14MTT72 INDUSTRIAL ROBOTICS

COURSE OUTCOMES
On completion of the course the students will be able to

CO1: Interpret the features of an industrial robot

CO2: Estimate the gripping force of robot end effector
CO3: Develop the forward and inverse kinematics for serial manipulator
CO4: Analyse the velocity and static force of serial manipulators
CO5: Formulate robot dynamics and trajectory
UNIT – I 9
Introduction: History of robotics – Components of industrial robot - Degree of
Freedom – Type of Joints - Classification of robots – Work volume - Reference frames
– Programming modes - Robot specifications - Precision of movements: Accuracy,
resolution, repeatability and dexterity – Singularity – Robot languages - Robot
applications.

UNIT – II 9
End Effectors: Types of end effectors - Mechanical Gripper - Vacuum cup - Magnetic
gripper - Special types of grippers- Gripper force analysis. Frame Transformation:
Descriptions: Position, Orientation and Frames - Matrix representation: Point, vector,
frame and rigid body - Homogeneous Transformation matrices – Representation:
Translation, Rotational and Combined transformation – simple problems.

UNIT – III 9
Robot Kinematics: Forward and inverse kinematics – Equations for position and
orientation – Denavit- Hartenberg Representation of forward kinematic equations: Two
and Three link planer, PUMA and SCARA - Inverse kinematic equation: Two and three
link planer.
UNIT – IV 9
Velocity and Static Force: Introduction - Linear and angular velocities of a rigid body
- Velocity propagation – Derivation of the Jacobian for serial manipulator –
Identification of Singularities - Static force analysis of serial manipulator.

UNIT – V 9
Robot Dynamics: Acceleration of a rigid body - Inertia of a link - Equation of motion:
Legrangian formulation – Euler- Lagrange formulation - Newton Euler formulation.
Trajectory Planning: Joint space trajectory: Point to point and Continuous path
planning - Cartesian space trajectory – Simple problems.
TOTAL: 45
BOOKS:
1. Groover M.P., “Industrial Robotics, Technology, Programming and Applications”,
2nd Edition, Tata Mcgraw-Hill, New Delhi, 2012.

2. Saeed B. Niku, “Introduction To Robotics: Analysis, Control, Applications”, 2 nd

Edition, Wiley India Pvt. Limited, 2012.

3. Craig John J., “Introduction to Robotics: Mechanics and Control”, 3 rd Edition,

Pearson Education, New Delhi, 2005.
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History of Robot

“Robota” - Forced Labour

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History of Robot

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History of Robot

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History of Robot

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History of Robot

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Evaluation of Industrial Manipulator

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 Industrial Robots Definition
A robot is a programmable arm
simulator

“A robot is a programmable,
multifunction manipulator designed to
move material, parts, tools, or special
devices through variable programmed
motions for the performance of a
variety of tasks”
Robot Institute of America
 Laws of Robotics
Isaac Asimov @ 1939

1. A robot may not injure a human being or, through

inaction, allow a human being to come to harm.

2. A robot must obey orders given it by human beings

except where such orders would conflict with the
First Law.

3. A robot must protect its own existence as long as

such protection does not conflict with the First or
Second Law.
Basic Components of Robot
Manipulator
The manipulator consists of segments that
may be jointed and that move about,
allowing the robot to do work. It moves
materials, parts, tools, or special devices
through various motions to provide useful
work.
 End Effector

The end effector is the robot’s hand, or the

end-of-arm tooling on the robot.

It is a device attached to the wrist of the

manipulator for the purpose of grasping,
lifting, transporting, maneuvering, or
performing operations on a workpiece.

Robot’s performance is a direct result of

how well the end effector meets the task
requirements.

Area within reach of the robot’s end

effector is called its work envelope.
 Controller
The controller is the part of a robot that
coordinates all movements of the
mechanical system.

It also receives input from the immediate

environment through various sensors.

The heart of the robot’s controller is

generally a microprocessor linked to
input/output and monitoring devices.

The commands issued by the controller

activate the motion control mechanism,
consisting of various controllers,
amplifiers, and actuators.

This movement is initiated by a series of

instructions, called a program, stored in
the controller’s memory.
 Means for Programming:
The means for programming is used to
record movements into the robot’s
memory.

A robot may be programmed using any

of several different methods. The teach
pendant, also called a teach box or
handheld programmer teaches a robot
the movements required to perform a
useful task.

The operator uses a teach pendant to

move the robot through the series of
points that describe its desired path. The
points are recorded by the controller for
later use.
 Power supply

Provides the energy to drive the controller and actuators.

It may convert ac voltage to the dc voltage required by the robot’s internal

circuits, or it may be a pump or compressor providing hydraulic or
pneumatic power.

