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Industrial Robotics and Material Handling System

Prabandh CHAKRABORTY

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Industrial Robotics and Material Handling System

➢Unit-4:
➢End Effector
❑The Concept
❑Classifications
❑Design Considerations
❑Material Hostile for Operations
❑Gripper Force Analysis
➢Selection of Robots
❑Factors influencing the choice of a robot
❑Robot Performance Testing
❑Economics of robotization
❑Impact of robot on industry and society
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Industrial Robotics and Material Handling System
➢ The Concept:
“End effector is gripper or end-arm tooling attached to the wrist of
manipulator to accomplish the desired task”
Or
“End effector is any object attached to the robot flange (“wrist”) that serves as
a function.”
❑ Any object attached to the robot flange (“wrist”) that serves a function.
This includes:
1. Robotic gripper
2. Robotic collision sensors
3. Robotic press tooling
4. Robotic point gun
5. Robotic tool changer
6. Robotic rotary joint
7. Compliance device
8. Robotic deburring tool
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Industrial Robotics and Material Handling System

End Effector

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➢ Classifications:
1. Mechanical Grippers
a. Linkage Actuation
b. Gear and Rack Actuation
c. Cam Actuation
d. Screw Actuation
2. Pneumatic Grippers
a. Parallel Gripper
b. Angular Gripper
c. O- ring Gripper
3. Hydraulic Grippers
4. Electromagnetic Grippers
5. Vacuum Grippers/Suction Gripper
6. Ultrasonic Grippers

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Industrial Robotics and Material Handling System
➢ Design Considerations:
❑ Joseph F. Engelberger, who is referred as Father of Robotics has described
several factors that are required to be considered in gripper selection and
design:
1. The gripper must have the ability to reach the surface of a work part.
2. The change in work part size must be accounted for providing accurate
positioning.
3. During machining operations, there will be a change in the work part size. As
a result, the gripper must be designed to hold a work part even when the size
is varied.
4. The gripper must not create any sort of distort and scratch in the fragile work
parts.
5. The gripper must hold the larger area of a work part if it has various
dimensions, which will certainly increase stability and control in positioning.
6. The gripper can be designed with resilient pads to provide more grasping
contacts in the work part. The replaceable fingers can also be employed for
holding different work part sizes by its interchangeability facility.
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Industrial Robotics and Material Handling System

➢ Design Considerations:
❑ The following significant factors must be considered to
determine the necessary gripping force:
1. Consideration must be taken to the weight of a work part.
2. It must be capable of grasping the work parts constantly at
its centre of mass.
3. The speed of robot arm movement and the connection
between the direction of movement and gripper position
on the work part should be considered.
4. It must determine either friction or physical constriction
helps to grip the work part.
5. It must consider the co-efficient of friction between the
gripper and work part.
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Industrial Robotics and Material Handling System
➢ Material for Hostile Operations:
❑ In the field of hostile conditions:
1. Outer space:
It is often considered the epitome of harsh environments. The aluminum and
aluminum composite, titanium alloys and SMA etc., which can withstand high
compressive, tensile loads with fluctuating temperature.
2. Nuclear Application:
❖ Composites of special interest to both fission and fusion next generation
nuclear reactors are carbon-fiber (C/C) and silicon carbide fiber
(SiCf /SiC), and more recently, C/SiC composites. These are continuous
fiber-reinforced materials of either carbon or silicon carbide fibers
infiltrated with a similar matrix.
❖ During the last two decades a number of studies have been conducted
to address the feasibility and response of the two composites to
different radiation environments of fission and fusion reactors and
identify their limitations The gripper must not create any sort of distort
and scratch in the fragile work parts.
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Industrial Robotics and Material Handling System

➢ Material for Hostile Operations:


❑ In the field of hostile conditions:
2. Nuclear Application:
❖ Carbon-fiber composites for example while they can
have customized architecture to enhance desired
properties, such as thermal conductivity, they too may
experience anisotropic dimensional changes and be
susceptible to irradiation-induced degradation.
❖ SiCf /SiC composites, on the other hand exhibit good
fracture resistance and low induced activity due to the
irradiation stability of the SiC crystal.

