ROBOTICS

FACT VS FANTASY (CPR)

FANTASY FACT
*human-like capability *Bug-like capabilities
*Complex Perception *Primitive Perception
*Complex Reasoning *Primitive Reasoning

-Refers to the study and use of robots

ISAAC ASIMOV -term was coined and FIRST
used by this Russian-born American scientist
and writer (born. Jan 2 1920, died April 6 1992)

Robots
- accdg to Robot Institute of America,
it is a reprogrammable, multifunctional
manipulator designed to move material, parts,
tools, or specialized devices through variable
programmed motions for the performance of
variety of tasks

-is a one-armed, blindidiot with limited
memory and which cannot speak, see or hear

EASY FOR
ROBOTS
EASY FOR
HUMANS
*Repetitive tasks *Reasoning
*Continuous
operation
*Adapting to new
situations
*Do complicated
calculations
*Flexible to
changing
requirements
*Refer to huge
data bases
*Integrating
multiple sensors
*Resolving
conflicting data
*Synthesizing
unrelated
information
*Creativity



What tasks would you give
robots?
Dangerous
Boring and/or repetitive
High precision or high speed

What subsystems make up a
robot? (ASM-PCS)
A Action
B Stationary base
C Mobile
D Sensors
E Control
F Power supply

Action do some function.
A Actuators
pneumatic
hydraulic
electric solenoid
B Motors
Analog (continuous)
Stepping (discrete increments)
C Gears, belts, screws, levers
D Manipulations

Three types of robot actions. (PCS)
A Pick and place
- Moves items between points.
B Continuous path control
-Moves along a programmable path
C Sensory
-Employs sensors for feedback

How do robots move?
A. Simple joints (2D)
* Prismatic-sliding along one axis
-square cylinder in square
tube
* Revolute rotating about one axis

B. Compound joints (3D)
*ball and socket = 3 revolute joints
* round cylinder in tube = 1 prismatic,
1 revolute
C. Degrees of freedom = Number of
independent motions
*3 degrees of freedom: 2 translation, 1 rotation
*6 degrees of freedom: 3 translation, 3 rotation

Mobility
* Legs
*Wheels
*Tracks
*Crawls
*Role

What sensors might robots have?
A. Optical
* Laser / radar
* 3D
* Color spectrum
B. Pressure
C. Temperature
D. Chemical
E. Motion & Accelerometer
F. Acoustic
* Ultrasonic

What use are sensors?
*Uses sensors for feedback
-Closed-loop robots use sensors in
conjunction with actuators to gain
higher accuracy servo motors.

* Uses include mobile robotics,
telepresence, search and rescue,
pick and place with machine vision.

Control - the Brain
* Open loop, i.e., no feedback,
deterministic
a. Instructions
b. Rules
*Closed loop, i.e., feedback
a. Learn
b. Adapt




Industrial Applications
Automation in Manufacturing
Goal: To integrate various operations to
-Improve Productivity
-Increase product quality and Uniformity
-Minimize cycle times and effort
-Reduce labor cost

*Computers- allows us to integrate
virtually all phases of manufacturing
operations.

*Computer-integrated
manufacturing(CIM)- Is the
computerized integration of all aspects
of design, planning, manufacturing,
distribution, and management.

AUTOMATION TECHNOLOGIES:
A. Numerical Control(NC):
-capability of flexibility of
operations, low cost, and ease of
making different parts with lower
operator skill.
B. Adaptive Control(AC):
- Continuously monitor the
operation and make necessary
adjustments in process
parameters.

* Flexible Manufacturing
System(FMS)- Integrate manufacturing
cells into a large unit, containing
industrial robots servicing
several machines, all interfaced with a
central host computer.

*Artificial Intelligence(AI)-Involves the
use do machines, computers and
industrial robots to replace human
intelligence.

* Expert Systems(ES)-Intelligent
programs to perform tasks and
solve difficult real life problems.

