Robots one day presentation
7 likes2,583 views
The document outlines a comprehensive workshop on industrial robotics, covering the history, definitions, specifications, classifications, and applications of robots. It discusses key concepts such as the three laws of robotics, robot control systems, advantages and disadvantages of using robots, as well as various types of robotic arms and their functionalities. Additionally, it addresses end effectors and their importance in robotic operations.
Robots one day presentation
- 1. Welcomes You One Day Workshop on Robotics
- 2. 1. INTRODUCTION D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8 1. INTRODUCTION D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8
- 3. Robotics History 1. The term “robot” was derived from Czech word “robota”. 2. “robota” means labourer or worker. 3. Karel Capek used the term in his play “Rossum's Universal Robots”. 4. Isaac Asimov coined the term “Robotics” and postulated the three laws of robotics. 3
- 4. Three Laws of Robotics 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 the orders given to 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. 4
- 5. Definition of an Industrial Robot Definition given by International Organization for Standardization (ISO) “An industrial robot is an automatically controlled reprogrammable multipurpose manipulator programmable in three or more axes.” 5
- 6. Robot System 1. A robotic arm with actuators 2. Endeffector 3. Sensors 4. Control computer system 5. Communication peripherals 6. Power supply 6
- 7. Robotic ArmRobotic Arm D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Base Waist Motor Power cable Lower arm Joint Link Upper arm Wrist Gripper mounting flange 7
- 8. Robot Specification – Physical Mechanical • Robot configuration • Number of axes of movement • Floor space required for mounting • Weight • Physical dimensions • Physical details Power • Power drive system • Power/services requirements Control Programming method Type of control system External sensors supported Program backing storage device Memory size
- 9. Operational Parameters of a Robot 1. Precision a) Accuracy b) Resolution c) Repeatability 2. Speed 3. Payload 9
- 10. Accuracy and ResolutionAccuracy and Resolution . . . . . . . . . . . . . . A1, A2, A3, A4 … An – Addressable points P – Actual endeffector position Accuracy Resolution (smallest unit displacement) Endeffector A1 (Target) A3 A4A2 AnP D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 10
- 13. Speed CurveSpeed Curve Time Velocity Starting point Maximum velocity phase (travels at maximum specified velocity) Acceleration phase Deceleration phase Settling phase Stopping point D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 13
- 14. Robot Classification 1. Classification based on intelligence level 2. Classification based on servo control system 3. Classification based on drive systems 4. Classification based on geometric configuration of the arm 5. Miscellaneous types 14
- 15. Classification Based on Intelligence Level 1. Sequence control robots – Fixed sequence and Variable sequence control robots 2. Playback robots – Point to point and continuous path robots 3. Numerically controlled robots 15
- 16. Classification Based on Servo Control System 1. Servo control robots – Hydraulic and electric robots. Uses closed loop control system 2. Non servo control robots – Pneumatic robots. Uses open loop control system 16
- 17. Classification Based on Drive Systems 1. Pneumatic robots – light load, cheaper, no accurate positioning, light weight mechanism. 2. Hydraulic robots – heavy load, expensive, firm and rigid positioning, bulky mechanism. 3. Electric robots – medium load, accurate positioning, easily controlled by electronic controllers, light weight mechanism. 17
- 18. Classification Based on Geometric Configuration of the Arm 1. Cartesian coordinate robots 2. Polar coordinate robots 3. Cylindrical robots 4. Articulated or Jointed arm robots 5. Pendulum robots 6. Spine robots 7. Multiple arm robots 18
- 19. Robot Specifications 1. Accuracy, resolution, repeatability, speed and payload. 2. Number of degrees of freedom. 3. Geometric configuration of the manipulator. 4. Maximum and Minimum reach. 5. Type of Drive system. 6. Type of Control system. 19
- 20. Robot Specifications 7. Programming method. 8. Memory capacity. 9. Supported communication protocols and interface ports. 10. Input power supply requirements. 11. Total robot weight and installing procedures. 20
- 21. Robot Control Systems • Limited sequence control – pick-and-place operations using mechanical stops to set positions • Playback with point-to-point control – records work cycle as a sequence of points, then plays back the sequence during program execution • Playback with continuous path control – greater memory capacity and/or interpolation capability to execute paths (in addition to points) • Intelligent control – exhibits behavior that makes it seem intelligent, e.g., responds to sensor inputs, makes decisions, communicates with humans