The three basic types of power supplies are electrical, pneumatic and
hydraulic.
 Degrees of Freedom
The individual joint motions associated with the performance of
task or Number of independent parameter required to define the
motion

Describe a robot’s freedom of motion in three dimensional space.

The ability to move
 to the left and to the right - rotational traverse (x- axis)
 forward and backward - radial traverse (y-axis)
 up and down - vertical traverse (z-axis)
 Degrees of Freedom
Additional degree of freedom can be obtained from wrist
 up and down - pitch (x-axis)
 side to side - yaw (y- axis)
 swivel - roll (z- axis)

A robot requires a total of six degrees of freedom to locate and

orient its hand at any point in its work envelope
 Manipulator Joints

• Translational motion
(Prismatic Joint (P))
– Linear joint (type L)
– Orthogonal joint (type O)

• Rotary motion
(Revolute Joint (R))
– Rotational joint (type R)
– Twisting joint (type T)
– Revolving joint (type V)
 Wrist Configurations
• Wrist assembly is attached to end-of-arm
• End effector is attached to wrist assembly
• Function of wrist assembly is to orient end effector
– Body-and-arm determines global position of end effector
• Two or three degrees of freedom:
– Roll
– Pitch
– Yaw
• Notation :RRT
 Joint Notation Scheme

• Uses the joint symbols (L, O, R, T, V) to designate

joint types used to construct robot manipulator
• Separates body-and-arm assembly from wrist
assembly using a colon (:)

• Example: TLR : TR

• Common body-and-arm configurations …

 Example
• Sketch following manipulator configurations
(a) TRT:R, (b) TVR:TR, (c) RR:T.
Solution:
R
R
T T R
R T
R
R V

T T

(a) TRT:R (b) TVR:TR (c) RR:T

Links
Joints & DoF
a) Revolute (1 DOF, 1 rotational)
b) Screw/Spiral (1 DOF, 1 rotational)
c) Prismatic (1 DOF, 1 translational)
d) Cylindrical (2 DOF, 1 translational &
1 rotational)
e) Planar (3 DOF, 2 translational &
1 rotational)
f) Spherical (3 DOF, 3 rotational)

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 DoF Calculation -  Kutzbach  Equation
(Planer Mechanism)

F = 3 (n-1) – 2J1 – J2
where:
F = Number of degrees of freedom
n = Total number of links in the mechanism
J1 = No. of joints with 1 DOF
J2 = No. of joints with 2 DOF

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Planer Mechanism – Slider Crank

n=4
J1 = 4
J2 = 0

F = 3 (n-1) – 2J1 – J2
F = 3 (4-1) – 2 (4) - 0 = 1

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Planer Mechanism

n=6
J1 = 7
J2 = 0

F = 3 (n-1) – 2J1 – J2
F = 3 (6-1) – 2 (7) - 0 = 1

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 Planer Mechanism – 5 Bar

n=5
J1 = 5
J2 = 0

F = 3 (n-1) – 2J1 – J2
F = 3 (5-1) – 2 (5) - 0 = 2
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 DoF Calculation -  Kutzbach  Equation
(Spatial Mechanism)
F = 6 (n-1) - 5J1 - 4J2 - 3J3 - 2J4 – J5
where:
F = Number of degrees of freedom
n = Total number of links in the mechanism
J1 = No. of joints with 1 DOF
J2 = No. of joints with 2 DOF
J3 = No. of joints with 3 DOF
J4 = No. of joints with 4 DOF
J5 = No. of joints with 5 DOF
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 Spatial Mechanism – Tripod

n=8
J1 =6
J2 =1
J3 =1
J4 =0
J5 =0

F = 6 (n-1) - 5J1 - 4J2 - 3J3 - 2J4 – J5

F = 6 (8-1) – 5(6) – 4(1) – 3(1) – 2(0) – (0) = 5
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Stewart Platform – 6 DoF Parallel
Manipulator
n=14, J1=6, J2=6, J3=6
J4 =0, J5 =0

F = 6 (n-1) - 5J1 - 4J2 -

3J3 - 2J4 – J5

F = 6 (14-1) – 5(6) –
4(6) – 3(6) – 2(0) – (0)

F=6

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• Planer Manipulator – 3 DoF
• Spatial Manipulator – 6 DoF
• Redundant Manipulator
 Planer Manipulator more than 3 DoF
 Spatial Manipulator more than 6 DoF
• Under Actuated Manipulator
 Planer Manipulator less than 3 DoF
 Spatial Manipulator less than 6 DoF
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 Polar Coordinate
Body-and-Arm Assembly
• Notation TRL/RRP/2RP:

• Consists of a sliding arm (L joint) actuated relative to

the body, which can rotate about both a vertical axis
(T joint) and horizontal axis (R joint)
 Cylindrical Body-and-Arm Assembly
• Notation TLO/RPP/R2P:

• Consists of a vertical column, relative to which an arm

assembly is moved up or down
• The arm can be moved in or out relative to the
column
 Cartesian Coordinate
Body-and-Arm Assembly
• Notation LOO/PPP/3P:
• Consists of three sliding joints,
two of which are orthogonal
• Other names include rectilinear
robot and x-y-z robot
 Jointed-Arm Robot (PUMA)

• Notation TRR/RRR/3R:

Programmable Universal
Machine for Assembly
 SCARA Robot
• Notation VRO/RRP/2RP
• SCARA stands for Selectively
Compliant Assembly Robot
Arm
• Similar to jointed-arm robot
except that vertical axes are
used for shoulder and elbow
joints to be compliant in
horizontal direction for
vertical insertion tasks
 Reach (Work Volume / Work envelop)
Spatial region within
which the end of the
robot’s wrist can be
manipulated
Determined by
– Physical configurations
– Size
– Number of axes
– The robot mounted position (overhead gantry, wall-mounted,
floor mounted, on tracks)
– Limits of arm and joint configurations
– The addition of an end-effector can move or offset the entire
work volume
 (a) Polar (b) Cylindrical

(c) Cartesian

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 Coordinate Systems

World coordinate system Tool coordinate system

 Technical Specifications
• Size of the working envelope • Motion control
• Precision of movement – path control
– Resolution – velocity control
– Accuracy • Types of drive motors
– Repeatability – hydraulic
• Lifting capability – electric
• Number of robot axes – pneumatic

• Speed of movement
– maximum speed
– acceleration/deceleration time
 Weight Carrying Capacity
(Pay load)
The lifting capability provided by manufacturer
doesn’t include the weight of the end effector
• Usual Range 2.5lb-2000lb (1.13 kg to 907.18 kg)
• Condition to be satisfied:
Load Capability > Total Wt. of workpiece
+ Wt. of end effector
+ Safety range
 Speed of Movement

Speed with which the robot can manipulate

the end effector

•Acceleration/deceleration times are crucial for cycle

time.
•Determined by
– Weight of the object
– Distance moved
– Precision with which object must be positioned
 Motion Control

• Path control - how accurately a robot traces a given path

(critical for gluing, painting, welding applications);
• Velocity control - how well the velocity is controlled
(critical for gluing, painting applications)
• Types of control path:
- point to point control (used in assembly, palletizing, machine loading);
- - continuous path control/walkthrough (paint spraying, welding).
- controlled path (paint spraying, welding).
 Type of Drive System

• Hydraulic
– High strength and high speed
– Large robots, Takes floor space
– Mechanical Simplicity
– Used usually for heavy payloads

• Electric Motor (Servo/Stepper)

– High accuracy and repeatability
– Low cost
– Less floor space
– Easy maintenance

• Pneumatic
– Smaller units, quick assembly
– High cycle rate
– Easy maintenance
 Example
(Motoman MA1400 DX100: Welding robot)
 Example
(Unimation – PUMA 500)

Model: 550 Actuator : Electrical Applications:

Axes : 6 DoF Payload : 3kg M/c tool loading, Part
Speed : 1000 m/s Repeatability : ±0.10 transfer, Assembly,
Welding, Inspection etc.
Precision of Movements: (i) Resolution

Smallest increment
of motion at the
wrist end that can
be controlled by
the robot

Depends on the
position control system,
feedback
measurement, and
mechanical accuracy
 (ii) Accuracy
Capability to position the wrist at a target point in
the work volume
• One half of the distance between two adjacent resolution points
• Affected by mechanical Inaccuracies
• Manufacturers don’t provide the accuracy (hard to control)
 (iii) Repeatability
Ability to position back to a point that was
previously taught
• Repeatability
errors form a
random variable
• Mechanical
inaccuracies in arm,
wrist components
• Larger robots have
less precise
repeatability values
 (iii) Dexterity
Skill in performing tasks, especially with the
hands
Robot's ability to cope with a variety of objects
and actions

(iii) Singularity

Loss of Degrees of Freedom

 Formula
Control
  Resolution = =
Where n : No. of bits in control memory

Spatial Resolution = Control Resolution + 6

Accuracy = Spatial Resolution / 2

Repeatability =  3
A cylindrical robot has a prismatic joint with a range of travel
of 800mm. The control memory for this joint has 10 bit. It has
been recorded that the associated mechanical inaccuracies
with above said arm show a random distribution of random
variable of the robot position gives a standard deviation of
0.1mm. The standard deviation is equal in all direction.
Determine,