ROBOT APPLICATIONS

* Need to replace human labor
by robots:
-Work environment hazardous for
human beings
-Repetitive tasks
-Boring and unpleasant tasks
-Multishift operations
-Infrequent changeovers
-Performing at a steady pace
-Operating for long hours without rest
-Responding in automated operations
-Minimizing variation

*Industrial Robot Applications
can be divided into:
A. Material-handling applications:
Involve the movement of material or
parts from one location to
another.
It include:
1. part placement
-simple pick and place
operations
-needs low technology robot
for cylindrical coordinate type
-only 2/3/4 joints reqd
2. palletizing and/or
depalletizing
-reqd robot to stack(palletize)
and unstack(depalletize) parts
one on top of the other
3. machine loading and
unloading.
-robot transfers parts into
and/or from a production
machine
-three cases: robot load, and
other unload . robot unloads,
and other load, robot load and
other load
-DIFFICULTIES- difference in
cycle time
4. Stacking and insertion
operations
*stacking- the robot places
flat parts on top of each other
*insertion- robot inserts parts
into compartments

B. Processing Operations:
Requires the robot to manipulate a
special process tool as the end
effector.
*Robot performs a processing
procedure on the part
*Manipulates the tooling relative to the
working part during the cycle
The application include:
- spot welding
-arc welding
-Spray painting
-Machining
-metal cutting and deburring
-rotating and spindle operations
-adhesives and sealant dispensing

C. Assembly Applications:
Involve part-handling manipulations of
a special tools and other
automatic tasks and operations.
*involve both material-handling and the
manipulation of tool
*traditionally labor-intensive activities
and highly repetitive and boring
*Classified as:
1. Batch Assembly (long
production runs)
2. Low Volume (sample run of
10k below)
*Assembly robot should be a
MODULAR CELL

D. Inspection Operations:
*require parts to be manipulated and
other requires that an inspection tool
can be manipulated.
x- requires HIGH PRECISION and
PATIENCE. And HUMAN JUDGEMENT
is often needed
*Three techniques:
1. using LVDT- linear variable
differential transformer: a feeler
gauge or linear displacement transducer
w/c the part being measured will come
in physical contact w/ instrument or by
means of air pressure w/c will cause it to
ride above the surface being measured.
2. by utilizing ROBOTIC VISION:
matrix video cameras are used
3. by invlolving the use of
OPTICS AND LIGHT: usually a laser or
infrared source
*Require the robot to position a workpart
to an inspection device.
*Involve the robot to manipulate a
device or sensor to perform the
inspection.
*active role- robot is responsible for
determining wheter the part is good or
bad
*Passive role- robot feeds a gauging
station with the part.

EVALUATION OF THE POTENTIAL
OF THE ROBOT DEPENDS ON:
A. Analysis of the application
Long- and short-term objectives
Manufacturing and processes involved
Space availability
Budget
System objectives
B. Feasibility Study
How a more automated system will
affect related operations in the plant
Material-handling methods
Commercial equipment available
CAD cell simulation
C. System Proposal
Functional specifications
System operation
Robot type
Tooling
Peripheral equipment
D. System Design
Microprocessor control
Software
Multiple levels of control
E. Construction Phase
It is a good procedure for the system to
be set up and thoroughly tested at the
suppliers facility.
This will minimize the interruption of
current production procedures.
F. Installation Phase
It is a good practice for the supplier to
supervise the step-by-step installation of
the system.
G. Training and Documentation

Future Applications
a. The medical applications of the
robot:
Routine examinations
Surgical procedures
b. Underwater applications
Involve prospecting for minerals
on the floor of the ocean.
Salvaging of sunken vessels,
repair the ship either at sea or in dry
dock.
Mobile firefighters to be used by
Air force and Navy.
c. Surveillance and Guard duty
In military
Power generating plants, oil
refineries and other civilian facilities that
are potential targets of terrorist groups.
In summary:
Aerospace
Agriculture
Construction
Health
Nuclear
Textile
Surveillance and guard duty
Navigation systems
Firefighting
Household robot
Industrial Robotics
-A general-purpose, programmable
machine possessing
certain anthropomorphic characteristics
*Hazardous work environments
*Repetitive work cycle
* Consistency and accuracy
* Difficult handling task for humans
* Multishift operations
* Reprogrammable, flexible
* Interfaced to other computer systems

1. Robot Anatomy
*Manipulator- consists of joints
and links. Two sections:
a. body and arm for
positioning objects in robots work
volume
b. Wrist assembly- for
orientation of objects
*Joints- provide relative motion:
linear or rotary. Each joints provides a
degree of freedom
*Links- rigid members between
joints
*degree of freedom- one joint one
degree of freedom
*Simple robots- 3 degrees of freedom
in XYZ axis
*Modern robot arms- up to 7 degrees
of freedom
*XYZ, roll , pitch and Yaw
*Crust Crawler- 5 degrees of freedom

