PENJANA KERJAYA MARA

“INTRODUCTION TO ROBOTICS”
Ts. DR JAYA BHANU RAO

10 ~ 11 OCT 2022
INTRODUCTION TO ROBOTICS

• History of Robotics
• Definition of Industrial Robot
• Types of Robot
• Application of Industrial Robot
BACKGROUND OF ROBOTICS

• With a need for increased productivity and delivery of products of uniform

quality, industry is turning more and more toward computer-based
automation

• Most automated manufacturing tasks are carried out by special-purpose

machines designed to perform specific function → Hard Automation

• The inflexibility of this machines (Hard Automation) have led to interest in

the use of robots capable of performing variety of manufacturing functions
in more flexible working environment
PRE-HISTORY

• Automata: a machine or control mechanism designed to

follow automatically a predetermined sequence of operations
or respond to encoded instructions
PRE-HISTORY

• B.C : Greeks & Egyptians build mechanical automata driven by waterpower or hydraulics as ornamentation
(decoration) at official ceremonies

• 14th century : Mechanical automata driven by clockwork mechanism in Europe and Arabia. Mainly for
ornamentation and entertainment

• 18th & 19th century : More complicated mechanisms are designed and the first programmable clockwork-
driven automata are built.

1738 :Vaucanson builds a duck which can quak, drink water and eat food
1774: Droz designs an automatic scribe which can write a massage with up to 40 characters
1805: Maillordet builds a mechanical painter which can draw a picture or write in French or English
1876: A large number of entertainment automata are presented at the world fair. (musical and card playing automata)
HISTORY OF ROBOTICS

Year History

1921 The word ‘robot’ is used for the first time by Czech playwrite Karel Capec. The Czech word
‘robota’ means “forced laborer”.

1954 George Devol patented the first programmable robot capable of performing
industrial tasks. With the formation of his company, Unimation, the
industrial robot industry began.

1960 Joseph Engelberger teamed with George Devol at Unimation to

start development of Unimate robot system.

1962 General Motors installed a Unimate robot on one of its automobile assembly
line. This was the first industrial application of robots in the production of
goods.
 WHAT IS A ROBOT?

• Hollywood’s imagination
• Science Fiction vs. Industrial Automation creates
some confusion
TRANSFORMER

Star Wars ROBOCOP TERMINATOR

Definition of Industrial Robot

- There are many definitions of an industrial robot. Here are the

definitions of two important robotics associations:
- The Japanese Industrial Robot Association (JIRA) uses a very
broad notion of robot which basically includes all devices
which have controllable degrees of freedom. Robots here are
divided into 6 classes:
DEFINITION OF INDUSTRIAL ROBOT
JIRA CLASSIFICATIONS

• Class 1 : Operator controlled robot

• Class 2 : Fixed sequence robot
• Class 3 :Variable sequence robot
• Class 4 : Playback robot
• Class 5 : Numerical control robot
• Class 6 : Intelligent robot
 Definition of Industrial Robot

- The Robotics Institute of America (RIA) uses more narrow

definition of robots which will only include devices which are
at least in class 3 of the Japanese classification:

“ A robot is a reprogrammable, multifunctional manipulator

designed to move materials, parts, tools, or specialized devices,
through variable programmed motions for the performance of
a variety of tasks.”
CHARACTERISTICS ESSENTIAL TO
INDUSTRIAL ROBOT

• reprogrammable
• actions are controlled by a stored program
• program can be changed

• multifunctional
• can perform more than one specific manufacturing task
• one robot can be used for various jobs in a factory
Robotics-involves Multi-discipline

1. Mechanical design
2. Computer science and engineering
3. Electrical engineering
4. Perception (vision) and neuroscience
(brain)
Types of Robot
• Two Kind of Robot

Industrial robots ~
used in factories to achieve precision and
safety. Basically positioning machines whose
intelligence has not changed much than 15
years ago
Service robots ~
Robot with superior intelligence and multiple
sensors that provides assistance at home,
services such as hospitals, building
management and also as toys and
companions
TYPES OF ROBOT

• Two Kind of Robot:-

1. Industrial robots ~ used in factories to achieve

precision and safety. Basically, positioning machines whose
intelligence has not changed much than 15 years ago

2. Service robots ~ Robot with superior intelligence and

multiple sensors that provides assistance at home,
services such as hospitals, building management and also
as toys and companions
Industrial Robots
• Some of the manufacturer….

