Introduction to Robotics/

Industrial Robotics
 Definition of robot, Basic concepts
 Robot configurations, Types of robot drives
 Basic robot motions
 Point to point (PTP) Control
 Continuous path control
 Robot: Introduction
1921: Czech author Karel Capek wrote a story called„
Rossum‟s Universal Robots ‟ (RUR) and introduced the
word„ Rabota‟ (meaning„ l abour‟)
1954: George Devol developed the first programmable
Robot.
1955: Denavit and Hartenberg developed the
homogenous transformation matrices
1962: Unimation was formed, first industrial Robots
appeared.
1973: Cincinnati Milacron introduced the T3 model
robot, which became very popular in industry.
 Definition of Robot/IR
Defined in International Standard of Organization(ISO):
A re-programmable, multifunctional manipulator designed to
move material, parts, tools or specialized devices through
variable programmed motions for the performance of a
variety of tasks
There are also definitions given by Robotics Institute of
America (RIA), The Japan Industrial Robot Association
(JIRA), British Robot Association (BRA) and others.
All definitions have two points in common.
The two points: Reprogrammable and multifunctional

Think: CNC machine tools vs. Robots. What makes them

difference?
 Types of robot
• Based on Purpose of uses:
i)Industrial Robots (pick & place, AGVs,
welding, painting, machining, etc.)
ii)Non-Industrial Robot (entertainment, toys,
services, etc.)
• Based on Location of uses:
i)Indoor robots (Structured environment)
(Transportation & services, customer support like
in
museum and shops, research, entertainment, toy, cleaning,
surveillance, etc)
ii) Outdoor robots (Unstructured environment)
(Space, forest, mining, agriculture, demining, air,
underwater, military, sewage tubes, fire fighting, etc.)
 Laws of robotics
1940: Isaac Asimov postulated 3 basic rules:
• 1. A robot must not harm a human being, or
through inaction allow one to come to harm.
• 2. A robot must always obey human beings, unless that is
in conflict with the first law.
• 3. A robot must protect from harm, unless that is
in conflict with the first two laws.
A 4th law was later introduced by Fuller (1999):
„A robot may take a human being‟s job but it may not
leave that person jobless‟
Think about uses of the following
robots
 Characteristics of IR
 Can work in Hazardous work environments
 Able to perform repetitive work
 Maintains consistency and accuracy
 Can deal with Difficult handling task
 Able to perform Multi-shift operations
 It is reprogrammable and flexible
 Can be interfaced to other computer systems
 Low operation & maintenance cost
 Faster and cost-effective production

 (Note: A human is the most flexible of all machines)

 When to decide about using IR?
(Thumb rules)
1. Is the job 4Ds task (dirty, dull,
dangerous and difficult)?
2. Does the using a robot leave a
human jobless?
3. Can you find people who are willing to do
the job?
4. Does the use of robot make short-term and
long-term economic sense?
 IR Structure Joint3
Link3

End of Arm

• Manipulator consists of joints and links

– Joints provide relative motion Link2
– Links are rigid members between joints Link1
– Various joint types: linear and rotary
– Each joint provides a “degree-of-freedom” Joint2
– Most robots possess five or six degrees-
Joint1
of- freedom
• Robot manipulator consists of two sections: Link0
Base
– Body-and-arm – for positioning of objects
in the robot's work volume
– Wrist assembly – for orientation of objects
 Robot Subsystem