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Industrial Robotics and Material Handling System
➢ Material for Hostile Operations:
❑ In the field of hostile conditions:
2. Nuclear Application:

Dimensional change in 2D C/C composite following proton irradiation and removal of fibre shrinkage (left) with
thermal annealing in the fibre direction and growth (right) induced in lattice along the normal to fibre direction as a
function of fluence (1 = 6.0 • 1020 p/cm2; 2 = 3.0 • 1020 p/cm2; 3 = 1.0 • 1020 p/cm2) , Courtesy: Nikolaos Simos
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Industrial Robotics and Material Handling System
➢ Material for Hostile Operations:
❑ In the field of hostile conditions:
2. Nuclear Application:

Dimensional change of un-irradiated SiC/SiC composite over two thermal cycles (noted as TC1 and TC2) and
comparison with 3D C/C , Courtesy: Nikolaos Simos et al. 2010
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➢ Material for Hostile Operations:
❑ In the field of hostile conditions:
2. Nuclear Application:
❖ Nanostructured coatings, along with AlBeMet, an aluminium-
beryllium metal matrix composite, and structures made of fusion-
bonded dissimilar materials constitute a special class of composites
consisting typically of ~62% commercially pure beryllium and 38% of
commercially pure aluminum by weight. The two metals involved in
forming AlBeMet do not fully mix but instead the beryllium particles
are embedded in a pure aluminum lattice.
❖ Post-irradiation studies revealed by studies of Brookhaven National
Laboratory(BNL) that AlBeMet is dimensionally stable following
irradiation and that it resists embrittlement and degradation even at
high proton fluences where materials such as graphite and carbon
composites have shown to undergo serious degradation.

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Industrial Robotics and Material Handling System
➢ Material for Hostile Operations:
❑ In the field of hostile conditions:
2. Nuclear Application:

Effects of 140 MeV proton irradiation on AlBeMet (left) and beryllium (right) on the stress-strain relations (range of
fluence of irradiated samples 0.4 - 1.2 1020 p/cm2), Courtesy: Nikolaos Simos et al. 2010
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Industrial Robotics and Material Handling System

➢ Material for Hostile Operations:


❑ In the field of hostile conditions:
3. Hazardous Chemical Application:
❖ The selection of material varies from the application to
various condition of operation in a chemical plant. From
applications such as like handling explosives, to working
condition in poisonous fumes and to the application of
tapping(removing slag from the furnace) based on the
condition of application the material specification and
design of end effector changes.

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➢ Gripper Force Analysis:

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➢ Gripper Force Analysis:
❑ Problem-2:

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➢ Gripper Force Analysis:
❑ Problem-3: A block of weight having 1400kg is to be gripped as shown in the figure. Find
the gripper force assuming safety factor of 2. Assume coefficient of friction as 0.2. The
center of gripping does not coincide with center of gravity.

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➢ Gripper Force Analysis: Mechanical Actuation-Linkage Actuation

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➢ Gripper Force Analysis: Mechanical Actuation-Cam Actuation

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Mechanical Actuation-Gear Actuation

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➢ Gripper Force Analysis: Mechanical Actuation-Screw Actuation

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➢ Gripper Force Analysis: Hydraulic and Pneumatic Actuation-O-Ring Gripper

❑ These Types of grippers are functioning similar to the power chuck except it
is used in assembly of O-Rings.
❑ These O-Rigs are used in Piston, pipes and various other applications.
❑ These grippers can be external as well as internal grippers based on
assembly requirement and design.
❑ The O-Ring grippers can be having from 3 Jaw Gripper Design to 8 Jaw
Gripper Design (even more no. of jaw design for certain cases).
❑ These type of grippers apart from O-Ring assembly can be used in certain
cases where the more stability of parts are required.

