❑ Robotic work cells can be integrated towards any project.
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❑ Robotic Palletizer VS Conventional
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52
53
❑ Types of Palletizing Robot:
1. Inline Palletizing Robot
2. Layer Depalletizing & Palletizing Robot
3. Mixed Case Palletizing Robot
54
1. Inline Palletizing Robot:
“In this the robot motion is synchronized with the conveyor speed thus allowing a
reliable layer forming process.”
❖ Since the packages are gripped actively, the process does not depend on friction
and packaging characteristics, which is often a challenge for shrink wrapped items.
❖ During the layer forming process, a little gap between the packages is added in
order to avoid potential collisions.
❖ Once a layer has been completed, a mechanical end stop is lowered and the layer
is conveyed to the pick-up position of the layer picking robot.
❖ Immediately after the layer has passed the end stop, the end stop is raised again
and the next layer can be assembled.
❖ Depending on the production line speed, the robot-based inline palletizing system
can be adapted to its required system performance. E.g., by adding another layer
forming robot, the throughput can be doubled.
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56
Benefits:
❖ One stop shop solution, from the planning to the world-wide after sales support
❖ High palletizing performance means a high profitability
❖ A scalable system concept adapted to your production needs
❖ Small floor space.
❖ High reliability due to layer forming based on form fitted gripping principle
❖ No package damages to due gentle product handling
❖ Fast, easy and automated switch over to different package types and dimensions
❖ Safe and accurate palletizing with layer gripper and integrated centering device
❖ Universal control architecture
❖ Robot equipment can easily be re-used in case of production change
❖ Slip sheet handling can be simply be added to overall system concept (Optional)
57
2. Layer Depalletizing & Palletizing Robot:
“In this the robot motion is used to transfer into layer picking systems, this implies that you are
able to control the process and that the deployed technology can handle the highest
percentage of your entire range of products and packaging types.”
❖ The variety of different product and packaging types (e.g. corrugated cardboard boxes,
shrink wrapped items, open trays or boxes) in a distribution center have little in common,
which makes automatic depalletizing and order picking difficult.
❖ However, as most package types have at least a flat bottom, universal gripping system has
been designed to incorporate a roll-up principle. This enables you to handle layers of
products where most other conventional technologies fail.
❖ In this process, two servo driven rubber rollers are pushing against the pallet layer from
opposite sides. The packages are thereby lifted up and rolled onto two symmetrical carrier
plates. The gripper control software automatically adjusts the contact pressure and height
position of the rubber rollers to suit the package weight and dimensions.
❖ The roll-up principle supports a multiple layer pick cycle; thus, the overall picking
performance can be significantly increased. The maximum layer number is limited by
either the maximum payload weight or the maximum payload height.
58
59
Benefits:
❖ One stop shop solution, from the planning to the world-wide after sales support
❖ Handling of a wide range of product and packaging types
❖ High palletizing performance means a high profitability
❖ No package damages due to gentle product handling and adaptive gripping
process
❖ High system availability and easy operation
❖ Increased throughput due to multiple layer picking capability (e.g., picking two
layers of open trays with cans in one cycle
❖ Low noise level due to servo drive approach
❖ Accurate layer placement due to integrated layer centering
❖ No product drop in case of a power failure
❖ Safe gripping of layers even with holes and gaps in the pallet pattern
❖ High flexibility of palletizing line due to the use of robots
❖ High standardization (reduction of costs).
60
3. Mixed Case Palletizing Robot:
“In this the robot motion is used to transfer automated order picking in distribution
centers growing orders, articles, and a wide variety of containers must be picked and
palletized, whether on pallets or pushcarts, right on schedule and with a minimum of
errors.”
❖ The dimensions and materials of the packaging units are virtually unlimited, be it
open or closed trays or beverages wrapped in PET film.
❖ In response to these demands, an application module called Pallet-MIX for
automated palletizing has been developed. The primary objective was the
development of an application module using service, proven jointed-arm robots
together with innovative software and gripper technology.
❖ A conscious decision was made in favor of a jointed-arm robot with six degrees of
freedom, in order to avoid the need for external turning of the packaging unit.
This represents a significant advantage over gantry solutions.
❖ Performance and reliable palletizing of the packages were the prime criteria, with
the aim of achieving high throughput rates.
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62
Benefits:
❖ Wide range of palletizable packing units
❖ Short cycle times, giving maximum cost-effectiveness
❖ Gentle handling using a servo gripper
❖ Minimized number of pallets
❖ Maximized packing density
❖ High system flexibility through the use of jointed-arm robots (no
additional turning station required)
❖ High level of standardization (reduction of costs).
63
➢ Packaging Robot:
“Most often, packaging robots are designed to open, fill, transport,
palletize, seal, code and/or label product packaging.”
❑ Just about any process involving the movement or packing of
goods can be automated by a packaging robot.
❑ This type of packaging automation not only lowers your costs
versus manual labor, but also saves you valuable production time.
❑ The industrial sector also sees high usage of packaging robots to
speed up cycle times and improve productivity, while the food and
beverage industry also uses packaging robots for similar reasons
where the pick and place operation is done for packaging.
