Introduction of Robotics-Overview Application of robots in Industries
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Introduction of Robotics-Overview A short history of industrial robots Application of Robot in Welding Car body assembly, painting Application of Robot in Machining Material Transfer- Kinematics and mechanism review Task Description Teaching and Programming End Effectors, System integration
Introduction of Robotics-Overview Application of robots in Industries
- 1. UNIT-1 Application of robots in Industries Prepared by- Dr. Mohd Aslam PhD. in Mechanical Engineering Sharad Institute of Technology College of Engineering Yadrav, Kolhapur Maharashtra India 416121.
- 2. Contents • Introduction of Robotics-Overview • A short history of industrial robots • Application of Robot in Welding • Car body assembly, painting • Application of Robot in Machining • Material Transfer- Kinematics and mechanism review • Task Description • Teaching and Programming • End Effectors, System integration 2 SITCOE YADRAV
- 3. SITCOE YADRAV Car body assembly • Robotics plays a crucial role in modern car body assembly, automating tasks like welding, sealing, and material handling, ensuring precision and efficiency in the manufacturing process 3
- 4. SITCOE YADRAV Key Tasks Performed by Robots • Welding: • Robots, particularly large industrial robots, are used for spot welding car body panels, while smaller collaborative robots (cobots) handle welding smaller parts like mounts and brackets. • Sealing and Gluing: • Robots apply adhesives and sealants to create strong joints between car body parts. • Material Handling: • Robots move and position car body parts and subassemblies, facilitating the smooth flow of the assembly line. • Assembly: • Robots install parts, such as windshields and wheels, and perform other intricate assembly processes. • Painting and Coating: • Robots apply paint and coatings to car bodies, ensuring consistent and even coverage. • Inspection: • Robots can perform quality inspections to verify that all parts are correctly assembled and working as intended. 4
- 5. SITCOE YADRAV Benefits of Using Robots in Car Body Assembly • Precision and Accuracy: • Robots can perform repetitive tasks with high precision and accuracy, ensuring consistent quality. • Speed and Efficiency: • Robots can work at high speeds and continuously, speeding up the assembly process. • Safety: • Robots can handle hazardous tasks, such as welding and painting, keeping human workers out of harm's way. • Flexibility: • Robots can be reprogrammed to assemble different car models, allowing for flexible production. • Reduced Labor Costs: • Automation with robots can reduce labor costs and improve productivity. 5
- 6. SITCOE YADRAV Types of Robots Used in Car Body Assembly • Large Industrial Robots: • These robots have high payload capabilities and long reach, suitable for tasks like spot welding car body panels. • Collaborative Robots (Cobots): • These robots are designed to work alongside human workers, performing tasks like welding smaller parts and assembly. • Specialized Robots: • Some robots are designed for specific tasks, such as dispensing adhesives or applying coatings. 6
- 7. SITCOE YADRAV Examples of Robotic Applications in Car Body Assembly: • Spot Welding: • Robots precisely weld car body panels together, ensuring strong and durable joints. • Sealing: • Robots apply sealant to car body seams, preventing leaks and ensuring a watertight seal. • Material Handling: • Robots move car body parts and subassemblies along the assembly line, ensuring a smooth and efficient flow of production. • Assembly: • Robots install parts, such as windshields and wheels, and perform other intricate assembly processes. • Painting and Coating: • Robots apply paint and coatings to car bodies, ensuring consistent and even coverage. 7
- 8. SITCOE YADRAV Painting • Industrial painting robots, also known as spray painting robots, are increasingly used in manufacturing to automate painting processes, improving efficiency, precision, and safety, particularly in industries like automotive and woodworking. 8
- 9. SITCOE YADRAV Benefits • Increased Efficiency: Robots can paint more consistently and quickly than humans, leading to faster production cycles. • Improved Precision: Robots can paint with high accuracy and repeatability, ensuring a consistent finish across all products. • Enhanced Safety: Robots can perform tasks in hazardous environments, protecting human workers from exposure to paint fumes and other dangers. • Reduced Costs: While the initial investment can be high, robots can reduce long-term costs by lowering labor expenses, waste, and rework. • Increased Flexibility: Robots can be easily reprogrammed to handle different products and painting tasks, making them adaptable to changing production needs. 9
