Bharatiya Vidya Bhavan’s

SARDAR PATEL COLLEGE OF ENGINEERING

(Government Aided Autonomous Institute)
Munshi Nagar, Andheri (W) Mumbai – 400058

Classification of robotic Systems

Mr. Rahul Chavhan

Assistant Professor
Department of Electrical Engineering
E-mail: rahul.chavhan@spce.ac.in
Robot Classification
To refine the general concept of a Key Classification Criteria:
robotic manipulator by classifying 1. Drive Technologies
it based on key criteria.
2. Work-Envelope Geometries
3. Motion Control Methods

Reference: Robert Shilling, Fundamentals of Robotics-Analysis and Control, Chapter 1

Robot Classification
1. Drive Technologies
The source of power used to drive the joints of the robot.

Two popular drive technologies:

 Electric
 Hydraulic

Both electric-drive robots and hydraulic drive robots often use pneumatic tools
or end-effectors, when only gripping action is required.
Robot Classification
1. Drive Technologies…
Electric Drives
Electric Drives play a crucial role Types of Electric Drives:
in providing the necessary motion 1. DC Motor (Direct Current)
and control for robotic systems. 2. AC Motor (Alternating Current)
3. Stepper Motors
They convert electrical energy into 4. Serve Motors
mechanical motion, allowing robots
to perform tasks like moving,
gripping, rotating, and lifting with
precision.
Robot Classification
1. DC Motor
Types:
1. Brushed DC Motors:
 Simple and cost-effective but require maintenance due to brush wear.

2. Brushless DC Motors (BLDC):

 More efficient, less maintenance, and offer better speed and torque control.

Applications: Widely used in mobile robots, robotic arms, and small actuators.
Robot Classification
2. AC Motor
Types:
1. Induction Motors:
 Rugged and reliable but complex control mechanisms.

2. Synchronous Motors:
 Provide precise speed control and are suitable for applications requiring constant
speed.

Applications: Industrial robots, conveyor systems.

Robot Classification
3. Stepper Motor
 Move in discrete steps, allowing precise control of angular position.

 No feedback system required, excellent for position control.

Applications: 3D printers, CNC machines, and robotic arms requiring precise

positioning.
Robot Classification
4. Servo Motor
 High-performance motors with built-in feedback systems for precise control of
position, speed, and torque.
 Types : AC, DC

 High accuracy, fast response, and smooth operation.

Applications: Humanoid robots, robotic arms, and precision tasks like surgical robots.
Robot Classification
1. Drive Technologies…
Types of Hydraulic Drives:
Hydraulic Drives:
1. Hydraulic Cylinders (Linear Drives)
Hydraulic drives are systems that
use pressurized fluid to generate 2. Hydraulic Motors (Rotary Drives)
mechanical motion.
They are widely used in industries
where high force and precise
control are required.
In robotics, they are less common
than electric drives but are crucial
in applications that demand heavy
lifting, high torque, and durability.
Robot Classification
1. Hydraulic Cylinders (Linear Drives)
 Provide linear motion and are commonly used for lifting, pushing, or
pulling heavy loads.

Applications: Excavators, robotic arms.

Robot Classification
2. Hydraulic Motors (Rotary Drives)
 Convert hydraulic pressure into rotational motion.

Applications: Winches, conveyors, and rotary actuators in robotics.

Robot Classification
2. Work-Envelope Geometries Major Axes:
The gross work envelope of a robot First three joints that determine the Types of joints:
is defined as the locus of points in wrist's position. 1. Revolute
2. Prismatic
three-dimensional space that can be Minor Axes: 3. Spherical
reached by the robot’s wrist. Remaining joints that establish the 4. Universal
tool’s orientation. 5. Cylindrical
6. Planar
The geometry of the work envelope is determined by the sequence of joints
used for the first three axes. Six types of robot joints are possible. However,
only two basic types are commonly used in industrial robots.
TYPES OF ROBOT JOINTS
Robot Classification
2. Work-Envelope Geometries….
The particular combination of revolute and prismatic joints for the three major
axes determines the geometry of the work envelope.

ROBOT WORK ENVELOPES BASED ON MAJOR AXES

P = Prismatic, R = Revolute
Robot Classification
2. Work-Envelope Geometries….
Cartesian Robot
Configuration: PPP (all three
major axes are prismatic).
This is the characteristics of
Cartesian-coordinate robot, also
called rectangular-coordinate
robot.
When a Cartesian-coordinate robot is
mounted in a rectangular frame, it is
referred to as a gantry robot. Fig. Cartesian Robot

Simple motion along three perpendicular axes (up/down, in/out, forward/back).

Work envelope: Rectangular box
Robot Classification
2. Work-Envelope Geometries….
Cylindrical Robot
If the first joint of a Cartesian-
coordinate robot is replaced with a
revolute joint (to form the
configuration RPP), this produces a
cylindrical-coordinate robot.

