Unit I

5/6/2022 10:34 AM ASIST MECH; ROBOTICS-II EEE 1
Submitted by
Dr. T. ELANGO,
Professor,
Department of Mechanical Engineering,
ASIST {an autonomous institution},
Paritala, Krishna District.
ROBOTICS
OBJECTIVES:
➢ To introduce the basic concepts, parts of robots and types of robots.
➢ To make the student familiar with the various drive systems for robot, sensors and their
applications in robots and programming of robots.
➢ •To discuss about the various applications of robots, justification and implementation of
robot.
UNIT- I: Introduction
Specifications of Robots- Classifications of robots – Work envelope - Flexible automation
versus Robotic technology – Applications of Robots ROBOT KINEMATICS AND DYNAMICS
Positions,
UNIT-II: Orientations and frames, Mappings
Changing descriptions from frame to frame, Operators: Translations, Rotations and
Transformations - Transformation Arithmetic - D-H Representation - Forward and inverse
Kinematics Of Six Degree of Freedom Robot Arm – Robot Arm dynamics
UNIT- III: Robot Drives and Power Transmission Systems
Robot drive mechanisms, hydraulic – electric – servomotor- stepper motor – pneumatic
drives, Mechanical transmission method - Gear transmission, Belt drives, cables, Roller
chains, Link - Rod systems - Rotary-to-Rotary motion conversion, Rotary-to-Linear motion
conversion, Rack and Pinion drives, Lead screws, Ball Bearing screws,
UNIT -IV: Manipulators
Construction of Manipulators, Manipulator Dynamic and Force Control, Electronic and
Pneumatic manipulators
UNIT- V: Robot End Effectors
Classification of End effectors – Tools as end effectors. Drive system for grippers- Mechanical adhesive-
vacuum-magnetic-grippers. Hooks&scoops. Gripper force analysis and gripper design. Active and passive
grippers.
UNIT -VI: Path planning & Programming
Trajectory planning and avoidance of obstacles, path planning, skew motion, joint integrated motion –
straight line motion-Robot languages-computer control and Robot software
OUTCOMES:
❖ •The Student must be able to design automatic manufacturing cells with robotic control using
❖ •The principle behind robotic drive system, end effectors, sensor, machine vision robot Kinematics and
programming.
TEXT BOOKS:
1. Deb S. R. and Deb S., “Robotics Technology and Flexible Automation”, Tata
McGraw HillEducation Pvt. Ltd, 2010.
2. John J.Craig, “Introduction to Robotics”, Pearson, 2009.
3. Mikell P. Grooveret. al., "Industrial Robots - Technology, Programming and
Applications", McGraw Hill, New York, 2008.
REFERENCE BOOKS:
1. Richard D Klafter, Thomas A Chmielewski, Michael Negin, "Robotics Engineering
– An Integrated Approach", Eastern Economy Edition, Prentice Hall of India Pvt. Ltd.,
2006.
2. Fu K S, Gonzalez R C, Lee C.S.G, "Robotics: Control, Sensing, Vision and
Intelligence", McGraw Hill, 1987
SPECIFICATIONS OF ROBOTS

ROBOTS
• Robots are devices that are programmed to move parts, or
to do work with a tool.
• Robotics is a multidisciplinary engineering field dedicated
to the development of autonomous devices, including
manipulators and mobile vehicles.
• Roboticists develop man-made mechanical devices that can
move by themselves.
• Robots motion must be modelled, planned, sensed,
actuated and controlled, and whose motion behaviour can
be influenced by “programming”.
• Robots are called “intelligent” if they succeed in moving in
safe interaction with an unstructured environment, while
autonomously achieving their specified tasks
ROBOTICS
• Robotics is an applied engineering science that has
been referred to as a combination of machine tool
technology and computer science.
It includes machine design, production theory,
micro electronics, computer programming & artificial
intelligence.
OR
• "Robotics" is defined as the science of designing and
building Robots which are suitable for real life
application in automated manufacturing and other
non-manufacturing environments
• An automatically controlled, reprogrammable, multipurpose,
manipulator programmable in three or more axes, which may
be either, fixed in place or mobile for use in industrial
automation applications.
• Typical applications of robots include welding, painting,
assembly, pick and place (such as packaging, palletizing and
Surface Mount Technology), product inspection, and testing;
all accomplished with high endurance, speed, and precision.
It has the following objectives,
1.To increase productivity
2. Reduce production life
3. Minimize labour requirement
4. Enhanced quality of the products
5. Minimize loss of man hours, on account of accidents.
6. Make reliable and high speed production.
Automation and robotics:-
• Automation and robotics are two closely related
technologies.
• In an industrial context, Automation as a technology that is
concerned with the use of mechanical, electronic, and
computer-based systems in the operation and control of
production.
• Examples of this technology include,
Transfer lines. Mechanized assembly machines, feedback
control systems (applied to industrial processes), numerically
controlled machine tools, and robots.
• Accordingly, robotics is a form of industrial automation.
Ex:- Robotics, CAD/CAM, FMS, CIMS