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Hydraulic and Pneumatic Actuation-O-Ring Gripper

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Hydraulic and Pneumatic Actuation-O-Ring Gripper

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➢ Gripper Force Analysis: Electromagnetic Gripper
❑ Electromagnetic gripper is a type of end effector mounted at the end of the
robotic arm, that can catch and transfer steel parts or ferrous materials in
automated assembly operations.
❑ Electromagnet gripper, switched on/off by a brief electric pulse.
❑ It is usually employed to position and retain parts in automated assembly
operations. It is another type of handling the work parts other than the
mechanical grippers and vacuum grippers.
❑ Electromagnetic gripper has several advantages for handling ferrous parts over
conventional impactive, ingressive or contiguitive grippers. These grippers offer
simple compact construction with no moving parts, uncomplicated energy supply,
flexibility in holding complex parts and reduced number of set-ups. Magnet size is
directly dependent on required gripping force.
❑ An electromagnet is a device consisting of a core of soft magnetic material
surrounded by a coil through which an electric current is passed to magnetize the
core.
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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Electromagnetic Gripper

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Electromagnetic Gripper

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Electromagnetic Gripper
❑ Electromagnet gripping force is systematized by known equations that characterize a
magnetic circuit. It is the force which is perpendicular to the attraction surface of the
electromagnetic gripper force exerted by a magnetic field described by the equation:

(1)
for a closed magnetic circuit with no air gap:
(2)

Where, B =magnetic flux density; A =cross-sectional area of the core; N=number of turns
of coil winding; I =current in the winding coil; L=length of the magnetic field path; µ
=permeability of the electromagnet core material and µo =permeability of free space
respectively.
❑ By substituting (2) in (1)

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Vacuum Gripper
“Vacuum-grippers are nothing but the suction cups, made of rubber uses the
principle vacuum pressure(-ve pressure) to hold the payload.”
❑ The suction cups are connected through tubes with under pressure
devices for picking up items and fo releasing items air is pumped out into
the suction cups.
❑ The under pressure can be created with the following devices:
❖ Vacuum pumps
❖ Ejectors
❖ Suction bellows
❖ Pneumatic cylinders

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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Vacuum Gripper

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➢ Gripper Force Analysis: Vacuum Gripper
❑ Universal Suction Cup: The universal suction cups are used for flat or slightly
arched surfaces. Universal suction cups are one of the cheapest suction cups in
the market but there are several disadvantages with this type of suction cups.
When the under pressure is too high, the suction cup decreases a lot which leads
to a greater wear.
❑ Flat Suction Cups: The flat suction cups with bars are suitable for flat or flexible
items that need assistance when lifted. These types of suction cups provides a
small movement under load and maintains the area that the under pressure is
acting on, this reduces the wear of the flat suction cup with bars, this leads to a
faster and safer movement.
❑ Suction cup with Bellows: Suction cups with bellows are usually used for curved
surfaces, for example when separation is needed or when a smaller item is being
gripped and needs a shorter movement. This type of suction cups can be used in
several areas but, they allow a lot of movement at gripping and low stability with
small under pressure.
❑ Depth Suction Cups: The depth suction cup can be used for surfaces that are very
irregular and curved or when an item needs to be lifted over an edge
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Industrial Robotics and Material Handling System
➢ Gripper Force Analysis: Vacuum Gripper

Vacuum Gripper Flow Chart

Courtesy :Felix Gabriel et al 2020


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➢ Gripper Force Analysis: Vacuum Gripper

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➢ Active and Passive Gripper:

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➢ Active and Passive Gripper: Active or Adaptive Gripper

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➢ Ultrasonic Gripper:
“A gripper that uses ultrasonics to suspend an object in midair, potentially making it suitable
for the most delicate tasks.”
❑ It’s done with an array of tiny speakers that emit sound at very carefully controlled
frequencies and volumes. These produce a sort of standing pressure wave that can hold an
object up or, if the pressure is coming from multiple directions, hold it in place or move it
around.