Fig. Cylindrical robot

 The revolute joint rotates the arm about a vertical axis.
 The prismatic joints then move the wrist up and down along the vertical axis
and in and out along a radial axis.
Work envelope: Volume between two vertical concentric cylinders.
Robot Classification
2. Work-Envelope Geometries….
Spherical Robot
If the second joint of a cylindrical-
coordinate robot is replaced with a
revolute joint (so that the
configuration is then RRP), this
produces a spherical-coordinate
robot.
Fig. Spherical Robot

 The first revolute joint swings the arm back and forth about a vertical base axis.
 The second revolute joint pitches the arm up and down about a horizontal shoulder

axis.
 The prismatic joint moves the wrist radially in and out.
Work envelope: Volume between two concentric spheres.
Robot Classification
2. Work-Envelope Geometries….
SCARA Robots
(Selective Compliance Assembly Robot Arm)
Like a spherical-coordinate robot, a SCARA
robot also has two revolute joints and one
prismatic joint (in the configuration RRP) to
position the wrist.
However, for a SCARA robot the axes of all
three joints are vertical. Fig. SCARA robot

 Two revolute joints control horizontal motion (base and forearm swing).
 One prismatic joint controls vertical motion.
 Designed for selective compliance in assembly applications.
Work envelope: Complex horizontal cross section due to joint travel limits.
Robot Classification
2. Work-Envelope Geometries….
Articulated Robots
When the last remaining prismatic joint is
replaced by a revolute joint (to yield the
configuration RRR), this produces an
articulated-coordinate robot.
Most anthropomorphic configuration; mimics
the anatomy human arm. Also called revolute
robots. Fig. Articulated robot

First joint: Swings about a vertical base axis.

Second joint: Pitches the arm (shoulder movement).
Third joint: Pitches the forearm (elbow movement).
Work envelope: Often crescent-shaped side-view cross section
Robot Classification
TYPES OF ROBOT MOTION CONTROL
3. Motion Control Methods
The method used to control the
movement of the end-effector or tool.
Point-to-point Motion
The tool moves to a sequence of discrete
points in the workspace.
The path between the points is not
explicitly controlled by the user. Continuous-Path Motion
Useful for operations which are discrete Sometimes called controlled-path motion.
in nature. The end-effector must follow a prescribed path
in three-dimensional space, and the speed of
motion along the path may vary.
This clearly presents a more challenging
control problem.
Robot Characteristics
Characteristics Units
Number of axes ---
Load carrying capacity Kg
Maximum speed, cycle time mm/sec
Reach and stroke mm
Tool orientation deg
Repeatability mm
Precision and accuracy mm
Operating environment ---

Reference: Robert Shilling, Fundamentals of Robotics-Analysis and Control, Chapter 1

Robot Characteristics
Number of Axes Classification:
Refers to the degrees of freedom in Major Axes (1-3):
a robotic manipulator. Control the position of the wrist.

Minor Axes (4-6):

Control the orientation of the tool
or gripper.

Redundant Axes (7 and beyond):

Enhance flexibility for obstacle
avoidance and complex task.
For example;
Industrial robots typically have 4 to 6 axes, with 6-axis robots capable of arbitrary
position and orientation control in 3D space.
Robot Characteristics
Capacity and Speed Speed Metrics:
Load Capacity: The maximum tool tip speed can
Varies from small an educational also vary substantially between
table top robots like the Minimover manipulators.
5 Microbot (2.2 kg) to heavy-duty
extended reach industrial robots The Westinghouse Series 4000
like the GCA-XR6 (4928 kg). robot has a tool tip speed of 92
mm/sec.
Maximum Speed: For instance, the Adept One SCARA robot reaches up to 9000 mm/sec.

Cycle Time: The time required to perform a periodic motion similar to a simple pick-and-place
operation.
More practical for evaluating performance in repetitive tasks. E.g., Adept One SCARA has a cycle
time of 0.9 sec for a 700-mm path.
Robot Characteristics
Reach and Stroke
The horizontal reach is defined
The reach and the stroke of a
as the maximum radial distance
robotic manipulator are rough the wrist mounting flange can
The horizontal stroke
measures of the size of the work be positioned from the vertical
represents the total radial
axis about which the robot
envelope. distance the wrist can travel.
rotates.
The vertical stroke
The horizontal reach minus the is the total vertical
distance that the
horizontal stroke represents the
wrist can travel.
minimum radial distance the wrist
The vertical reach of
can be positioned from the base a robot is the
axis. maximum elevation
above the work
𝑆𝑡𝑟𝑜𝑘𝑒 ≤ 𝑅𝑒𝑎𝑐ℎ surface that the wrist
mounting flange can
Fig. Reach and Stroke of a cylindrical robot.
reach.
Robot Characteristics
Tool Orientation
Yaw: Rotation about the
The tool orientation convention that vertical axis.
will be used here is the yaw-pitch- Roll: Rotation about the
longitudinal axis.
roll (YPR) system.