FLEXIBLE AUTOMATION:-
• A computer integrated manufacturing system which is
an extension of programmable automation is referred
as flexible automation.
• It is developed to minimize the time loss between the
changeover of the batch production from one product
to another while reloading.
• The program to produce new products and changing
the physical setup
i.e., it produces different products with no loss of
time.
• This automation is more flexible in interconnecting
work stations with material handling and storage
system.

• Advantages:-
1.High Production rates 2. Lead time decreases
3. Storing capacity decreases 4. Human errors are eliminated.
5. Labour cost is decreases.
• Disadvantages:-
1.Initial cost of raw material is very high, 2. Maintenance cost is high,
3. Required high skilled Labour.
4. Indirect cost for research development & programming increases.
Reasons for implementation of automated systems in manufacture
industries:-
(i) To Increase the Productivity Rate of Labour
(ii) To Decrease the Cost of Labour
(iii) To Minimize the Effect of Shortage of Labour
(iv) To Obtain High Quality of Products
(vi) To Decrease the Manufacturing Lead Time
(vii) To upgrade the Safety of Workers.

ROBOT ANATOMY / CLASSIFICATION OF ROBOTS
The anatomy of robot is also known as structure
of robot.
1. The basic components or sections in anatomy of
robots are as follows.
• The Robotics Industries Association (RIA) has officially
given the definition for Industrial Robots.
“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.”
• The Anatomy of Industrial Robots deals with the
assembling of outer components of a robot such as
wrist, arm, and body.
KEY FACTS ABOUT ROBOT ANATOMY
• End Effectors:
A hand of a robot is considered as end effectors.
➢ The grippers and tools are the two significant types of end
effectors.
❖ The grippers are used to pick and place an object.
❖ while the tools are used to carry out operations like spray painting,
spot welding, etc. on a work piece.
• Robot Joints:
The joints in an industrial robot are helpful to perform sliding and
rotating movements of a component.
• Manipulator:
The manipulators in a robot are developed by the integration of
links and joints.
In the body and arm, it is applied for moving the tools in the work
volume. It is also used in the wrist to adjust the tools.
• ·Kinematics: It concerns with the assembling of robot links and
joints. It is also used to illustrate the robot motions.
1. ROBOT CONFIGURATIONS and TYPES
• A coordinate system defines a plane or space by axes
from a fixed point called the origin.
• Robot targets and positions are located by
measurements along the axes of coordinate systems.
• A robot uses several coordinate systems, each suitable
for specific types of jogging or programming.
• The Robots are mostly divided into four major
configurations based on their appearances, sizes, etc.
such as:
1) Cylindrical Configuration,
2) Polar Configuration [Spherical],
3) Jointed Arm Configuration, and
4) Cartesian Co-ordinate Configuration.
CYLINDRICAL CONFIGURATION:
• This kind of robots incorporates a slide in the horizontal
position and a column in the vertical position.
• It also includes a robot arm at the end of the slide.
• Here, THE SLIDE IS CAPABLE OF MOVING in up & down motion
with the help of the column. In addition, it can reach the
work space in a rotary movement as like a cylinder.
• Example: GMF Model M1A Robot.
Advantages:
• Increased rigidity, and
• Capacity of carrying high payloads.
Disadvantages:
• Floor space required is more, and
• Less work volume.
POLAR CONFIGURATION:
• The polar configuration robots will possess an arm,
which can move up and down.
• It comprises of a rotational base along with a pivot.
• It has one linear & two rotary joints that allows the
robot to operate in a spherical work volume.
• It is also stated as Spherical Coordinate Robots.
• Example: Unimate 2000 Series Robot.
• Advantages:
• Long reach capability
• in the horizontal
position
• Vertical reach is low.
JOINTED ARM CONFIGURATION
➢ The arm in these configuration robots looks almost like a human arm.
➢ It gets three rotary joints and three wrist axes, which form into six
degrees of freedoms. As a result,
➢ It has the capability to be controlled at any adjustments in the work
space.
➢ These types of robots are used for performing several operations like
spray painting, spot welding, arc welding, and more.
➢ Example: Cincinnati Milacron T3 776 Robot
Advantages:
• Increased flexibility,
• Huge work volume, and
• Quick operation.
Disadvantages:
• Very expensive,
• Difficult operating procedures, and
• Plenty of components.