A robotic system generally has 3 subsystems: a

motion subsystem, a recognition subsystem and
a control subsystem
ROBOT GEOMETRICAL CONFIGURATIONS
 Manipulator Joints
• Translational motion
– Linear joint (type L)
– Orthogonal joint
(type O)
• Rotary motion
– Rotational joint
(type R)
– Twisting joint (type
T)
– Revolving joint
 Robot Configurations
Some of the commonly used configurations in Robotics are:
• Cartesian/Rectangular Gantry(3P) : These Robots are made of 3
Prismatic joints that orient the end effector, which are usually followed by
additional revolute joints.
• -Large volume space
• -rigid structure
• -provides an accurate position of end-effector
• -maintenance is difficult (as linear motion is
obtained through a set of rotary actuators coupled
with other mechanical components)
• -Dust accumulated in the screws may jam
the smoothMotion of the robot.
 Robot Configurations (cont‟d)
• Cylindrical (R2P): Cylindrical coordinate Robots have 2 prismatic joints
and 1 revolute joint. It has a base rotation, an elevation and the reach.
• These are successfully used when a task requires reaching into
small openings or working on cylindrical surfaces, e.g., welding two
pipes.
 Robot Configurations (cont‟d)
• Spherical or Polar (2RP): They follow a spherical coordinate system,
which has 2 revolute joints and 1 prismatic joint. The arm movements
represents the base rotation, elevation angle and reach. Its workspace
is spherical shape.
 Spherical/Polar Robots
Advantages:
• large working envelope.
• two rotary drives are easily sealed against liquids/dust.

Disadvantages:
• complex coordinates more difficult to visualize, control,
and program.
• exposed linear drive.
• low accuracy.

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 Robot Configurations (cont‟d)
• Articulated/anthropomorphic(3R) :An articulated robot‟s
joints are all revolute, similar to a human‟s arm. It has also
sphere-like workspace, but the internal structure of the space is
difficult to determine. These robots are relatively simpler to
fabricate and to maintain.
 Articulated Robots
Advantages:
• all rotary joints allows for maximum flexibility
• any point in total volume can be reached.
• all joints can be sealed from the environment.

Disadvantages:
• extremely difficult to visualize, control, and program.
• restricted volume coverage.
• low accuracy

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 Robot Configurations (cont’d)
• Selective Compliance Assembly Robot Arm (SCARA) (2R1P): They
have two revolute joints that are parallel rotational axis and allow the Robot
to move in a horizontal plane, plus an additional prismatic joint that moves
vertically. Its workspace is also cylindrical type, but here reach is obtained
by a revolute joint instead of prismatic joint. It is very useful for assembly
operations & highly used in industrial purpose.
 SCARA
Advantages:
• high speed.
Robots
• height axis is rigid
• large work area for floor space
• moderately easy to program.
Disadvantages:
• limited applications.
• 2 ways to reach point
• difficult to program off-line
• highly complex arm

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1(b) Find the value of θ1 and θ2 for the following 2R robot
when the gripper position is at (2, 2). Given that the link
length a1=2 m and a2= 1 m.
Robot Configurations
 Think about configuration
Cylindrical

Cartesian
Spherical

Articulated SCARA
 Transformation of robot
Type 1 (base): 2(elevation): 3 (reach):
motion motion motion
Cartesian

Cylindrical

Spherical

Articulated

Use: +P for adding prismatic joint, P for keeping prismatic

joint, -P for removing prismatic joint,+R for adding revolute joint,
R for keeping revolute joint
 Transformation of robot
Type 1 (base): 2(elevation): 3 (reach):
motion motion motion

Cartesian +P +P +P

Cylindrical -P +R P P

Spherical R -P+R P

Articulated R R -P+R

Use: +P for adding prismatic joint, P for keeping

prismatic joint, -P for removing prismatic joint, +R
for adding revolute joint, R for keeping revolute joint
 Robot classification by
Actuation system
Robot

Fluid Power driven Electric power driven

Hydraulic
Pneumatic
Robot classification by Control method
A) Motion control strategy:
-Servo control(Closed-loop control)
-Non-servo control (Open loop)
B) Motion path control strategy:
-Point-to-point path control
-Continuous path control
C) Programming method:
-Online programming
-Offline programming
 Review Question of Lecture 1-4
• From which word, the “robot" term is derived? What is
the meaning of that word?
• What is the difference between a robot & CNC?
• What are the 4D‟s of the robot,s task?
• Mention 3 applications of industrial robot.
• What is the 4th law of robotics
• What is dead zone?
• What are the types of robot configuration?
• What is the difference between spherical & SCARA?
Robot Drives
 Types of Robot Drives
• The drive system is an important element of a
robot. Without it, robot can‟t do any task.
• The drive system supplies the power,
which enable the robot to move.
• The dynamic performance of a robot
mainly depends on the type of power source.
• Robot drive systems are of 3 types based
on the sources: Hydraulic, Pneumatic and
Electric
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 Selection criteria of Robot Drives