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➢ Multiple Degrees of Freedom Grippers/Universal Grippers:
❑ The multiple degrees of freedom grippers are types of grippers which can
move more than on plan for the gripping action.
❑ Theses grippers are also called universal grippers.
❑ The concept of universal gripper design has been the development in
robotic applications in handling different objects
❑ In this a robotic arm does not need to change its end-effector while in
present usage in industry, particular end-effector is required for particular
object shape.
❑ According to their main structure, the actuation mechanism of these
smart, universal, and intelligent robot grippers can be roughly divided into
three categories:
1. Cable Driven
2. Pneumatic Driven
3. Motor Driven
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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/ Universal Grippers :
1. Cable Driven:
❖ The cable driven mechanism controls finger’s flexion and extension by
exerting force through cables.
❖ Because of its actuation through cables, it can simply add sensors inside the
structure without conflicting with mechanical parts that are used to
transmit forces.
❖ Designers can increase gripper performance by changing its driving source
such as motors without making major redesign of the structure.
❖ However, it is difficult to predict the relative angle between adjacent
linkages in a robotic gripper using cable-driven mechanism due to nonlinear
relationship between motion and cable movement. To overcome such
difficulties, soft joints using elastic rubber is used.
❖ Such design is found to be simple yet effective for cable-driven grippers
with a bit of compliance through soft joint at the same time.
❖ Such design can be cooperated with multiple cables to control flexion and
extension motion of the gripper fingers separately.
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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers
/Universal Grippers :
1. Cable Driven:

Courtesy: Li-Wei Chang et al 2018


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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/Universal Grippers :
2. Pneumatic Driven:
❖ Pneumatic type employs air or hydraulic pressure to drive piston or to expand
and contract chamber for actuation.
❖ Although design with pneumatic-driven mechanism is commonly space
demanding, it does offer greater driving force than the cable-driven
mechanism.
❖ This kind of driving method is relatively rare on the market at present.
❖ Festo company’s product Exohand, which use the piston as the main driving
source to drive four-bar linkage structures for transmitting the piston force into
the fingertips.
❖ In Raphael Deimel et al 2013, uses special rubber chambers set as driving
sources as well as gripper’s structure. When the driving pressure goes high, the
gripper’s chambers expand and close the gripper. Such design can be simply
used to control holding or releasing action with controlling the chamber
pressure. Due to its use of soft silicon chambers as gripper structure, it can
grasp objects with full contracting with the surface of objects.

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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers /Universal Grippers :
2. Pneumatic Driven:

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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/Universal Grippers :
2. Pneumatic Driven:

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➢ Multiple Degrees of Freedom Grippers/Universal Grippers :
3. Motor Driven:
❖ It uses power of motor to drive for actuation via linkages.
❖ It is used in various fields due to its simple structure, stability, and ease of
design, a motor-driven mechanism is found to offer significant gripping force
for robotic gripper.
❖ Based on numbers of DOF between mechanical structures and driving motors,
gripper with motor-driven mechanism can be catalogued into two groups:
❖ Group-1:When the number of gripper’s degrees of freedom equals to
number of driving sources. With this arrangement, gripper’s motion and
gestures can be easily calculated by using forward kinematics. Such design
can be seen in various commercial robotic grippers. For examples, Schunk’s
five fingers humanoid hand and Kinova’s KG series for assistive robotics
❖ Group-2:When it has redundant degrees of freedom i.e, the number of
gripper’s degrees of freedom is greater than the number of driving sources.
With such design, the gripper can morph or change its gesture based on
the shape of target objects without additional driving motor. Examples,
Marc Manz’s self adaptive gripper and Kuat Telegenov’s adaptive 3D
printed robotic gripper
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Industrial Robotics and Material Handling System

➢ Multiple Degrees of Freedom Grippers/Universal Grippers :


3. Motor Driven:
❖ Based on numbers of DOF between mechanical structures and driving motors, gripper with motor-driven
mechanism can be catalogued into two groups:
❖ Group-1:When the number of gripper’s degrees of freedom equals to number of driving sources.