CARTESIAN CO-ORDINATE CONFIGURATION [Gantry Robot]
• These robots are also called as XYZ robots, because it is
equipped with three rotary joints for assembling XYZ axes.
• The robots will process in a rectangular work space by
means of this three joints movement.
• It is capable of carrying high payloads with the help of its
rigid structure.
• It is mainly integrated in some functions like pick and place,
material handling, loading and unloading, and so on.
• Example: IBM 7565 Robot.
• Advantages:
• Disadvantages:
• • Less work envelope, Reduced flexibility.

DEGREES OF FREEDOM
• Industrial robots are designed to perform productive
work such as pick and place, welding, assembly, etc.,
• The work is accomplished by enabling the robot to
move its body, arm and wrist through a series of
motion and positions.
• The individual joint motions associated with the
performance of a task are referred to by the term
Degrees of Freedom (DOF)
• The number of degrees of freedom is equal to the
total number of independent displacements or
aspects of motion
WORK ENVELOP
• It is the shape created when a manipulator reaches
forward, backward, up and down.
• These distances are determined by the length of a
robot's arm and the design of its axes. Each axis
contributes its own range of motion.
• A robot can only perform within the confines of this
work envelope.
• Still, many of the robots are designed with
considerable flexibility.
• Gantry robots move along track systems to create
large work spaces.
• Degrees of Freedom associated with wrist of
robot Configurations FIG 1
• Wrist Roll: Also called as wrist swivel, this involves rotation of the
wrist mechanism about the arm axis
• Wrist Pitch: Given that the wrist roll is in the center position, the
pitch would involve the up and down rotation of the wrist.
• Wrist Yaw: Given that the wrist roll is the center position, the Yaw
would involve the right or left rotation of the wrist.
FIG 1
FIG 1

• Degrees of Freedom Associated with Arm and Body
of the Robot [FIG 2]
• Vertical Traverse: This is the capability to move the
wrist up or down to provide the desired vertical
attitude.
• Radial Traverse: This is the capability to move the
wrist front and back which provides the extension and
retraction movement.
• Rotational Traverse: This is the capability to rotate the
arm in vertical axis.

FIG 2
JOINTS AND ITS TYPES
• The robot's motion are accomplished by means of
powered joints.
• Three joints are associated with the action of body and
arm.
• Another three joints are generally used to actuate the
wrist
Joints used in the industrial robotics are of two types,
• Prismatic Joints - Used for Linear Motions
• Revolute Joints - Used for Rotational Motions

PRISMATIC JOINT
• A prismatic joint provides a linear sliding
movement between two bodies, and is often called
a slider, as in the slider-crank linkage.
• A prismatic pair is also called as sliding pair.
• A prismatic joint can be formed with a polygonal
cross-section to resist rotation.
REVOLUTE JOINT
• A revolute joint (also called pin joint or hinge
joint) is a one-degree-of-freedom kinematic pair
used in mechanisms.
• Revolute joints provide single-axis rotation
function used in many places such as door
hinges, folding mechanisms, and other uni-axial
rotation devices
CONTROL SYSTEMS:-
• With respect to robotics, the motion control
system used to control the movement of the
end-effector or tool.
1.Limited sequence robots (Non-servo)
2. Playback robots with point to point (servo)
3. Play back robots with continuous path control,
4. Intelligent robots.

