UNIT 1

INTRODUCTION
 INDUSTRIAL ROBOT

• The “official” definition of an industrial robot is provided by the

Robotics Industries Association (RIA)

• “An industrial robot is a reprogrammable , multifunctional

manipulator designed to move materials, parts, tools or special
devices through variable programmed motions for the performance
of a variety of tasks.”
 ROBOTICS IN SCIENCE FICTION:

• First work of robotics in science fiction was a novel by name Mary

shelley, published in England in 1817, titled Frankenstein.

• A Czechoslovakian play in the early 1920s by Karel Capek, called

Rossum’s Universal Robots, gave rise to the term robot. The
Czech word “robota” means servitude of forced worker.

• Among science fiction writers, Issac Asimov contributed a number

of stories about robots, starting in 1939 and he coined the term
“robotics”.
• The robot in his work follows three principles:
• 1. A robot may not injure a human being or, through inaction,
allow a human to be harmed.
• 2. A robots must obey orders given by humans except what that
conflicts with the first law
• 3. A robot must protect its own existence unless that conflict with
the first or second law.

• These principles were called the Three laws of Robotics by

Asimov,.

• A number of movies and television shows have added to the lore

of robotics.

• 1951 movie “The day the earth stood still” robot named Gort.
• 1968 movie “2001: A space Odyssey”
• The star war series.
HISTORICAL DEVELOPMENTS IN THE TECHNOLOGY
OF ROBOTICS – CHRONOLOGICAL ORDER.

• mid – 1700s -> j.de vaucanson built several human sized

mechanical dolls that played music.

• 1801 -> invention of jaquard loom, by j jacquard, a programmable

machine for weaving threads.

• 1805 -> construction of mechanical doll capable of drawing pictures

by H. Maillardet – a series of cams were used as the “program” to
guide the device.

• 1951 -> development work on teleoperators (remote control

manipulators) for handling radio active materials.

• 1952 - > development of numerical control prototype and

subsequent development of APT (Automatically programmed
tooling) in the year 1961.
• 1954 -> G.C . Devol develops design for programmable article
transfer – receives patent.

• 1959 -> First commercial robot introduced by planet corporation

which was controlled by limit switches and cams.

• 1960 -> first ‘unimate’ robot introduced. It used numerical control

principle and was a hydraulic drive robot.

• 1961 -> Unimate installed at ford motor company.

• 1968 -> A mobile robot named “ shakey” developed at “Stanford

research institute”. It was equipped with a variety of sensors,
including vision camera and touch sensor, and it can move about
the floor.
• 1973 -> Development of robot programming language like AL, VAL .

• 1974 -> Cincinnati Milacron introduced the T 3 robot with computer

control.

• 1978 -> PUMA (Programmable universal machine for assembly) for

assembly operation introduced by Unimation.

• 1979 -> Development of SCARA type robot.

• 1980 -> Bin picking robotic system through machine vision.

• 1981 - > A direct drive robot – which used electric motors located at
the manipulator joints.

• 1982 -> IBM introduces the RS – 1 robot for assembly.

 AUTOMATION AND ROBOTICS
• Robotics and industrial Automation is two closely related
technologies

• Whenever units of products and rate of manufacture are very high,

then a Specialized Machines(SPM) are required.

INDUSTRIAL AUTOMATION

• Industrial Automation Is Defined As A Technology That Is

Concerned With The Use Of Mechanical, Electronics And
Computer Based Systems In The Operation And Control Of
Production.
• Examples

 Transfer lines
 Mechanized assembly machines
 Feed Back control systems
 Numerically controlled machine tools
 Robots
• All Automatic Machines are not robots.

• But Robotics is a type of Industrial Automation.

• Based on flexibility and adoptability to volume and speed of

different type of production processes the Industrial production is
classified into

• a)Hard Automation
• b) Soft Automation

COMPARISON BETWEEN HARD AND SOFT

AUTOMATION IS SHOWN IN THE NEXT SLIDE.
Features Hard Automation Soft
Automation
Cost Good at very high Good for moderate
production volume production volume.
Flexibility limited High
Life cycle To be for a longer For short and medium
Duration production Duration
cycle
Batch Production Not suitable Highly suitable
Control through Not possible Easily possible
software
Obsolescence of the Happens with change Does not happen
machine in models for which because the software
part is manufactured can be changed
Efficiency of the Comparably high Equally high
operation
Examples Automatic machines, CNC machines, Robots,
SPM,TL and reprogrammable
machines etc.
Cost Effectiveness Comparison of Hard
Automation & soft automation
 RISKS OF HARD AUTOMATION

• As initial investment of the machine is too high, volume of

production is lower, profit declines.

