DV04PUB11 Study Guide

Industrial Robotics
Training Objective
After watching the program and reviewing this printed material, the viewer will learn the basics of industrial
robot technology and how robots are used in a variety of manufacturing and assembly operations.
An overview of robot technology is provided

The primary types of industrial robots are shown
Programming methods are demonstrated
Robot tooling and sensors are detailed
Robotics Overview
Industrial robots are defined as 'multi-functional manipulators designed to move materials, parts, tools, or
specialized devices through various programmed motions'. As such, robots provides consistent reliable
performance, repetitive accuracy and are able to handle heavy work loads and perform in harsh
environments. Additionally, robots can be quickly reprogrammed to reflect changes in production needs and
cycles. All of the above result in vastly improved productivity and quality. However, this technology has
certain disadvantages, which can include:
The need for skilled programmers

The high cost of robotic systems
Constant maintenance procedures
Unique worker safety precautions
Robots can have either hydraulic, electric, or pneumatic power sources. Movement configurations can range
from simple arm extension and retraction movements to very complex movements involving body, upper
arm, lower arm, and wrist movement. These various configurations are differentiated by the number of
'degrees of freedom' or 'axes of motion'. The number of axes determines the overall dexterity of the robot.
Robots may have up to seven axes of motion which include four arm motions and three wrist motions. The
axes, or joints, can be either linear or rotary in motion. Another defining aspect is the robots work envelope
which is its maximum reach in all directions.
Robots are broadly classified by their arms geometry. The primary types are:
Rectangular Arm Robots - also called Cartesian Robots, or Gantry Robots, move in the standard
Cartesian coordinate axes 'X', 'Y', and 'Z'. This type is usually used for handling small parts in pick and
place operations and is easily integrated into assembly operations.
Selective Compliant Articulated Robot for Assembly (SCARA) Robots - these SCARA robots have two
parallel rotary axes that enable vertical axis insertion from the end of the wrist. SCARA robots are
especially well suited for assembly work.
Articulated Robots - also call jointed arm robots, they have three axes of rotary arm motion but do not
have any corresponding coordinate system. Being able to move simultaneously along its three axes, the
articulated robot is used for very complex tasks.
Robots are typically fixtured in place and thus have a clearly defined but finite work envelope. In some
instances the robot may be mounted on a slide, transporter, or gantry. This arrangement allows the robot to
service multiple work stations or machines.
Fundamental Manufacturing Processes Study Guide, DV04PUB11 -1-

Industrial Robotics
Robot Wrist & End of Arm Tools
The wrist provides one, two, or three axes of motion relative to the arm itself. The motions are:
Pitch - motion in the vertical plane

Yaw - motion in the horizontal plane
Roll - a rotary motion
Additionally, the wrist serves as the mounting point for a variety of devices. These 'end effectors' are either
hand, or gripping devices, or job specific tools.
Gripping devices can include:
Suction cups
Multiple jaw grippers that grip internal or external surfaces
A system of interchangeable grippers
Tools can include welding guns, paint spraying nozzles, and a wide variety of machining tools:
Welding - both arc and spot welding can be effectively done with robots while providing fast, high quality
assembly line production capability
Part coatings - robots facilitate the accurate and consistently stable application of paints, adhesives, and
powder coating to flat, curved, and hard to reach surfaces
Machining - wrist mounted drills, mills, boring, and deburring tools are typical of a wide variety of tools
used in manufacturing operations
Robot Programming
Programming gives the robot system specific instructions governing the movement of the arm and its end
effector. These include:
Direction
Path
Distances to move
Sequences
Tool selections
These programs may be created either on-line or off-line with each method having distinct advantages or
disadvantages.
On-line Programming - uses a 'teach pendant' to direct the robots movement. Taught data is stored in
the pendants memory then transferred to the robots controller. This is a convenient and easy method of
programming when tasks are simple and revisions or adjustments can be made on the spot. However,
the production line must be stopped during the programming and there are safety issues to consider as
the programmer must work within the robots work envelope.
Off-line Programming - this method is accomplished on computers located away from the robot station.
Using simulation software, data is generated then sent to the robots controller where it is translated into
instructions. Additionally, the software contains modeling data which assists selection of the best robot
configuration for a particular application. A primary advantage of off-line programming is that production
need not be interrupted in order to create an initial or revised program.

Industrial Robotics
Robot Sensors
Sensors are used to monitor part location and orientation during the production cycle. In so doing, the
sensors can allow the robot to compensate for any variation in the parts or other aspects of the process. The
sensors may either be contact or non-contact in function.
Contact sensors include force gages and compliance devices which compensate for part positioning errors.
Non-contact sensors include:
Pneumatic sensors which detect part presence by air flow disturbance

Ultrasonic sensors that analyze sound waves reflected from a part
Proximity sensors that register the approach, arrival, or removal of parts
Optical sensors utilizing interrupted light beams across the path of an incoming part
Machine Vision Systems that use visual sensors, usually video cameras, to provide data that allows the
robot to make intelligent decisions regarding parts

Industrial Robotics
Review Questions
1. 'Degrees of Freedom' refer to:

a. a robot being stationary or movable
b. the number of axes of motion
c. the robots reach
d. the size of the work envelope
2. Robot dexterity is determined by:

a. its programming
b. its end effectors
c. the number of axes of motion
d. its size
3. The number of robot wrist motions possible is:

a. 1
b. 4
c. 7
d. 3
4. Another name for Rectangular Arm Robots is:

a. Coordinate Robot
b. SCARA Robot
c. Cartesian Robot
d. Jointed Arm Robot
5. SCARA Robots are well suited for:

a. assembly work
b. welding
c. paint spraying
d. machining
6. 'Pitch and Yaw' refer to:

a. upper arm movements
b. robot column movements
c. forearm movements
d. wrist movements
7. The primary advantage of off-line programming is:

a. programmer safety
b. ability to do complex programming
c. little or no production downtime
d. all of the above
8. Simulation software is used for:

a. teach pendants
b. for on-line programming
c. for off-line programming
d. optical sensors

Industrial Robotics
Answers
1. b
2. c
3. d
4. c
5. a
6. d
7. d
8. c

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Industrial Robotics

An overview of robot technology is provided

The need for skilled programmers

Fundamental Manufacturing Processes Study Guide, DV04PUB11 -1-

Robot Wrist & End of Arm Tools

Pitch - motion in the vertical plane

Gripping devices can include:

Fundamental Manufacturing Processes Study Guide, DV04PUB11 -2-

Pneumatic sensors which detect part presence by air flow disturbance

Fundamental Manufacturing Processes Study Guide, DV04PUB11 -3-

1. 'Degrees of Freedom' refer to:

2. Robot dexterity is determined by:

3. The number of robot wrist motions possible is:

4. Another name for Rectangular Arm Robots is:

5. SCARA Robots are well suited for:

6. 'Pitch and Yaw' refer to:

7. The primary advantage of off-line programming is:

8. Simulation software is used for:

Fundamental Manufacturing Processes Study Guide, DV04PUB11 -4-

Fundamental Manufacturing Processes Study Guide, DV04PUB11 -5-

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