Limited sequence robots (Non-servo):-
• Limited sequence robots do not give servo controlled to
inclined relative positions of the joints; instead they are
controlled by setting limit switches & are mechanical stops.
• There is generally no feedback associated with a limited
sequence robot to indicate that the desired position, has
been achieved generally thin type of robots involves simple
motion as pick & place operations.
Point to point motion:-
• These type robots are capable of controlling velocity
acceleration & path of motion, from the beginning to the
end of the path.
• It uses complex control programs, PLC’s (programmable logic
controller’s) computers to control the motion.
• The point to point control motion robots are capable of
performing motion cycle that consists of a series of desired
point location. The robot is tough & recorded, unit.
Continuous path motion:-
• In this robots are capable of performing motion cycle in which
the path followed by the robot in controlled.
• The robot move through a series of closely space point which
describe the desired path.
Ex:- Spray painting, arc welding & complicate assembly
operations.
Intelligent robots:-
• This type of robots not only programmable motion cycle but
also interact with its environment in a way that years
intelligent.
• It taken make logical decisions based on sensor data receive
from the operation.
• There robots are usually programmed using an English like
symbolic language not like a computer programming
language.
ROBOT PARTS AND FUNCTIONS
THE CONTROLLER IS THE "BRAIN" of the industrial robotic arm and allows
the parts of the robot to operate together.
• It works as a computer and allows the robot to also be connected to
other systems.
• The robotic arm controller runs a set of instructions written in code
called a program.
• The program is inputted with a teach pendant.
• Many of today's industrial robot arms use an interface that resembles or
is built on the Windows operating system.
INDUSTRIAL ROBOT ARMS can vary in size and shape.
• The industrial robot arm is the part that positions the end effectors.
• With the robot arm, the shoulder, elbow, and wrist move and twist to
position the end effector in the exact right spot.
• Each of these joints gives the robot another degree of freedom.
• A simple robot with three degrees of freedom can move in three ways:
up & down, left & right, and forward & backward.
• Many industrial robots in factories today are six axis robots

THE END EFFECTOR connects to the robot's arm and functions as a hand.
▪ This part comes in direct contact with the material the robot is manipulating.
▪ Some variations of an effector are a gripper, a vacuum pump, magnets, and welding
torches.
▪ Some robots are capable of changing end effectors and can be programmed for
different sets of tasks.
THE DRIVE is the engine or motor that moves the links into their designated positions.
▪ The links are the sections between the joints.
▪ Industrial robot arms generally use one of the following types of drives: hydraulic,
electric, or pneumatic.
▪ Hydraulic drive systems give a robot great speed and strength. An electric system
provides a robot with less speed and strength.
▪ Pneumatic drive systems are used for smaller robots that have fewer axes of
movement.
▪ Drives should be periodically inspected for wear and replaced if necessary.
SENSORS allow the industrial robotic arm to receive feedback about its environment.
▪ They can give the robot a limited sense of sight and sound.
▪ The sensor collects information and sends it electronically to the robot controlled.
▪ One use10:34
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these sensors is to keep twoROBOTICS-II
ASIST MECH; robots that
EEE work closely together from34
ROBOT SPECIFICATIONS
➢ Axes
➢ Payload
➢ Repeatability
➢ Reach
➢ Robot Mass
➢ Structure
➢ Motion Speed
➢ Motion Range