MANIPULATOR JOINTS
A. Translational Motion
*Linear (type L)
*Orthogonal joint (Type O)
B. Rotary Motion
*Rotational(type R)
*Twisting (Type T)
*Revolving (Type V)

ROBOTIC JOINTS
- different robotic joints can be used to
provide a variety of degrees of freedom
a. Rotary Joints
*Waist Joint
*Elbow Joints
b. Linear/Prismatic Joints
*Sliding Joints
*Simple Axial Direction
2. Robot Control Systems
3. End Effectors
4. Industrial Robot Applications
5. Robot Programming

Joint Notation Scheme
-Uses the joint symbols (L, O, R, T, V) to
designate jointtypes used to construct
robot manipulator
-Separates body-and-arm assembly
from wrist assembly using a colon (:)
Example: TLR : TR

*Work Envelope- The volume of space
in which a robot can operate
-define the space around
that is accessible to the mounting point
for the end-effector

Classification of Robots
1. Cartesian
2. Cylindrical
3. Spherical/Polar
1. Cartesian Coordinate

Body and Arm assembly
*Notation LOO
-consists of 3 sliding joints, two of
which are orthogonal
-other names include rectilinear
robot and XYZ robot

Frame
-most familiar system
-uses three axes at 90 degrees to
each other
-right hand rule

Cartesian robot
-three prismatic joints
-pick and place

2. Polar coordinate
Body and Arm assembly
*Notation TRL
-1 sliding arm (L joint) actuated
relative to body, which can rotate about
a vertical axis (T joint) and horizontal
axis (R joint)
*similar to finding a point on the
earths surface (Radius, latitude,
longitude)

Spherical/Polar Robot
*Spot, gas and arc welding
*Reaching horizontal or inclined
tunnels/areas

3. Cylindrical coordinate
Body and arm assembly
*Notation TLO
-a vertical columns, relative to
which an arm assembly is moved up
or down
- the arm can be moved in or out
relative to column

*Jointed-Arm Robot
-Notation TRR
*SCARA robot
-Selectively Compliant Assembly
Robot Arm
-Notation VRO
-similar to jointed-arm robot
except that vertical axes are used for
shoulders and elbow joints to be
complaint in horizontal direction for
vertical insertion tasks
-developed to meet the needs of
modern assembly
-fast movement w/ light payloads
-rapid placement of electronic
components on PCB
-combination of two horizontal
rotational axes and one linear joint

*Revolute Robot or puma
- most resembles the human arm
-robot rotates like the human
waist
-ideal for spray painting and
welding as it mimics human movement

*Humanoid Robot
-previously developed for
recreational and enetertainment value
- use for household chores aid for
elderly aid

*Wrist assembly- attached to end-of-
arm and use to orient end effector
3 degress of freedom- roll, pitch , yaw
*Notation: RRT
*End effector- attached to wrist
assembly

JOINT DRIVE SYSTEMS
1.Electric- uses electric motors,
preferred drive system in todays robot
2. hydraulic- for high power and lift
capacity. Uses hydraulic pistons and
rotary vane actuators
3. Pneumatic- limited to smaller robots
and simple material transfer applications


Actuators
*Motors- control the movement
of a robot
A. DC Motors
-most common and cheapest
-powered w/ two wires
-draws large amount of current
-cannot be wired straight to PIC
-no accuracy and speed
B. Stepper Motors
-many electromagnets
-controlled by sequential turning
on and off of magnets
-poor control w/ a large angle
-better step angle achieved w/
toothed disc
C. Servo Motors
-smoothest control
-rotate to specific point
-offer good torque and control
-ideal for powering robot arm
-degree of revolution is limited
-not suitable for continuous
rotation
-motor,gearbox,driver controller,
and potentiometer
D. End Effector
-correct name for the hands
attached to the end of robot
-used for grasping, drilling . etc
-can be Grippers or Tools
*tools- to perform process
*grippers- to grasp/manipulate object
A. mechanical
-two finger most common
-applies force that causes
enough friction
-not suitable for brittle
B. magnetic
-ferrous material required
-electro and permanent magnets
used
C. pneumatic
-suction cups for plastic/rubber
-smooth even surface reqd
ROBOT CONTROL SYSTEM
*Limited Sequence Control- pick and
place operations using mechanical
stops to set positions
*Playback w/ point to point control-
records work cycle as a sequence of
points, then plays back the sequence
during program execution
*Playback w/ continuous path
control- greater memory capacity and
interpolation capability to execute paths
*Intelligence Control- exhibits behavior
that makes it seem intelligent