A mobile tool coordinate frame M

= {m¹, m², m³} is attached to the
Pitch: Rotation about the lateral axis.
tool and moves with the tool.
Fig. Yaw, pitch, and roll of tool.

YAW, PITCH, AND ROLL MOTION Spherical Wrist: A robot has a spherical wrist if and only
if the axes used to orient the tool intersect at a point.
Robot Characteristics
Repeatability: Precision:
Repeatability is a measure of the The precision of a robotic manipulator is a
ability of the robot to position the measure of the spatial resolution with
tool tip in the same place which the tool can be positioned within the
repeatedly. work envelope.
Accuracy: The degree to which the robot can achieve a target position.

Precision means consistency (low deviation

between repeated attempts).

Accuracy means closeness to the true target.

Repeatability (a subset of precision) refers to

Fig. Adjacent tool positions.
how well a robot can return to the same
position multiple times.
Robot Characteristics

Precision Variability:
Cartesian Robots: Uniform precision throughout the workspace.
Cylindrical and Spherical Robots: Precision decreases with radial distance.
Articulated Robots: Precision varies depending on configuration.

HORIZONTAL AND VERTICAL PRECISION

Robot Characteristics
Operating Environment Examples
Environmental Factors: Robots  Industrial Environments
may need to operate in specialized  Domestic Environments
conditions like clean rooms,  Medical Environments

underwater environments, or  Military and Defense Environments

hazardous areas, influencing their  Space Exploration

design and materials.  Underwater Environments

 Agricultural Environments

 Disaster Response Environments

 Entertainment and Service Environments

 Laboratory and Research Environments

Robot Characteristics
Dexterity Key Aspects are:
Dexterity refers to the ability of a Degrees of Freedom (DOF):
robotic manipulator to perform Higher DOF allows for more flexible
complex tasks with precision and movement and better task execution.
control within its workspace. Workspace Accessibility:
It is a measure of how well a robot The ability to reach various points in the
can position and orient its end workspace from multiple orientations.
effector (tool or gripper) to achieve Manipulability:
various tasks Refers to how easily the robot can change the
Applications: position and orientation of its end effector.
Assembly of small components in Fine Motor Control:
electronics.
Surgical robotics where fine, precise
The ability to make small, precise adjustments
movements are critical. for delicate operations.
Handling fragile objects without causing
damage.
Robot Characteristics
Compliance Types of Compliance:
Compliance in robotics refers to the Passive Compliance:
flexibility or adaptability of a robot Achieved through mechanical
when interacting with its design, such as flexible joints or
environment, particularly in springs.
response to external forces.
Active Compliance:
A compliant robot can adjust its Achieved through sensors and
position or force to accommodate control algorithms that adjust the
irregularities or unexpected robot’s movements in real-time
obstacles. based on feedback.
Robot Characteristics
Benefits of Compliance: Applications:
Safety: Collaborative robots (cobots)
Reduces the risk of damage to both working alongside humans.
the robot and its environment.
Improved Task Execution: Gripping and manipulating objects
Helps in tasks like insertion or with unknown properties.
assembly where exact positioning
may not be feasible. Tasks requiring force control, like
Adaptability: Allows robots to polishing or sanding.
handle varying object shapes and
sizes or work in dynamic
environments.
Robot Characteristics
Remote Center Compliance (RCC) Working Principle:
Device: The RCC device decouples the
An RCC device is a mechanical translational and rotational
component designed to enhance the movements of the end effector,
compliance of robotic allowing it to adjust its orientation
manipulators, particularly in tasks automatically when an external
that involve insertion or alignment. force is applied.

It allows the end effector to pivot This helps in aligning parts without
around a remote center point, the need for precise programming.
facilitating easier alignment of
parts during assembly operations.
Robot Characteristics
Key Features: Applications:
Passive Alignment: Peg-in-hole assembly operations.
Automatically compensates for
small misalignments between the Precision insertion tasks in
robot and the workpiece. manufacturing.
Simplifies Programming:
Reduces the need for precise Robotics tasks requiring precise
motion planning. alignment without complex control
Enhances Dexterity and systems.
Compliance:
Works in conjunction with the
robot’s control system to improve
task performance.
Industrial Applications of Robot
The applications will be examined as per their actions of end-effector as:
Material Handling:
In these applications, the robot grasps an object, e.g., a machined component, with the help
of a gripper, and moves it to another location, say, on a conveyor belt.