Schunk’s 5 finger hand Kinova’s 3 finger gripper


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Industrial Robotics and Material Handling System

➢ Multiple Degrees of Freedom Grippers/Universal Grippers :


3. Motor Driven:
❖ Based on numbers of DOF between mechanical structures and driving motors, gripper with motor-driven
mechanism can be catalogued into two groups:
❖ Group-2:When it has redundant degrees of freedom

Marc Manz’s Adaptive Gripper Tutalov’s 3D printed gripper


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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/Universal Grippers: Design
Framing Inverse Kinematics Equation

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➢ Multiple Degrees of Freedom Grippers/Universal Grippers: Design

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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/Universal Grippers: Design

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Industrial Robotics and Material Handling System
➢ Multiple Degrees of Freedom Grippers/Universal Grippers: Design

(Refer: Design and implementation of a


multi-degrees-of-freedom cable-driven
parallel robot with gripper by Li-Wei,
International Journal of Advanced
Robotic Systems)

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Industrial Robotics and Material Handling System

Selection of Robots

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➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
1. Reach and Work envelop:
❖ Depending upon application of robot the maximum reach of the robot
forming a volume of space of operation utilized by the robot during
operation which called as the work envelop.
❖ The work envelop and the reach varies with configuration of robot and
severity of application( see the video at slide 51 of Unit-iii).

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Industrial Robotics and Material Handling System
➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
2. Payload:
❖ Payload is the second most important factor. If the robot can’t carry the parts
it is handling, then it is not going to work.
❖ Payload calculations get trickier than the reach calculations sometimes. It is a
common mistake to forget to include the gripper’s weight into consideration
when you do these payload calculations. And that’s not even enough. Most
robot manufacturers will specify their robot’s payload exactly at the end of
it’s last joint.
❖ So, you need to find a graph in their manual that shows the payload capacity
of the robot at a distance from the end of the arm. Finding that graph is
definitely harder than calculating the load.
❖ Other, is you can calculate the payload capacity by using forward kinematics
and dynamic analysis using either of Newton-Euler and Langrang’s Equation.

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Industrial Robotics and Material Handling System
➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
2. Payload:

Payload capacity w.r.t. distance from end link to gripper

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Industrial Robotics and Material Handling System
➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
3. Speed:
❖ Most of the applications, the robot is servicing another machine or
limited by another equipment down the manufacturing line. So, the
robot’s speed is dictated by the cycle time of those bottlenecks.
❖ Let’s say we are in a bottling plant and every bottle takes about 5
seconds to get filled, labeled and inspected. Every 5 seconds, we will be
seeing a bottle to be picked up by the robot. Our robot needs to be
able to complete its task under 5 seconds and be ready for the next
one.
❖ This is where we can start being clever. 5 seconds is not too fast for
industrial robots, but for cobots, it definitely stretches their “safe”
speeds. Now, we should ask the question, can we handle more than
one bottle at a time? If we can handle 6 bottles at a time and do the
task that’s required, now our cycle time is about 30 seconds.

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Industrial Robotics and Material Handling System

➢ Factors influencing the choice of a robot:


❑ The major factors affecting Robot Selection are:
3. Speed:
❖ After making sure of the details and understanding how
many parts to handle, the best way to test is to do a real
time cycle time test with the specific robot.
❖ If the robot manufacturer offers a simulator, that might also
be a good way to estimate the cycle time.
❖ Speeds that are listed on spec sheets are good for getting an
overall feel, but you really should test the robot if your
application is speed critical.
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➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
4. Application Type and Versatility:
❖ It is important to consider all types of robots in the application at
first but, some application types just require different robots.
❖ Doing a very delicate and precise quality inspection, you might
need a robot with high precision, or if you need to orient your
part, you want to go with an articulated robot rather than a
SCARA.
❖ You also need to consider if the specified robot can handle other
applications in the future. This is one of the reasons collaborative
robots are so popular these days since they are easy to deploy
and versatile.