AXES
➢ A robot axis represents a degree of freedom.
➢ A degree of freedom determines an independent motion of
the robot.
➢ The more axes a robot has the more flexibility or movement
it will be capable of.
➢ Most industrial robots have between three to seven axes.
➢ It is important to consider the number of axes when
selecting an industrial robot as it will determine its range of
motion.
➢ Six-axis robots tend to be the most common since they have
a high level of flexibility, making them capable of performing
complex applications.
➢ More simple applications may require less range of motion,
which is why the four-axis FANUC M-410ic/185 is popular for
basic robotic palletizingASISTtasks.
5/6/2022 10:34 AM MECH; ROBOTICS-II EEE 36
PAYLOAD
➢ Payload capacity represents the maximum amount of
weight a robot arm can tolerate.
➢ Robotic payload is typically expressed in kilograms.
Payload varies greatly among industrial robots, from
0.5 kg to over 1000 kg.
➢ Considering the workpieces as well as the weight of
any end-effectors integrated with the robot will help
guide you to selecting a robot with an appropriate
payload capacity.
➢ For instance, if your application involves palletizing
boxes, the FANUC R2000ib/125L would be an ideal
option with its heavy lifting capabilities.

REPEATABILITY
➢ Repeatability references a robot’s ability to return
to the exact same position over and over.
➢ In other words, it defines how precise a robot may
be. Repeatability is expressed in millimeters plus or
minus the point of alteration to determine the
robot’s margin of error.
➢ The FANUC M20ia has a repeatability of +/-0.08
mm.
➢ This means its arm will fall within 0.08 mm of the
programmed position with each cycle run.

REACH
➢ A robot’s reach may be broken down into two
types; vertical and horizontal.
➢ Vertical reach determines the maximum height a
robot arm can obtain when extended upward from
its base.
➢ Horizontal reach defines the maximum distance
obtained from the center of the robot base to its
wrist.
➢ A robot’s reach can determine the scope of
its work envelope.

Robot Mass
➢ Robot mass is the weight of a robot.
➢ It is usually expressed in kilograms and references
the weight of the robotic manipulator only.
➢ This can be important to consider if you are looking
to mount a robot on a shelf, table, or overhead.

STRUCTURE
➢ Structure refers to the type of robot.
➢ There are many types of industrial robots with the
most common including articulated, delta, SCARA,
and gantry.
➢ This specification is important because it
determines a robot’s work envelope and
functionality.
➢ Articulated robots are generally the most common
used in welding automation and robotic assembly.

MOTION SPEED
➢ Motion speed lists the degrees traveled per second to
define the speed of each robotic axis.
➢ The T-Axis on the Motoman MA1400 is 610 degrees
per second.
MOTION RANGE
➢ This specification defines the scope of movement for
each robotic axis as expressed in degrees.
➢ The motion range on axis 6 of the ABB 4600-60 is ±400
degrees.

REACH AND STROKE
➢ The horizontal reach maximum radial distance be
positioned from the vertical axis about which the
robot rotates.
➢ The horizontal stroke defined as the total radial
distance the wrist can travel.
➢ The vertical reach maximum elevation above the
work surface that the tool can reach.
➢ The vertical stroke is defined as the total vertical
distance the wrist can travel.

TOOL ORIENTATION
ORIENTATION:
A robot’s orientation is measured by roll, pitch, and
yaw
ANGLES.
To specify the tool orientation, a mobile coordinate
frame M= {m1, m2, m3} is attached to the tool and
moves with the tool.
Initially, the mobile tool frame M starts out coincident
with a fixed wrist coordinate frame F {f1, f2, f3}