• The SPM becomes obsolete when the design of the model is

changed.
 • Three broad classes of Industrial Automation:

• 1. Fixed Automation
• 2. Programmable Automation
• 3. Flexible Automation.

Fixed Automation
• Fixed Automation is used when the volume of production is very
large/high.

• It requires appropriate design to the specialized equipment to

process the product very efficiently and at high production rates.

• The best example of fixed type of automation is automated

industry, where highly integrated transfer lines consisting of dozens
of workstations are used to perform machining operations on
engines and transmission components.
 The Soft Automation consists of

• 1. Programmable Automation
• 2.Flexible Automation

• Key features of Programmable Automation.

 Products of small batches are produced one after the other.

 Machines is reprogrammed after one other.
 Example Industrial Robot.
 Key features of Flexible Automation
 Using same manufacturing facility, different product configuration
can be produced at the same instance.

 Variety of product configuration can be processed parallelly

through preloaded programs.

 It depends on computational power of the computer integrated with

systems.

 The best examples FMS, CIM etc.

Relation between fixed, flexible and programmable
automation.
 UNDERSTANDING A ROBOT
o The general understanding of a robot applicable in industries in
particular are discussed below.

o DEGREE OF FREEDOM: The translatory and rotary motions of

the arms of the robot.

o THE REFERENCE FRAMES: The Cartesian frames attributed to

the base, joints and the tip of the robot arm.

o ROBOT JOINTS: The type of arm connections between which

different types of motions like linear and rotational are possible.

o CONFIGURATIONS: Different movements of the robot

manipulator.
o ROBOT CONFIGURATIONS: Parts and accessories of a robot
like Arms, End-effector, Actuators, Sensors, Controllers and
software and hardware.

o ROBOT SPECIFICATIONS: Specifications of a robot like

Number of axes, capacity, speed etc.

o MODES OF PROGRAMMING AND CONTROL: AL and

VAL.
 DEGREES OF FREEDOM

• A body suspended in space can have 6 positive degrees of freedom

and 6 negative degrees of freedom.

• The three degrees of freedom are the translatory or linear degrees of

freedoms along the positive Cartesian axis and three along the
negative Cartesian axis which are opposite.

• Six rotary movements about the Cartesian axes of which three are
clockwise and remaining three are anticlockwise.

• The illustration of degree of freedom is shown in the figure.

 DEGREE OF FREEDOM

The selection of the DOF depends on the application to reach a

specific point in the work envelope in which the job is located.
 THE REFERENCE FRAMES

• There are three types of reference frames attributed to the robot

structure.

• BASE REFERENCE FRAME: The basic X, Y & Z are the three axes
of the base. Base may be fixed or rotate about the z-axis according to
the need of the applications. It is also called a s Universal Reference
Frame.
• JOINT REFERENCE FRAME: The reference axes defined at the
joints of the robot, are called the joint reference frame. The joint can
have both translatory and rotational movements about it defined
axes. Here frame is not fixed. (Fig 1).

Fig 1 Fig 2

• TOOL REFERENCE FRAME: This is the local frame of reference

defined by the axes at the arm tip or the robot hand. This reference
frame is related to the base reference frame by the transformations
of the co-ordinates. (Fig 2)
 ROBOT JOINTS

• The relative motion featured by the sliding action between the two
surfaces describes the characteristic connection known as the “Lower
Pair”. The lower pair formed between two links is termed as joint

• The robot joints are made to produce motions which can be linear,
rotary or spherical in nature.

• The joints that give linear motion are called PRISMATIC JOINTS.

• The joints that produce rotary movements are called REVOLUTE

JOINTS.

• The joints that produce multiple rotations are called SPHERICAL

JOINTS.

• The motion of the joints can be given by Hydraulic, Pneumatic or

Electric Drives.
• DIFFERENT ROBOT JOINTS IN ROBOTS.

Prismatic pair
Revolute pair Cylindrical Pair

Planar Joint Screw Pair Spherical Joint

• Joints – its motion – and Degree of Freedom
 ANATOMY OF A ROBOT.

• The industrial robots resembles the human arm in its physical

structure.
• As the industrial robot compares with the human hand, they are
also know as “Anthropomorphic or articulated robots”.

• The drives or motion to the links is provided at the joints. The joint
motion can be rotational or translatory. The tool known as end
effector (gripper) is attached to the wrist.

• The end- effectors are not considered as a part in the robot

anatomy.
 ROBOT CONFIGURATIONS
• The basic four robot configurations are:
• 1. Polar configuration.
• 2. Cylindrical Configuration.
• 3. Cartesian Coordinate configuration.
• 4. Jointed arm configuration.

• Polar Configuration or Spherical Coordinate robot (2RP).