 Speed of Operation.
 Reliability & efficiency
 Service Life.
 Sensitivity to Environment.
 Ease of Maintenance.
 Availability
 Transportability
 Explosion proof nature
 Cleanliness
 Overload safety
 Hydraulic drives
It is an actuator that uses pumps, valves and
pressurized liquid to create mechanical motion
Advantages:
• Provide fast movements
• High efficiency and high power-to-size ratio
• Complete & accurate control over speed, position
and direction of actuators
• Preferred for moving heavy parts
• Self-lubricating and non-corrosive
• Can meet sudden demands in power
• Preferred to be used in explosive environments

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 Hydraulic drives
Disadvantages:
• Occupy large space area
• There is a danger of oil leak to the shop floor
• The power pack can be noisy (about 70 dB)
• Changes in temperature alter the viscosity
of the hydraulic fluid.
• For smaller robots, it is not
economically feasible
• Servo-control of hydraulic systems is complex
 Hydraulic drives
Application:
 Spray-painting, Welding, cutting
 Handling heavy forging and die casting
operations
• Note1: 4 essential components: a reservoir (to
hold the liquid), pumps (to move it), Valves (to
control flow), Actuator( to carry the dictates of
the fluid on some load)
• Note2: Fluid two properties: viscosity and bulk
modulus
 Structure of a hydraulic drive

Aggregate Control Actuator

elements

Pump, motor Various valves: Elements doing

Fluid reservoir determining the work
Pressure path, pressure, flow • Linear
rate of the working
relief valve • Rotational
fluid
Filter • Swinging
Piping

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Hydraulic drives
 Hydraulic fluids - requirements
 Functional
 Good lubrication characteristics
 Viscosity should not depend strongly on temperature and
pressure
 Good heat conductivity
 Low heat expansion coefficient
 Large elasticity modulus

 Economic
 Low price
 Slow aging and thermal and chemical stability  long
life cycle
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Pneumatic drives
 Pneumatic drives
They utilize pneumatic energy provided by a compressor
and transforms it into mechanical energy by means of
pistons/turbines.
Advantages:
• Preferred for smaller robots as they are compact
• Compressed air can be stored & conveyed easily
• Compresses air is clean, explosion-proof & insensitive
to temperature fluctuation
• They have a very quick action & response time
• Inherently reliable and reducing maintenance cost
• Less expensive than electric or hydraulic robots
• Safe to use in explosive areas.
• Control is simple.
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 Pneumatic drives
Disadvantages/Drawbacks:
• Suitable for relatively less degrees of freedom design
• Suitable for simple pick and place application
• Since air is compressible, precise control of speed and
position is not easily obtainable.
• These are not suitable for moving heavy loads under
precise control due to compressibility of air.
• If moisture penetrates the units and ferrous metals
have been used, then damage to components can
result
Applications: Pick & Place operations
Pneumatic drive system
 To System
Safe Working Pressure
Test Pressure Pressure Relief Valve
Identification (Safety Valve)

Shut Off
Valve
Pressure Gauge

From
Compresso
r
I
n
s
p
e Water Drain
c
t
i
o
n

P
 Air Preparation
Water Separation.
 Water causes corrosion.
 Washes away lubrication.
Filtration.
 Dust is responsible for abrasion.
 Reduces the effectiveness of lubricants.
Pressure Regulation.
 Constant pressure is required for uniform performance of
pneumatic components.
Lubrication.
 Lubrication is required to replace lubricant lost due to effects of
dust and water over prolonged periods.
 Reduces internal friction in components.
Electric drive
 Electric drive
Electric motor drives the robot link through
some
mechanical transmission e.g. gears, chains, belts
etc. The most used type of drive in robot
Advantages:
• High power conversion efficiency
• Good for small and medium size robots
• Better positioning accuracy and repeatability
• They are easily maintained and repaired
• Cleaner environment (No pollution)
• The drive system is well suited to electronic control
• The basic drive elements are usually lighter than that
for fluid power