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➢ Factors influencing the choice of a robot:
❑ The major factors affecting Robot Selection are:
5. Cost:
❖ Cost is obviously a very strong factor in the decision making process.
The key parts to justifying the cost of the robot is to understand the
cost reduction that it will introduce and the return on investment of it.
Obviously that return on investment will take a shorter amount of time
if the price of the robot is cheaper, however, you should get the robot
that is suitable for the job and also checks out the other factors listed.
❑ In some scenarios, one factor might be more important than others, but
everything starts with understanding the application requirements.
❑ Other factors can be computational efficiency(determined processing
speed), drives(electrical, mechanical, hydraulic and pneumatic), cables and
harness, manipulability (skillful and possible movements and orientations
of the robot’s links/joints ),&power source(decided by design
requirement).

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Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
❑ The ISO9283 describes the tests to evaluate the performance of industrial
robots.
❑ According to the ISO9283 norm, all the testing should be performed inside
the so-called ISO test cube. The ISO test cube is supposed to be the largest
cube that can fit inside the robot workspace.
❑ There are 5 parameters that should be evaluated 30 times .Those 5
parameters are:
1. Performance and Repeatability
2. Path Accuracy
3. Resolution
4. Safety
5. Reliability
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➢ Performance Testing of Robots:
1. Performance and Repeatability:
❖ The robot is first calibrated, the accuracy of an industrial robot can be improved
through robot calibration.
❖ A measurement system is required to calibrate a robot. A measurement
system can be any laser tracker such as Leica, API or Faro and or optical CMM
such as the C-Track stereo-camera from Creaform should work.
❖ Two objects are required: a tool object (held by the robot) and a base reference
object (static in the cell). The tracker must be able to see the tool object and
the base reference object for each measurement.
❖ The tracker tracks the position of these targets providing the reference frame
of these objects as a measurement with respect to the tracker. The user
interface or the software integrated with computer measures the performance
with respect to base frame.
❖ These performance that is recorded is than checked for validation and
repeatability.
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➢ Performance Testing of Robots:
1. Performance and Repeatability:
❖ Most of the performance tests associated with industrial robots may be tailored to
measure either of two types of behavior: point-to-point and path.
❖ Parameters such as quasi-static accuracy, dynamic stability, or quasi-static repeatability
are measured by point-to-point tests, as opposed to kinematic repeatability or
kinematic accuracy by path tests.

Generating the performance record ,and checking for repeatability and accuracy
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➢ Performance Testing of Robots:
1. Performance and Repeatability:
❖The validation is done for the performance
recorded .
❖The same procedure that is used for position
accuracy validation during robot calibration can
also be used for position accuracy testing.
Repeatability statistics can also be obtained if the
measurements are taken sequentially through the
same group of points(see slide 61)

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➢ Performance Testing of Robots:


1. Performance and Repeatability:

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Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
2. Path Accuracy:
❖ It is also required to have a measurement system that can track the
position of the end effector and provide the position measurements
with respect to a reference frame.
❖ It is required to use the base setup and tool setup procedures in the
robotic software to identify the robot base frame and tool frame.
❖ The measurement data must be acquired while moving the robot along
the program. The measurements should be recorded continuously, using
the default software provided by the manufacturer of the measurement
system.
❖ The XYZ position data as well as the time stamp for each measurement
collected must be saved and then validated for the best path.
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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
2. Path Accuracy:
❖ It is also required to have a measurement system that can track the
position of the end effector and provide the position measurements
with respect to a reference frame.
❖ It is required to use the base setup and tool setup procedures in the
robotic software to identify the robot base frame and tool frame.
❖ The measurement data must be acquired while moving the robot along
the program. The measurements should be recorded continuously, using
the default software provided by the manufacturer of the measurement
system.
❖ The XYZ position data as well as the time stamp for each measurement
collected must be saved and then validated for the best path.
64
Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
3. Resolution:
❖ With respect to robots, the resolution is determined by the capability
offer feed back devices such as resolvers and encoders to determine a
certain point's locality and, ultimately, the robot arm's end point
position. In broader perspectives, resolution may simply be described as
a measure of the change in a device's variable output.
4. Repeatability:
❖ This is the closeness of concurrence of repeated position movements of
the robot to the same location when subject to the same conditions.
Repeatability is one of the greatest advantages of a robot because of its
ability to repeat programmed motions consistently.