• Cylindrical Configuration (2PR)
• Cartesian Coordinate Configuration(3P). Jointed Arm configuration(3R).
• SCARA (SELECTIVE COMPLIANCE ASSENBLY ROBOT ARM)

It has two horizontal and parallel revolute joints with the axis vertical
and one prismatic joint which can move the arm vertically up and
down.

This find use in assembly operations.

 WORK VOLUME.

• Work volume is the term that refers to the space within which the
robot can manipulate its wrist end.

• The work volume is determined by the following physical

characteristics of the robot.

• 1. The robot physical configuration

• 2. The size of the body, arm, and wrist components.
• 3. The limits of the robot joint movements
• WORK VOLUME OF VARIOUS RBOT CONFIGURATIONS.

Polar Coordinate – partial sphere Cylindrical Coordinate – Cylindrical

Cartesian Coordinate – Rectangular

• Comparative Advantages of Different Configurations.
 WRIST MOVEMENTS:

• The wrist movement is designed to enable the robot to orient the

end effector properly with respect to the task to be performed.

• For example, the hand must be oriented at the appropriate angle

with respect to the work piece in order to grasp it.

• The wrist is normally provided with up to 3 DOF.

• Wrist Roll: Also called wrist swivel, this involves rotation of the
wrist mechanism about the arm axis.
Wrist Pitch: Given that the wrist roll is in its centre position, Pitch
would involves the up and down rotation of the wrist. Also called wrist
bend.

Wrist Yaw: Again, given that the wrist roll is in the centre position of its
range, Wrist yaw involve the right or left rotation of the wrist.

3 DOF associated with the robot wrist

 ROBOT COMPONENTS
• 1) Arms(MANUPULATORS)
• 2)End Effectors
• 3)Actuators
• 4)Sensors
• 5)Controllers
• 6)Software and Hardware
 ROBOT ACCESSORIES
A Robot is a system, consists of the following elements, which are
integrated to form a whole:

• Manipulator / Rover : This is the main body of the Robot and

consists of links, joints and structural elements of the Robot.
• End Effectors :This is the part that generally handles objects, makes
connection to other machines, or performs the required tasks.

• It can vary in size and complexity from a endeffector on the space

shuttle to a small gripper
 ACCESSORIES
• Actuators : Actuators are the muscles of the manipulators.
Common types of actuators are servomotors, stepper motors,
pneumatic cylinders etc.

• Sensors : Sensors are used to collect information about the

internal state of the robot or to communicate with the outside
environment. Robots are often equipped with external sensory
devices such as a vision system, touch and tactile sensors etc
which help to communicate with the environment

• Controller : The controller receives data from the computer,

controls the motions of the actuator and coordinates these
motions with the sensory feedback information.
 NEED FOR ROBOTS
• Accuracy aspect
• Environmental aspects
• Human aspect
• Skill aspect
• Performance aspect
• Automation aspect
 CLASSIFICATION OF ROBOTS

According to Japanese Industrial Robot Association( JIRA)

• Class 1 : Material handling device.

• Class 2: Fixes sequence Robot
• Class3: Variable Sequence Robot.
• Class4:Playback Robot
• Class 5:Numerically Controlled Robot (operator programmes APT)
• Class6:Intelligent Robot.
 ROBOT LINKS

• It is the two adjacent joint axes of a robot manipulator are

connected and defined by a rigid body called Link.

• These Links maintains a fixed relationship between the two joint

axes through the kinematic function.

• The two Kinematic functions represents the length of a link, and

twist of a link
ROBOT LINKS
 DESIGN CONSIDERATIONS

• Strength and stiffness

• Material used for fabrication
• Weight and inertia
• Location of bearings/ selection
• The fits and tolerances of joints
• The external shape and aesthetics
• The friction and lubrication
 ROBOT DRIVES SYSTEMS

• The Robot’s capacity to move its body, arm, and wrist is provided by its
drive systems which is basically power to the Robots.

• The drive system determines the speed of Arm movements, strength

of robots, and dynamic performance.

• It is basically drive systems is selected based on its typical

applications.

• Types of drive system

• 1. Hydraulic Drive
• 2. Electric Drive
• 3. Pneumatic Drive
 HYDRAULIC DRIVES
• Hydraulic Drives is generally associated with larger robots, such as
unimate.

• The major advantage of this is that it provides robots with great

strength and speed.

• The major disadvantage of this is that it acquires maximum floor

space, leakage of oil which is nuisance.

• The Hydraulic drives is designed to actuate linear or rotary joints

• Rotary vanes, Hydraulic pistons examples

 Pneumatic Drives
Pneumatic power can be readily adapted to the actuation of piston to
provide translatory motion of sliding joints.

It can also be used for rotary actuation.