CRS - Canada FANUC - Japan

ABB - Sweden Adept - USA COMAU - Italy

Staubli - Switzerland
Panasonic - Japan Motoman - UK
KUKA - Germany Kawasaki - Japan
• Service Robots

Aerial Robots Wheeled mobile robots

Legged robots

Humanoid Underwater robots

MORE……..SERVICE ROBOT
SERVICE ROBOTS

• Typically mobile robots

• Uses vision for seeing, ultrasonic for hearing and may have
manipulators with tactile sensors.
• Emulating human behavior as close as possible
• Having the intelligence to process information from several
sources and consequently making decisions.
• Sources of information includes tactile and non tactile sensing.
• Capable of emotional interaction
WHY USE ROBOTS?

• Application in 4D environments
• Dangerous
• Dirty
• Dull
• Difficult
• 4A tasks
• Automation
• Augmentation (expansion)
• Assistance
• Autonomous (independent)
HISTORY - THE KEY GOALS

From 1970’s onwards, the robot development expands,

the key goals were:

• repeatability
• payload (weight capacity)
• serviceability
• ease of reprogramming
REASONS FOR SURGE IN
INDUSTRIAL ROBOTS
• From 1945-1970, the USA was world leader in robot industry

• In 1970’s, world economic situation changed

• competition from Japan in high technology

• competition from third world in consumer goods

• inflation

• demand for defect-free, quality products from consumers

 MAN VS. ROBOT

HUMAN FACTOR GIVE RISE TO PROBLEMS

• Mental and Physical Fatigue • Inconsistent Work Quality
• Interruptions due to • Unstable Production
personal problems • High Labour Turnover
• Interactions with others • Delay in Product delivery
• Easily affected by adverse • Escalation in product cost
conditions
• Always demand higher pay
 MAN VS. ROBOT

ROBOT ON THE OTHER HAND :

• Does not tire out
• Not emotional
• Does not take holidays
• Does not demand higher pay or promotion
• No Monday morning, Friday afternoon syndrome
• Does not argue with superiors
• Does not form Trade Unions
BENEFITS OF INDUSTRIAL ROBOTS
APPLICATIONS

• Increased output rates

• Elimination of dangerous or undesirable jobs for human
• Improved product quality
• Increased manufacturing flexibility
• Reduce material wastage
• Reduce labor turnover
APPLICATION OF INDUSTRIAL
ROBOTS
How are they used?
• Industrial robots
• 70% welding and painting
• 20% pick and place (assembly)
• 10% others (water jet cutting etc.)

• Research focus on
• Manipulator control
• End-effector design
• Compliance device
• Dexterity robot hand
• Visual and force feedback
• Flexible automation
APPLICATION OF INDUSTRIAL
ROBOTS
Electronics Assembly - hard disk assembly
• Product: computer hard disks
• Challenges:
• quality of work (accurate assembly)
• damage-free part handling and assembly
• synchronization of the various components of the assembly system
• vision for part recognition
• part feeding
• Special Features:
• fully automated assembly operation
• tool change
• multi-capability robot gripper
• robot vision hardware and software
APPLICATION OF INDUSTRIAL
ROBOTS
Coating and Sealing - Automotive Spray Painting
• Product: car body
• Challenges:
• quality of work (uniform coating)
• synchronization of the hood-, and door- openers, and the spray-
painting robots
• Special Features:
• multi-robot, hood-, and door- openers coordination
• highly automated production line
• off-line programming with motion optimization
APPLICATION OF INDUSTRIAL
ROBOTS
3. Material Handling, Machine Tending and Positioning - Heavy-duty Robot Handling
Operations
• Product: truck axles