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
5. Safety:
❖ There are many system safety analysis techniques available out of which
six of the following are logical based:
i. Fault Tree Analysis(FTA)
ii. Event Tree Analysis(ETA)
iii. Failure modes and effects analysis (FMEA)
iv. Management oversight and risk tree (MORT)
v. Network logic analysis(NLA)
vi. Sneak circuit analysis(SCA)

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
5. Safety:

FTA
FTA

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
5. Safety:

ETA

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Prabandh CHAKRABORTY
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FMEA
70
MORT
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
5. Safety:

SCA
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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Performance Testing of Robots:
5. Reliability:
❖ During the product life cycle, there are several identifiable data sources, and some of
these are tests (environmental qualification, field installation, and field
demonstration), warranty claims, previous experience with similar products, data
systems operated by customers, repair records, inspection records, and so on.
❖ As electrical, mechanical, and electronic components may be used in a robot, the
failure data for such components could be obtained from the existing data banks in the
various sectors of industry.

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Economics of Robots:
❑ Economics could be the one major factor for the rapid growth in the
robot industry.
❑ These were the reduced cost of labor, a better quality product,
elimination of dangerous jobs, a better output rate, increased
product flexibility, reduction in material waste, lower labor turnover,
lower capital cost, etc.
❑ However, the economic viability of robot use in the factory depends
upon several factors. Some of those are business size, investment
cost (cost of installation, acquisition cost, and adapting workshop
cost), type of work to be performed, degree to which the existing
workshop is automated, and ownership cost (reliability,
maintenance, fuel, expected life, etc.).

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Economics of Robots:
❑ Factors for Installing Robots and Advantages of
Robotization:
1. Reducing costs
2. Improving product quality
3. Task requiring too precise movements
4. Handling dangerous loads such as explosives, toxics, and
radioactive material
5. Eliminating repetitive tasks
6. Speeding up an operation
7. Human unable to gain access
8. Handling loads which are rather heavy for a human being.

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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Economics of Robots:
❑ Cost of Installing Robots and Their Economic Benefits:
A robot project cost may be divided into eight categories:
1. Safety cost: The safety cost is made up of elements such as alarm
devices cost, safety training cost, safety enclosure cost, and operator
protection devices cost.
2. Computing cost: The computer cost is composed of two main cost
elements: hardware cost and software cost.
3. Manufacturing equipment cost: this includes the manipulator and
associated control system and motive source), system interfaces,
grippers or work handlers, package enhancements, system interlocks,
jigs, fixtures, and tools cost.
4. Cost associated with personnel: The components of the cost associated
with personnel are skill training, wage settlements, redeployment,
redundancies, and recruitment cost.

75
Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Economics of Robots:
❑ Cost of Installing Robots and Their Economic Benefits:
A robot project cost may be divided into eight categories:
5. Systems engineering cost: Labor is the dictating factor in the system
engineering cost because the time of engineers and technicians is
costly. Labor time is associated with tasks such as testing the system
against system criteria, purchasing equipment for the system,
reassembly, retesting, testing equipment against manufacturers'
specifications, etc.
6. Project management cost: The project management cost includes the
costs associated with managing the project: project manager's salary,
cost of secretarial help, etc.
7. Ancillary equipment and structural modification cost: It is associated
with the work to be performed prior to the installation of the robot.
8. Miscellaneous cost: The miscellaneous cost includes costs of the
feasibility study, spares, maintenance, etc.
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Prabandh CHAKRABORTY
Industrial Robotics and Material Handling System
➢ Economics of Robots:
❑ Cost of Installing Robots and Their Economic Benefits:

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Prabandh CHAKRABORTY

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