 ELECTRIC DRIVES
• In case of , servomotor is a rotary actuator or linear actuator that allows
for precise control of angular or linear position.

•  It is a closed-loop servomechanism that uses position feedback to

control its motion and final position. 

• Servomotors are used in applications such as Robotics, CNC machinery

or automated manufacturing.

• Generally Electrical drives do not provide as much as speed and

power when compared to Hydraulic drives.

• Here Accuracy , Resolution, Repeatability is of better aspects or quality.

• Consequently electrical robots tend to be smaller requiring lesser
floor area.

• Their applications are more towards precise such as assembly

processes.

• Electrical motors are used to actuate linear joints ,basically it is

actuated by DC servo and Stepper motors.

• In robotics stepper motors are primarily used in stationary robots

as they tend to consume quite a lot of power. They are ideal for
movements that have to be accurate and are larger than 180°.

• Example telescopic arms.

 ROBOT SPECIFICATIONS
• Payload:
• It is related load carrying capacity of an industrial robot
and it is basically defined by its weight.
• That weight which is defined is of any object or a tool
held by the gripper.
• These weight does not affect other functional
characteristics like tip deflection, control of motion along
defined path.
• The over load may lead to malfunction of robot
 SPATIAL RESOLUTION
• The spatial resolution of a robot is the smallest increment of movement
into which the robot can divide its work volume.

• Spatial resolution depends on two factors:

• 1. The system’s control resolution
• 2. The robot’s mechanical inaccuracies.

• The control resolution is determined by the robot’s position control

system and its feedback measurement system.

• It is the controller ability to divide the total range of movement for the
particular joint into individual increment that can be addressed in the
controller.
• The increments are sometimes referred to as “addressable points”.

• The ability to divide the joint range into increments depends on the
bit storage capacity in the control memory.

• The number of separate, identifiable increments (addressable points)

for a particular axis is given by Number of Increments = 2n , n = no.
of bits in control memory

• The control resolution would be defined as the total motion range

divided by the number of increments.

• Mechanical inaccuracies in the robot’s links and joint components

and its feedback measurement system (if it is a servo controlled
robot) constitute the other factor that contributes to spatial
resolution.
• Mechanical inaccuracies come from elastic deflection in structural
members, gear backlash, stretching of pulley cords, leakage of
hydraulic fluid, and other imperfection in the mechanical systems.

• The other inaccuracies would also be influenced by such factors as

the load being handled, the speed with which the arm is moving,
the condition of maintenance of the robot, and other similar factors.

• Spatial resolution can be improved by increasing the bit capacity of

the control memory
 ACCURACY

• Accuracy refers to a robot’s ability to position its wrist end as a

desired target point within the work volume.

• The accuracy of a robot can be defined in terms of spatial resolution

because the ability to achieve a given target point depends on how
closely the robot can define the control increments for each of its
joint motions.

• In the worst case, the desired point would lie in the middle between
two adjacent control increments.

• Accuracy is defined as one half of the control resolution

(Mechanical inaccuracies neglected).
• The mechanical inaccuracies would affect the ability to reach the
target position. Accordingly robot’s accuracy to be one half of its
spatial resolution.

• Accuracy varies when the arm is in the outer range of its work
volume and it is better when the arm is closer to its base.

• The accuracy is improved if the motion cycle is restricted to a limited

work range.

• Heavier workload carried by a robot affect the accuracy.

 REPEATABILITY

• The accuracy with which particular defined position can

be repeatedly achieved by a robot is called
Repeatability.
• Here Statistical procedure of distribution of positions
have to be recorded and analyzed.
• The error which is obtained is later adjusted through
programming.
• The repeatability is affected by the condition of robo
components also…..
 PRECISION
• The reach of position of a robot is defined by resolution
of actuators , sensors and control this mainly depends
on feed back systems.
• The robot precision is given in length units.
 REACH
• Here basically the lengths of links, the configurations
define the reach of an Industrial Robot.

• The maximum and minimum extends of the robot

positions give an idea about reach about the robot.

• This Reach is also useful in specifications of the work

envelop of the robot
GRIPPER TYPES
• NON MECHANICAL TYPES

• 1. Vacuum cup type.

• 2.Adhesive gripper
• 3. Magnetic gripper
• 4. Expandable bladder type
 Advantages of Robotics
• Environmental Safety
• Productivity
• Unit cost in long run and batches
• Replacement of robots in populated places
• Accuracy, repeatability and work quality
• Advanced accessories – Sensors, camera
 Disadvantages of robotics
• Cost constraint in investment
• Decision Intelligence is complex
• Replacement of labour
• Real time responses have been the limitations on the
programming capabilities.
• Degeneration of human skill and capability