TYPES OF DRIVE SYSTEMS
1. HYDRAULIC DRIVE
2. ELECTRIC DRIVE
3. PNEUMATIC DRIVE
1. HYDRAULIC DRIVE:-
❖ Hydraulic drive and electric drive arc the two main types of drives used
on more sophisticated robots.
❖ Hydraulic drive is generally associated with larger robots, such as the
Unimate 2000 series.
❖ The usual advantages of the hydraulic drive system are that it provides
the robot with greater speed and strength.
❖ The disadvantages of the hydraulic drive system are that it typically
adds to the floor space required by the robot, and that a hydraulic
system is inclined to leak on which is a nuisance.
❖ This type of system can also be called as non-air powered cylinders. In
this system, oil is used as a working fluid instead of compressed air.
❖ Hydraulic system need pump to generate the required pressure and
flow rate.
❖ These systems are quite complex, costly and require maintenance.
2. Electric drive:-
o Electric drive systems do not generally provide as much speed or
power as hydraulic systems.
o However, the accuracy and repeatability of electric drive robots
are usually better.
o Consequently, electric robots tend to be smaller. Require less
floor space, and their applications tend toward more precise work
such as assembly.
o In this System, power is developed by an electric current. It
required little maintenance and the operation is noise less.
3. Pneumatic drive:-
✓ Pneumatic drive is generally reserved for smaller robots that
possess fewer degrees of freedom (two- to four joint motions).
✓ In this system, air is used as a working fluid, hence it is also called
air-powered cylinders.
✓ Air is compressed in the cylinder with the aid of pump the
compressed air is used to generate the power with required
amount of pressure and flow rates.
NEED OF ROBOT AND ITS APPLICATION
INDUSTRIAL APPLICATIONS
Industrial robots are used to assemble the vehicle parts.
• As the assembly of the machine parts is a repetitive task to be
performed, the robots are conveniently used instead of using
mankind (which is more costly and less précised compared to
robots.)
AUTO INDUSTRY:
➢ The auto industry is the largest users of robots, which automate
the production of various components and then help, assemble
them on the finished vehicle.
➢ Car production is the primary example of the employment of
large and complex robots for producing products.
➢ Robots are used in that process for the painting, welding and
assembly of the cars.
➢ Robots are good for such tasks because the tasks can be
accurately defined and must be performed the same every time,
with little need for feedback to control the exact process being
performed.
Material Transfer, Machine Loading And Unloading
➢ There are many robot applications in which the robot is required to
move a work part or other material from one location to another.
➢ The most basic of these applications is where the robot picks the part
up from one position and transfers it to another position. In other
applications, the robot is used to load and/or unload a production
machine of some type.
➢ Material transfer applications are defined as operations in which the
primary objective is to move a part from one location to another
location. They are usually considered to be among the most
straightforward of robot applications to implement.
➢ The applications usually require a relatively unsophisticated robot,
and interlocking requirements with other equipments are typically
uncomplicated. These are the pick ad place operations.
➢ The machine loading and unloading applications are material
handling operations in which the robot is used to service a
production machine by transferring parts to and/or from the
machine.
➢ Robots have been successfully applied to accomplish the loading
and/or unloading function in the production operations
• Die casting
• Plastic moulding
• Forging and related operations
• Machining operations
• Stamping press operations
➢The other industrial applications of robotics
include processing operations such as spot
welding, continuous arc welding; spray coating,
also in assembly of machine parts and their
inspection.

Medical Applications
• Medical robotics is a growing field and regulatory
approval has been granted for the use of robots
in minimally invasive procedures.
• Robots are being used in performing highly
delicate, accurate surgery, or to allow a surgeon
who is located remotely from their patient to
perform a procedure using a robot controlled
remotely.
• More recently, robots can be used autonomously
in surgery.

APPLICATIONS OF ROBOTS-
Present Applications of Robots:-
(i) Material transfer applications
(ii) Machine loading and unloading
(iii) Processing operations like,
(a) Spot welding
(b) Continuous arc welding
(c) Spray coating
(d) Drilling, routing, machining operations
(e) Grinding, polishing debarring wire brushing
(g) Laser drilling and cutting etc.
(iv) Assembly tasks, assembly cell designs, parts mating.
(v) Inspection, automation.
FUTURE APPLICATIONS OF ROBOTS
The profile of the future robot based on the research activities will include the
following,
(i) Intelligence
(ii) Sensor capabilities
(iii) Telepresence
(iv) Mechanical design
(v) Mobility and navigation (walking machines)
(vi) Universal gripper
(vii) Systems and integration and networking
(viii) FMS (Flexible Manufacturing Systems)
(Ix) Hazardous and inaccessible non-manufacturing environments
(x) Underground coal mining
(xi) Fire fighting operations
(xii) Robots in space
(xiii) Security guards
(xiv) Garbage collection and waste disposal operations
(xv) Household robots
(xvi) Medical care and hospital duties etc.
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