- 10. SITCOE YADRAV Industries Utilizing Painting Robots • Automotive: Painting car bodies and components. • Woodworking: Painting furniture, doors, and other wood products. • Aerospace: Coating aircraft components. • General Manufacturing: Painting various industrial products. • Key Manufacturers of Painting Robots: • FANUC: Known for its PaintMate series and other painting robots. • ABB: Offers FlexPainter robots and other painting solutions. • Yaskawa Motoman: Provides a range of robots for paint spraying and coating. • KUKA: Offers painting robots optimized for various applications. • Dürr: A leading provider of painting and assembly systems. • B+M: Specializes in fully automated painting systems. • CMA Robotics: Focuses on automated painting solutions for the wood industry. • 10
- 11. SITCOE YADRAV Types of Painting Robots: • Spray Painting Robots: These robots use spray guns to apply paint to objects. • Coating Robots: These robots apply various types of coatings, including paints, primers, and sealants. • Powder Coating Robots: • Key Considerations: • Spatial Awareness: Robots need to be able to understand their position in the work envelope and avoid collisions. • Collision Detection: Robots need to be equipped with sensors to detect and avoid collisions with objects in their environment. • Paint Application Technology: Choosing the right paint application technology (e.g., spray guns, electrostatic spray) is crucial for achieving the desired finish. • Robot Programming: Robots need to be programmed to follow the desired painting path and spray patterns. 11
- 12. SITCOE YADRAV Brief History of Painting Robots in Industry (Year-Wise) • 1960s – Early Automation in Painting • 1961: The first industrial robot, Unimate, was deployed at General Motors, leading to robotic automation in manufacturing. • 1969: Early robotic spray painting systems introduced, reducing human exposure to toxic fumes. • 1970s – First Dedicated Painting Robots • 1973: KUKA and ABB developed early robotic arms for painting applications. • 1979: FANUC introduced robotic arms for spray painting in automotive factories. 12
- 13. SITCOE YADRAV Brief History of Painting Robots in Industry (Year-Wise) • 1980s – Advancement in Spray Painting Robots • 1982: General Motors implemented PUMA (Programmable Universal Machine for Assembly) robots for painting car bodies. • 1985: ABB’s TR5000 robot introduced for precision painting. • 1990s – Improved Accuracy & Environmental Efficiency • 1994: Introduction of electrostatic spray painting using robots, reducing paint waste. • 1998: Nissan & Toyota automated entire vehicle painting processes with robotics. 13
- 14. SITCOE YADRAV Brief History of Painting Robots in Industry (Year-Wise) • 2000s – AI & Smart Robotics in Painting • 2005: Robots with machine vision improved accuracy in detecting surfaces. • 2008: Dürr EcoRP robotic system enhanced automation in automotive painting. • 2010s – Industry 4.0 & Adaptive Robotics • 2015: AI-driven painting robots adjusted spray patterns based on object shape. • 2018: Collaborative painting robots (cobots) introduced, allowing safer human-robot interaction. • 2020s – AI & Sustainable Robotics • 2021: Smart painting robots reduced VOC (Volatile Organic Compound) emissions. • 2023: AI-powered robots with self-learning capabilities optimized paint application for minimal waste. 14
- 15. SITCOE YADRAV Application of Robot in Machining • Robots are increasingly used in machining for operations like milling, drilling, grinding, and deburring, offering benefits like increased precision, repeatability, and efficiency, particularly in industries like aerospace, automotive, and medical. 15
- 16. SITCOE YADRAV Types of Machining Operations • Low Material Removal Rate (MRR): • Robots are used for tasks like grinding, polishing, and deburring, where precise control and consistent force are crucial. • High MRR Operations: • Robots can also perform milling and drilling operations, requiring greater force and precision. • Cutting: • Robots can be used for cutting various materials, including metal, plastic, and wood, with applications like plasma cutting for sheet metal and steel plates. • Industries Utilizing Robotic Machining: • Aerospace: • Robots are used for drilling holes in aircraft fuselages and other complex parts. • Automotive: • Robots are used for deburring, milling, and other operations in the automotive industry. • Medical: • Robots can be used for machining medical implants and other precision parts. • Foundry: • Robots can be used for tasks such as de-gating and cleaning castings. 16
- 17. SITCOE YADRAV Advantages of Using Robots in Machining • Increased Precision and Accuracy: • Robots can perform machining operations with consistent accuracy and repeatability, leading to higher-quality parts. • Improved Efficiency and Productivity: • Robots can work continuously and at high speeds, increasing overall production output. • Reduced Human Error: • Robots can perform repetitive and potentially hazardous tasks, reducing the risk of human error and injuries. • Flexibility and Adaptability: • Robots can be easily reprogrammed and adapted to different machining tasks and materials. • Cost-Effectiveness: • While the initial investment in robots can be high, they can offer long-term cost savings through increased efficiency and reduced labor costs. • Material Handling: • Robots can be used for material handling tasks, such as loading and unloading parts into CNC machines, which can improve workflow efficiency. 17