Control Systems elements
1. The control- brain, reads
instruction
2. Current amplifier- receives order
from brain and sends required
signal to motor
3. Servo motors-output
*Open loop control- the controller is
told whether the output device needs to
be. Much cheaper but low accuracy.
Doesnt receive feedback
*Closed loops control- provided
feedback . this actual position is found
using an encoder
*Encoder- gives the control unit
information as to the actual position of
motor.
-light shines through a slotted
disc, the light sensor counts the speed
and number of breaks in light
*Closed loop control- desired value is
compared to actual.
*Comparator- subtracts actual
from desired
*On-Off control-simplest closed loop
*rubber band effect- greater the
distance from the desired more
corrective force applied
*AD/DA conversion-necessary to
convert analogue to digital
*Analogue- has a large number of
values bet. 0-5v. depends on resolution
INDUSTRIAL ROBOTS APPLICATION
1. Material Handling application
*Material transfer- pick and
place, palletizing
*Machine loading or
unloading
2. Processing operations
-welding, spray coating, cutting
etc
3. Assembly and inspection

FCAW- flux colored arc welding

ROBOT PROGRAMMING
*Leadthrough programming- work
cycle is taught to robot by moving the
manipulator through the required motion
cycle
*Powered leadthrough- common
for point-to-point robots
-uses teach pendant
*Manual Leadthrough- for
continuous path control robots

ADVANTAGES
*Easily learned by shop personnel
*Logical way to teach a robot
*No computer programming

DISADVANTAGES
*Downtime during programming
*limited programming logic capability
*Not compatible w. supervisory control
*Robot Programming languages-
Textual programming language to enter
commands into robot controller
*Simulation and off-line
programming- program is prepared at
a remote computer terminal and
download to robot controller for
execution

Robot Programming
Textural programming languages
Enhanced sensor capabilities
Improved output capabilities to control
external equipment
Program logic
Computations and data processing
Communications with supervisory
computers

WELDING

MIG WELDING (GMAW)
-Metal Inert Gas or Gas Metal Arc
Welding
-DC or AC electric arc
-Consumable electrode
-Shielding Gas

HISTORY
-developed in 1940s to weld aluminum,
magnesium and other non-ferrous alloys
-use in steel originally limited by cost of
inert gas
-1950s carbon dioxide was used
-1960s increased versatility in
process
-commonly used in industrial welding

EQUIPMENT
Welding torch
Workpiece
Power supply
Wire feed mechanism
Electrode
Shielding Gas (argon-CO2 mixed)

PROCESS
-Arc creates weld pool to bond material
-Shielding gas protects the weld pool
from atmospheric gas effects
Porosity and embrittlement
-Technique
Simple: electrode is fed
automatically
Torch is guided along weld area
keeping a constant tip to workpiece
distance

CAPABILITIES
-Inexpensive machines ($500)
-Required skill level is relatively low
-Can weld many ferrous and non-ferrous
materials
Different results and
requirements must be expected
(shielding gas, technique, electrode, etc)
-Power of machine will determine what it
can weld
More power thicker material
GMAW can be automated more easily
than other methods

INDUSTRIES
-Automotive
Almost exclusive
-Pressure Vessels
-Heavy rail and construction equipment

-At Home
Easy and inexpensive
-Automobile/Agricultural repair


TIG - Welding
-Tungsten Inert Gas (TIG) or Gas
Tungsten Arc Welding (GTAW)
-AC or DC Electric Arc
-Non-consumable tungsten electrode
-Shielding Gas
-Hand fed filler

HISTORY
-Early 1900s welding non-ferrous
materials was difficult
Reacted with air making welds
weak and porous
-Process was improved in the 1930s
and 1940s
Gas shielding increased weld
quality

AC machines allowed for high
quality welds on aluminum and
magnesium

EQUIPMENT
-Welding Torch
Directs shielding gas and holds
electrode
-Power Supply
AC typically used for aluminum
and magnesium
DC with a negatively charged
electrode is typically used for steels
-Electrode
Made from tungsten or tungsten
alloys
ISO standards for each alloy
-Filler Rod
-Shielding Gas
Argon is most common
Helium is sometimes used when