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 Electric drive
Disadvantages/Drawbacks:
• Slower movement compare to the fluid powered robots
• They require some sort of mechanical transmission
system which adds mass and unwanted movement. As a
result additional power is required and control makes
complicate
• Additional cost is incurred for their maintenance
• Electric motors are not intrinsically safe. They can‟t be
used in for explosive environment
Note: The above drawbacks are gradually being overcome
with introduction of direct drive motor system, in which it
is a part of the relevant robot arm joint.
 Electric drive
Different types of electric motors are: stepper
motors, DC motors and AC motors
Stepper motors: variable reluctance, permanent
magnet and hybrid type
DC motors: Permanent magnet and Brushless
permanent magnet
AC motors: Main two groups are: single-phase and
Poly-phase. Each group being further divided into
induction and synchronous motor.
Note:
• stepper motor drive: open loop control
• DC motor drive: closed loop control
 Electric drive
DC stepper motor:
• Uses discrete voltage pulses to create required motion (angle)
•More accurate to be used in open-loop control system
DC servo motor:
• Incorporated feed back control loop
• Sensor like optical encoder continuously monitors the
position
• Continuous and smoother movement
Applications:
• General purpose application
• Automatics assembly operations
 Selection of drives

• For any application of robots, one must decide

which of the available actuators is
most suitable
based on positioning
reliability speed accuracy, of
,
torque requirement,control, type costof
robot structure,
and other factors path,
Basic Robot Motion
 Basic Robot Motion
Four types of robot motion control:

1. Point-to-point (PTP) control robot

2. Continuous-path (CP) control robot

3. Controlled-path robot

4. Stop-to-Stop
Note: It is also needed to know about absolute and
incremental position control

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 Point to Point Control Robot
• The PTP robot is capable of moving from one point
to another point
• The locations are recorded in the control memory.
PTP robots do not control the path to get from one
point to the next point.
• Calculates to provide minimum travel time
• Common applications include:
– component insertion
– spot welding
– hole drilling
– machine loading and unloading
– assembly operations
– Pick & place
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 Continuous-Path Control Robot
• The CP robot is capable of performing movements along the
controlled path.
• The robot can stop at any specified point along the controlled
path.
• All the points along the path must be stored explicitly in the
robot's control memory.
• Straight-line motion is the simplest example for this type of
robot.
• Some continuous-path controlled robots also have the
capability to follow a smooth curve path that has been defined
by the programmer. In such cases the programmer manually
moves the robot arm through the desired path and the
controller unit stores a large number of individual point
locations along the path in memory (teach-in).

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 Continuous-Path Control Robot

Typical applications include:

– spray painting
– finishing
– gluing
– arc welding operations
– Cutting

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 Controlled-Path Robot
 In controlled-path robots, the control equipment can generate
paths of different geometry such as straight lines, circles, and
interpolated curves with a high degree of accuracy.

 Good accuracy can be obtained at any point along

the
specified path.

 Only the start and finish points and the path definition function
must be stored in the robot's control memory.

 It is important to mention that all controlled-path robots have a

servo capability to correct their path
 Stop-to-stop control

 It is open loop system

 Position and velocity unknown to controller
 On/off commands stored as valve states
 End travel set by mechanical
 Work Envelop
Work envelope (also known as the robot reach
or work volume) is the space of all points in
the surrounding space that can be reached by
the robot arm.
Work envelop is one of the most important
characteristics to be considered in selecting a
suitable robot because the application space
should not fall out of the selected robot's
reach.

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 Work Envelop
• For a Cartesian configuration the reach is
a rectangular-type space.
• For a cylindrical configuration the reach is
a hollow cylindrical space.
• For a polar configuration the reach is part of a
hollow spherical shape.
• Robot reach for a jointed-arm
configuration does not have a specific shape.

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 Assignment-1
1. Why there are some dead zones in the workspace
of a robot?
2. Draw a typical speed-torque plot of a DC motor.
3. What is motor constant? What is the significance of
it?
4. What kind of robot configuration is suitable for
painting a shaft? Why?
5. Show that maximum power from a DC motor is
attainable at the half of maximum speed.