- 18. SITCOE YADRAV Brief History of the Application of Robots in Machining (Year-Wise) • 1950s – Early Concepts of Industrial Robotics • 1956: George Devol and Joseph Engelberger developed the first industrial robot concept. • 1959: The first prototype, Unimate, was introduced, laying the foundation for robotic automation. • 1960s – First Industrial Robots in Manufacturing • 1961: General Motors deployed Unimate, the first industrial robot, for die-casting and welding. • 1969: Stanford Research Institute developed the Stanford Arm, an early robotic arm for precision tasks. 18
- 19. SITCOE YADRAV • 1980s – Rise of CNC and Robotic Integration • 1982: Robots were integrated with CNC machines, improving efficiency in metal cutting and drilling. • 1985: Grinding and polishing robots were introduced in automotive manufacturing. • 1990s – Advanced Precision & Multi-Tasking Robots • 1992: Deburring and finishing robots enhanced aerospace and medical device manufacturing. • 1998: Robots were widely used in laser cutting and high- precision machining. 2000s – AI & Vision-Based Machining Robots • 2005: Introduction of AI-powered machining robots with real- time error detection. • 2008: 3D vision systems enabled robots to adapt to complex shapes for machining. 19 Brief History of the Application of Robots in Machining (Year-Wise)
- 20. SITCOE YADRAV • 1970s – Introduction of Robots in Machining • 1973: KUKA introduced the first six-axis robotic arm, increasing robotic capabilities in machining. • 1979: Fanuc and ABB developed robots for material handling and machine tending in CNC machining. • 2010s – Smart Factories & Industry 4.0 • 2015: Collaborative robots (Cobots) started working alongside humans in machining. • 2018: Hybrid machining systems combined robotics with AI and IoT for adaptive manufacturing. • 2020s – AI-Driven Autonomous Machining Robots • 2021: Robots with machine learning optimized tool paths and precision in CNC machining. • 2023: Smart factories implemented fully autonomous machining robots, reducing human supervision. 20 Brief History of the Application of Robots in Machining (Year-Wise)
- 21. SITCOE YADRAV Material Transfer- Kinematics and mechanism review • Material transfer is a critical function in industrial automation, where robots and mechanisms are used to move objects efficiently. The study of kinematics and mechanisms helps optimize robotic movement for speed, accuracy, and energy efficiency. • Kinematics in Material Transfer • Kinematics focuses on the motion of robotic arms and conveyors without considering forces. 21
- 22. SITCOE YADRAV Kinematics in Material Transfer • Kinematics focuses on the motion of robotic arms and conveyors without considering forces. • Types of Kinematic Motion in Material Transfer • ✅ Linear Motion: Straight-line movement (e.g., conveyors, shuttle systems). ✅ Rotational Motion: Rotation about a fixed axis (e.g., robotic arms). ✅ Cylindrical Motion: Combination of linear and rotational motion (e.g., SCARA robots). ✅ Spherical Motion: Multi-axis motion for flexible object handling (e.g., articulated robots). 22
- 23. SITCOE YADRAV Kinematic Equations for Robotics • Forward Kinematics: Determines the position of the end- effector based on joint angles. • Inverse Kinematics: Calculates the joint angles required to move the end-effector to a specific position. • 💡 Example: In pick-and-place robots, inverse kinematics ensures accurate movement of objects from one location to another. 23
- 24. SITCOE YADRAV Kinematic Equations for Robotics 24
- 25. SITCOE YADRAV Mechanisms for Material Transfer • Different mechanisms are used to move objects efficiently in manufacturing and logistics. • A. Conveyor-Based Systems • 🔹 Belt Conveyors – Continuous material flow (e.g., airport baggage handling). 🔹 Roller Conveyors – Transporting heavy loads (e.g., warehouse automation). 🔹 Overhead Conveyors – Space-saving systems for hanging parts (e.g., car assembly lines). • B. Robotic Material Handling • 🔹 SCARA Robots – Fast pick-and-place operations in assembly lines. 🔹 Articulated Robots – Flexible movement for warehouse sorting. 🔹 Gantry Robots – Cartesian motion for precise material handling in packaging. 25
- 26. SITCOE YADRAV Mechanisms for Material Transfer • C. Automated Guided Vehicles (AGVs) & Autonomous Mobile Robots (AMRs) • 🔹 AGVs follow fixed paths for warehouse logistics. 🔹 AMRs use AI and sensors for dynamic, self-navigating material transfer. • 💡 Example: Amazon’s warehouse robots use AMRs to autonomously transport packages. 26
- 27. SITCOE YADRAV Optimization in Material Transfer Systems • ✅ Path Planning Algorithms – Reduce energy consumption and improve efficiency. ✅ Sensor-Based Feedback Systems – Enhance precision and avoid obstacles. ✅ AI and Machine Learning – Improve robot adaptability to dynamic environments. • 📌 Conclusion: The combination of kinematics and advanced mechanisms in material transfer leads to faster, more efficient, and safer industrial automation. 🚀 27