❑ In this the robot used can be articulated, delta or SCARA
depending up on the material to be packaged.
64
❑ Most manufacturers who implement packaging robots see a major
boost in throughput because the speed of production is not
hindered by how quickly manual processes can package, move,
and/or label products.
❑ Further, packaging robots streamline production. They can lift more
products at one time, feature far higher uptimes than manual labor,
and create labor cost reductions. Packaging robots can complete
more packaging tasks at a lower cost and more consistently than
with manual labor.
❑ Packaging robots are becoming a staple of production in a wide
range of applications, from the medical field to industrial
production, they’re bringing serious bottom-line benefits for
manufacturers.
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➢ Assembly Robot:
“Assembly Robot involves a robot that assembles a variety of products—ranging
from large-scale systems to microscopic items—in the most efficient operation.”
❑ Assembly robots offer a range of capabilities that can allow it to position,
mate, fit, and assemble components or parts for a product.
❑ Every robotic assembly operation is tailored to the specific part, application,
and production requirements.
❑ However, despite the unique qualities and capabilities each automated
assembly system entails, it’s not uncommon for an assembly robot to be
integrated with some type of parts feeding system, machine vision
technology, tooling, and/or grippers.
❑ To identify and sort the components, ensure proper placement, and inspect
the finished product, vision systems are commonly integrated into the robotic
assembly system as well.
❑ Specialized tooling or grippers are often attached to the end of the robotic
arm to allow it to manipulate, handle, and attach parts and components to
complete the assembly.
67
➢ Assembly Robot:
❑ Whether you’re manufacturing automotive assemblies, consumer
products, medical devices, or some other type of product, assembly
robots are ideal for tasks demanding speed, precision, and accuracy.
❑ Different robotic assembly applications include but are not limited to:
❖ Increased productivity: The high-speed capabilities of assembly
robots enable manufacturers to meet desired cycle times and
provide faster time-to-market.
❖ Improved efficiency: By eliminating or reducing manual labor and
providing faster changeover times, assembly robots optimize
workflows for a streamlined assembly process.
❖ Increased product quality: Robotic systems can be programmed to
identify correct components, ensure proper placement, and
inspect the finished assembly to ensure a quality final product
every time.
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➢ Assembly Robot:
69
Robots for Inspection
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➢ Robotic vision systems:
“a robotic vision system is a technology that enables a robot to see. These systems
enable the machine to be able to identify, navigate, inspect or handle parts or
tasks.”
❑ A robotic vision system consists of one or more cameras connected to a
computer. The computer contains a processing software program that helps
the robot interpret what it sees.
❑ Then, the robot follows the program’s instructions—specified by the
manufacturing facility’s staff—to complete the specified task.
❑ Additional elements, such as lighting, image sensors, communications
devices or other components, can be incorporated to add to the machine’s
overall capabilities.
❑ A robotic vision system could determine the difference between two
products being built and select the appropriate part to be installed at that
step in the process. This allows for greater flexibility to construct different
units on the same line without the need to reprogram a “blind” robot that is
expecting the same thing every time.
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➢ Robotic vision systems: Image Analysis and Processing
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➢ Robotic vision systems: Image Analysis
https://www.youtube.com/watch?v=rYaTu3Y2DMY
https://www.youtube.com/watch?v=HITCMaNCFQ8
https://www.youtube.com/watch?v=HQgU76ZOP0o
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➢ Robotic vision systems: Object recognition and categorization
❑ Object detection and classification has traditionally been challenging due to
variations in viewpoints, different sized images, and dynamic illumination
conditions.
❑ One solution that can help is to employ a neural network(NN) that has been
trained to detect and classify objects. An NN is based on a collection of
connected units or nodes called artificial neurons, which loosely model the
neurons in a biological brain. Each connection, like the synapses in a
biological brain, can transmit a signal to other neurons. An artificial neuron
receives signals then processes them and can signal neurons connected to it.
The "signal" at a connection is a real number is identified into an object
specification.
❑ One popular approach is to employ a convolutional neural network (CNN),
where small regions of the image are fed into the network in a process known
as “sliding windows.”
❑ To determine the orientation of objects, main challenge here is determining
the orientation of an object and/or the robot itself in 3D world-space.
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➢ Robotic vision systems: Depth Measurement
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➢ Robotic vision systems: Depth Measurement
https://www.youtube.com/watch?v=fx4uXLQWWi4&t=303s
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Industrial Robotics and Material Handling System

Powder is typically applied using a type of sprayer to charge the powder

❖ A rotary atomization system is a mechanism that broadens the coating pattern

➢ Coating and painting Robots:

➢ Coating and painting Robots:

Robots for Inspection

➢ Robotic vision systems:

➢ Robotic vision systems:

➢ Robotic vision systems: Image Analysis and Processing

➢ Robotic vision systems: Image Analysis

➢ Robotic vision systems: Object recognition and categorization

➢ Robotic vision systems: Object recognition and categorization

➢ Robotic vision systems: Depth Measurement

➢ Robotic vision systems: Depth Measurement

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