• Challenges:
• accurate handling of heavy axles from a workstation to a storage conveyor
• damage-free, safe handling of axles

• Special Features:
• ability to correctly grip, balance, carry and release axles
• high robot payload capacity
• dimensions of the robot links match the size of the axles
• special gripper and gripper-controller
APPLICATION OF INDUSTRIAL
ROBOTS
Kitting - Kitting Pharmaceutical Pills
• Product: pharmaceutical pills

• Challenges:
• damage-free handling of pills
• clean environment per pharmaceutical industry standards

• Special Features:
• delicate handling of fragile, small pills
• robot vision for locating pills on conveyor
• flexible feeding of pills and pill containers
APPLICATION OF INDUSTRIAL
ROBOTS
5. Construction - Construction Robots

• Challenges:
• tele-operation-based control
• power and resilience in harsh construction environment

• Special Features:
• unique end-effector to apply different tools
• intelligent motion control with vision system
• high payload robot capacity
APPLICATION OF INDUSTRIAL
ROBOTS
6. Wiring - Lamp Frame Wiring
• Product: lamp fixtures

• Challenges:
• integration of part holding, vision and wire tending, and bolt setting
• handling non-rigid wires
• synchronization of the various components of the production process

• Special Features:
• programming of wire tending
• trajectory control during wiring
• fully automated production process
 APPLICATION OF INDUSTRIAL
ROBOTS
7. Palletizing - Case Palletizing
• Product: medium-size cardboard boxes
• Challenges:
• correct placement of boxes on pallets
• damage-free handling of boxes
• Special Features:
• palletizing programmed by software macros
• vacuum gripper designed for variable box sizes and weights
• gripper designed to safely grip and release boxes
 APPLICATION OF INDUSTRIAL
ROBOTS
8. Inspection and Testing - Testing and Sorting
• Product: automotive engine control module

• Challenges:
• damage-free handling of workpieces
• machine loading/unloading of several workpieces at a time
• synchronization of testing, sorting, functions of the robotic workcell

• Special Features:
• fully automated robotic workcell
• robot gripper designed to handle several workpieces at a time
• in-process test and sorting
• infrared workpiece identification for sorting
• a single robot serving several workstations
 APPLICATION OF INDUSTRIAL
ROBOTS
9. Surgery - Surgical Assistance
• Challenges:
• continuous motion control
• quality of work (accurate drilling of femur)
• precise tool positioning
• Special Features:
• precise trajectory control of gripper
• unique gripper to execute delicate surgery on humans
• online communication for safety control
APPLICATION OF INDUSTRIAL
ROBOTS
10. Vision - Vision-based Motion Guidance and Inspection
• Challenges:
• coordinated, safe operation of human and robot
• vision guided motions
• conveyor tracking and vision-based robot operation
• vision-based inspection of sausages integrity
• lighting conditions
• Special Features:
• locating sausages by vision
• robot vision and conveyor tracking software
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APPLICATION OF INDUSTRIAL
ROBOTS
11. Welding - Arc Welding
• Product: metal brackets
• Challenges:
• quality of work (uniform welding)
• accuracy
• continuous motion control with weaving function
• Special Features:
• gripper designed for several welding tasks
• precise trajectory control
• sensors for real-time weld control weld1.mpg
weld2.mpg
APPLICATION OF INDUSTRIAL
ROBOTS
12. Mechanical Assembly - Automotive component assembly
• Product: ABS valve
• Challenges:
• accurate component assembly
• synchronization of the various elements of the assembly line
• Special Features:
• fully automated assembly line
• handling of multiple product models

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INSTALLED INDUSTRIAL ROBOTS