PROCESS
-Arc creates weld pool to bond material
AC or DC used depending on
base material
-Shielding gas protects the weld pool
from atmospheric gas effects
Porosity and impurities
-Technique
Requires two hands
Torch is moved forward as filler
rod is dipped into the weld pool
Filler rod must remain inside the
gas shield at all times
Considered one of the most
difficult welding methods low melt
alloys increase difficulty

CAPABILITIES
-Produces welds with very similar
material properties of the base metal
-GTAW can produce high quality welds
on materials such as aluminum,
magnesium, titanium, copper, nickel,
steel.
-Dissimilar materials copper and
stainless
-Requires a skilled welder considered
to be one of the more difficult types of
welding
-Automation is possible, but not as
common as GMAW due to the increase
complexities

INDUSTRIES
-Aircraft
-Spacecraft
-Bicycles
-Crack repair

Shielded Metal Arc Welding
(Stick Welding)

-common welding technique
-stick is synonymous w/ coated
electrode
-arc created between metal and
electrode
-metal is melted and coalesces to form
weld

Coating
Common: cellulosic, rutile, limestone
-ease process through slag creation,
and help to strengthen weld

Advantages
-simple
-portable
-versatile
-inexpensive equipment

Disadvantages
-limited shielding
-limited deposition rates
-usually done by hand
-highly trained labor required

Diffusion Welding
-diffusion bonding, solid state bonding
-can be used to join metals and
ceramics
-accdg to American welding society:
diffusion is a solid state welding
process that produces a weld by the
application of pressure at elevated
temperature w/ no macroscopic
deformation or relative motion of work
pieces

-Two materials are heated and pressed
upon one another
-Pressure causes heated atoms to
diffuse into surface, creating a bond
upon recrystalization
-D=D0e-(Q/KT)

EQUIPMENT
-A press is needed, which can create
pressure in a variety of ways
-Heat needs to be generated as well
-Fixturing system required

Advantages
-Perfect weld possible
-Special material properties
-Even weld properties throughout
material
-Close tolerances
-Expensive materials

Disadvantages
-Only perpendicular surfaces
-Specially designed components
-Requires inert atmosphere
-Expensive


Friction Welding (FW)
-Solid state welding process
-Generates heat through friction
between moving surfaces
-Heat in combination with lateral force
called upset fuses two materials
together
-First Patent for the development of FW
was applied for in 1891


Types of Friction Welding
1. Spin Welding (inertia,
rotational, inertial friction)
-Involves the rotation of one
surface relative to another while
applying pressure along the axis
of rotation
-Work pieces are held by
chucks in spin welding machines
Flywheel is used to store the
energy produced by the motor
-Requires circular joining points

2. Linear Friction Welding (LFW)
-Lateral motion of surfaces rather
than rotational
-Most surface can be joined

3. Friction Stir Welding
-A cylindrical probe rotates and
constant speed and fed at a
constant rate across the joint of
two components
-Parts must be rigidly clamped
together to prevent them from
being forced apart from welding
process

4. Friction Surfacing
-Coating of material applied to
surface of another material
-Rod composed of coating
material is rotated under pressure
across the surface of a separate
material
-Closely resembles a hot forging
process so problems associated
with more traditional welding

ADVANTAGES

-Fast joining times
-Small heat affected zones
-Joined with little preparation of surfaces
-Believed that flash carries away dirt
and debris from surfaces
-Welding of dissimilar metals
Aerospace - Aluminum and Steel
Nuclear - Copper and Steel

DISADVANTAGES
-Uneconomical for short production runs
due to high equipment costs
-Excludes delicate and intricate part

Explosion Welding (EXW)
-Solid state welding process
-Plates are bonded through pressure
created from a controlled detonation of
explosive charge
-Originates from WWI when it was
discovered that pieces of shrapnel were
welded to armor plating on tanks
-Later development occurred in the
decades following WWII
-Primarily used to clad inexpensive
structural material with corrosion
resistant material

ADVANTAGES
-Large surfaces may be welded
-Produces a high quality bond
-Low cost
-Simple
-little surface preparation required
-Dissimilar metals can be welded

DISADVANTAGES
-Brittle materials cannot be processed
-Only simple shapes
- Plates and Cylinders
-Thickness of flyer plate is limited
-There are many safety concerns when
storing and detonating explosives

Common Bi-Metals Produced
-Copper to Steel
-Nickel to steel
-Aluminum to steel
-Tungsten to steel
-Titanium to steel
-Copper to aluminum