Control
  Resolution =

Spatial Resolution = CR+6 = 0.78+6(0.1) = 1.38 mm

Accuracy = SR / 2 = 1.38 / 2 = 0.69 mm

Repeatability =  3 =  3(0.1) =  0.3 mm

 Robot Programming
• Leadthrough programming
– Work cycle is taught to robot by moving the
manipulator through the required motion cycle and
simultaneously entering the program into controller
memory for later playback
• Robot programming
– Textual programming language to enter commands
into robot controller
• Simulation and off-line programming
– Program is prepared at a remote computer terminal
and downloaded to robot controller for execution
without need for leadthrough methods
 Leadthrough Programming

1. Powered leadthrough
– Common for point-to-
point robots
– Uses teach pendant
2. Manual leadthrough
– Convenient for
continuous path control
robots
– Human programmer
physical moves
manipulator
 Leadthrough Programming

• 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 with supervisory control
 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
• Programming Languages:
– WAVE, AL, VAL, AML, RAIL, HELP, JARS, RPL, PAL, ADA etc.
(200+)
 Classification of Robot Languages

First generation language:

– Off-line programming in combination with the programming
through teach pendant
– Limited handling of sensory data (Except On/OFF binary
data) and communication with other computers
– Branching, I/O interfacing and commands leading to
sequence of movements of arm and body, and opening and
closing of end effecter are possible
– E.g. VAL
 Example Program (VAL)
1. APPRO PART, 50 : - Move to location, 50 mm above location PART (location
to be defined)
2. MOVES PART :- Move along a straight line to PART
3. CLOSEI: - Close the gripper jaws to grip the object immediately
4. DEPARTS 150:- Withdraw 150 mm from PART along straight line path
5. APPROS BOX, 200 : - Approach along straight line to location 200 mm above
the location, BOX ( to be defined later)
6. MOVE BOX :- Move to BOX
7. OPENI :- Open the hand ( and drop the object)
8. DEPART 75 : - Withdraw 75 mm from BOX
END
Line 1,6,7 : Joint interpolated motion
Line 2,4,5 : Straight line motion
Line 3,7 : hand control instructions
 Classification of Robot Languages
Second generation language:
– Structured programming languages performing complex task
– Handle both analog and digital signals
– Force, torque, slip and other sensors can be incorporated on the
joints
– Wrist or gripper fingers and the robot controller is capable of
communicating with sensory device
– If error or faults occurs, the first generation robot will probably stop
functioning and it can not cope with situation. But it can recover in
the event of malfunction probably by activating some other
programs
– Better interacting facility with other computers
– Data processing, file management and keeping all records of event
happening in the work cell can be done more efficiently
– E.g.: AML, RAIL, MCL, VAL II etc.
 Classification of Robot Languages

World modelling and task-oriented object level language

– Advanced future language
– Task is defined through command
– Capable of performing step by step functions to accomplish
the objective
– Possible only if the robot is capable of sensing the world
around it
– Intelligent required and robot should be capable of making
decisions

Simulation and off-line programming

 Computer control and Robot
software
Monitor Mode:
• Programmer can define location
• Load a particular piece of information in a particular register
• Store information in the memory
• Save, transfer program from storage into computer control
system memory
• Enable or disable, move back and forth into edit or run mode
Editor mode:
• Programmer can edit or change a set of instructions of existing
programs or introduce new set of program
• Erase some instructions and replace them by new lines
• Error can be corrected
 Computer control and Robot
software
Run mode or Execute mode:
• Program to carry out the predefined task can be executed in the
run mode
• Sequential steps as written by the programmer are followed
during run mode
• Sometimes dry run can be tested by making the switch disable
(e.g. Arc welding: Trajectory can be tested by dry run)
• Error can be rectified by debugging
• Interpreter or complier used to translate the source program to
machine language
 Singularity
• Control of manipulator in Cartesian space arises some problem
to position the robot is known as singularities or degeneracy due
to inverse mapping from Cartesian space to joint space.
• At a singularity, the mobility of the robot is reduced. Usually,
arbitrary motion of the manipulator in Cartesian direction is lost.
This referred as “Losing of DoF’.
Types:
1. Workspace/Boundary singularities:
The manipulator is fully stretched out or folded back on itself
such that the end-effector is near or at the boundary of the
workspace.
2. Internal/Joint space singularities:
Two or more joints axes lining up or alignment of robot axes in
space
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 Robot Applications
• Spot welding, Arc welding , Spray painting, Grinding
• Drilling holes, Routing, Polishing, Nut running, Driving
of screws
• Parts handling/Transfer, Assembly operation, parts
sorting, part inspection
• Teleoperators, Gauging, Space, Under water,
Harvesting, Prosthetics, Medical, Surgery, Millitary

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 Smart Robotics Application
BigDog

 Carry 340 lb
 Run 4 mph
 Climb, run, and walk
 Move over rough terrain
 Robot with rough-terrain mobility that could carry equipment to remote location
 Smart Robotics Application

Cleans Gutter Vacuum Floors

 Medical Applications

Prosthetics
 Arms, Legs, and other body parts
can be replaced with
electromechanical ones