Processing:
Here, the robot uses a tool, e.g., an electrode, rather than a gripper in order to perform some
processing task, say, welding.

Assembling:
These tasks are more complex than other two, as the robot has to interact with a fixture or
another robot in order to put together two or more components or sub-assemblies to
complete an assembly task.

Reference: S. K. Saha, “Introduction to Robotics”, Chapter 2.

Industrial Applications of Robot
1. Material Handling
2. Welding (Processing)
a. Spot Welding
b. Arc Welding
3. Spray Painting (Processing)
4. Machining (Processing)
a. Drilling
b. Deburring
5. Assembling
Industrial Applications of Robot
1. Material Handling Types of Material Handling Configurations:
Material handling involves the Single Machine Tending:
movement of objects within a A robot is dedicated to loading and unloading a
manufacturing environment. single machine, ideal for operations with short
machining times.
Multiple Machine Serving:
A robot handles several machines, suitable for
processes requiring a sequence of operations.

Robots use grippers to pick up and move objects, such as machined components,
onto conveyor belts or between workstations.
Cylindrical, polar, and revolute robots are commonly used, while rectangular types
are preferred for light-duty work in restricted spaces.
Point-to-point (PTP) control is essential for precise material handling.
Industrial Applications of Robot
2. Welding (Processing) Types of Welding Robots:
Welding robots are widely used in 1. Spot Welding Robots:
industries, particularly automotive Join metal pieces at specific points using heat
manufacturing, where precision and generated by an electric current.
speed are critical. Common in automotive industries for joining thin
Robots ensure consistent weld sheet metals.
quality and can operate Typically hydraulically powered to handle heavy
continuously, enhancing production welding guns.
efficiency. Offer high repeatability (±1 mm), outperforming
human welders in consistency.
2. Arc Welding Robots:
Join metal pieces along continuous paths with filler materials. Use consumable wire electrodes
(MIG welding) or non-consumable tungsten electrodes (TIG welding).Controlled by Continuous
Path (CP) systems for smooth, continuous welds.
Industrial Applications of Robot
3. Spray Painting (Processing) Characteristics of Spray-Painting
Spray painting is one of the earliest Robots:
industrial applications of robots  High manipulator dexterity for
due to the hazardous environment complex surfaces.
of painting booths.  Large working volume despite a
Robots eliminate health risks to compact base.
workers and ensure uniform paint  Lightweight design due to minimal
application. payload requirements (e.g., 1 kg
spray guns).
 Low accuracy and repeatability

requirements (±2 mm) compared to

welding or machining.
Industrial Applications of Robot
4. Machining (Processing)
Machining is a key manufacturing process involving the removal of material to
shape a product.

There are five primary types of machine tools used in machining:

1. Drilling Machine
2. Lathe (Turning Machine)
3. Milling Machine Out of these, drilling is the most successfully automated
process using robots, particularly in the aircraft industry.
4. Shaper
Another machining-related task performed by robots is the
5. Grinder deburring of metal parts.
Industrial Applications of Robot
4. Machining (Processing)… The process involves:
1. Drilling  The robot’s gripper holding a
Robots can effectively replace portable drill.
manual operators in drilling tasks,  The robot guiding the drill from

especially when the template holes hole to hole.

are equipped with chamfered  At each hole, a fixed drill cycle is

guides. performed before moving to the

next position.

Programming the robot for drilling tasks is straightforward since drilling is a

Point-to-Point (PTP) operation.
The manual teaching method is often used for this purpose.
Industrial Applications of Robot
4. Machining (Processing)… Two approaches to robotized deburring:
1. Deburring Lightweight parts:
Deburring involves removing burrs, The robot picks up the part and moves it
which are unwanted pieces of to the deburring tool.
material left on metal parts after
machining. Heavy parts:
Burrs can appear: The robot holds and maneuvers the
 Between a machined surface deburring tool around the part.
and a raw surface. In both cases, tool support is critical, whether it is held by
 At the intersection of two the robot or mounted on a worktable. The operation requires
machined surfaces. Continuous Path (CP) motion with high repeatability (~0.2
mm) and controlled speed.

Deburring is traditionally an expensive, manual process, but industrial robots can

effectively perform this task by mimicking manual techniques.
Industrial Applications of Robot
Advantages of Using Industrial Robots:
Increased Efficiency: Robots operate continuously without fatigue, boosting
production rates.

Consistency: High precision and repeatability ensure uniform product quality.

Safety: Robots handle dangerous tasks, reducing workplace injuries.

Flexibility: Modern robots can be reprogrammed for different tasks, though some
applications still require specialized designs.
 References:
1. Robert Shilling, Fundamentals of Robotics-Analysis and Control, Prentice Hall of India.
2. S. K. Saha, “Introduction to Robotics” 2e, TATA McGraw Hills Education (2014).

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