- 22. Robot Control System Joint 1 Joint 2 Joint 3 Joint 4 Joint 5 Joint 6 Controller & Program Cell Supervisor Sensors Level 0 Level 1 Level 2
- 23. Advantages of using Robots 1. Consistent production quality. 2. High production quantity. 3. Can be employed at hazardous places. 4. Improvement in productivity, minimal material wastage, reduced work in progress and faster through put times. 5. Highly flexible to accommodate product design changes. 23
- 24. Advantages of using Robots 6. Working conditions are improved. 7. Occupational safety for workers is achieved. 8. Higher load carrying capacity. 9. Available at all times. 10. Manufactures can stay ahead in the market with state of the art robotic production facilities. 24
- 25. Disadvantages of Robots 1. High initial investment. 2. Inventory of endeffectors should be maintained. 3. Expensive spares and accessories. 4. Needs skilled personnel for programming. 5. Increases the risk of human unemployment. 25
- 26. 2. ROBOT MANIPULATOR2. ROBOT MANIPULATOR D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8 Thanks SABARIGIRIVASAN.R
- 27. Robot Manipulator 1. Manipulator is also known as robotic arm. 2. The arm is made up of a finite number of individual rigid segments. 3. Each rigid segment is called as a Link. 4. Links are connected to each other by joints. 5. Links move with respect to its joint. 27
- 28. Robotic ArmRobotic Arm D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Base Waist Motor Power cable Lower arm Joint Link Upper arm Wrist Gripper mounting flange 28
- 29. Types of Joints Joints are of two types 1. Linear joint – links move in linear fashion with respect to its joint when actuated. 2. Rotary joint – links move in rotary fashion with respect to its joint when actuated. 29
- 30. Types of JointsTypes of Joints D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Link – 1 Link – 1 Link Joint Joint Link (a) Rotary joint (b) Linear joint 30
- 33. Degrees of Freedom 1. Degrees of freedom (DOF) is defined as the ability of a joint to produce linear or rotary movement when actuated. 2. Number of DOF for a robot is equal to the number of joint axes in the robotic arm. 33
- 34. Lower Pair Joints 1. A lower pair joint is the joint in which two contacting surfaces can slide over with one another in rotary or linear manner. 2. They are of six types a) Revolute joint – 1 DOF b) Prismatic joint – 1 DOF c) Screw joint – 1 DOF d) Cylindrical joint – 2 DOF e) Planar joint – 3 DOF f) Spherical joint – 3 DOF 34
- 35. Lower Pair JointsLower Pair Joints (a) Revolute joint (b) Prismatic joint (c) Screw joint (d) Cylindrical joint (a) (b) (c) (d) D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 35
- 36. Lower Pair JointsLower Pair Joints D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R (e) Planar joint (f) Spherical joint (e) (f) 36
- 37. Link Parameters 1. Link length – 𝑎 2. Twist angle – 𝛼 3. Joint angle – 𝜃 4. Link offset – 𝑑 37
- 38. Wrist Motion 1. Yaw – Rotary motion executed about 𝑧 axis. Causes movement in left and right directions. 2. Pitch – Rotary motion executed about 𝑦 axis. Causes movement in up and down directions. 3. Roll – Rotary motion executed about 𝑥 axis. 38
- 39. Wrist MotionWrist Motion Yaw Pitch Roll Robot wrist 𝑧 𝑦 𝑥 D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 39
- 43. Robot’s Work Volume 1. The three dimensional space around the robot where it can sweep its wrist end within the points of maximum and minimum reach is called as Robot’s work Volume. 2. Maximum Reach is the point where the wrist end can go as far as possible from its base. 3. Minimum reach is the point where the wrist end can go as close as possible to its base. 43
- 44. Work envelope • The region of space a robot can reach
- 45. Work cell • Programming of Robots/Manipulators are typically only a minor part of an automated process • Work cell describes a local collection of equipments which includes one (or) more manipulators, conveyor system, Part feeders, & fixtures, etc.., • Sometimes workcell may be interconnected with factory network. So computers can control the overall flow.
- 46. Dexterous and Reachable workspace • Dexterous workspace is the volume of space which the robot can reach with all orientations. That is, at each point in the dexterous workspace, the end-effector can be arbitrarily oriented • The Reachable workspace is the volume of space which the robot can reach in at least one orientation • In the dexterous workspace the robot has complete manipulative capability. However, in the Reachable workspace, the manipulator's operational capacity is limited because the terminal device can only be placed in a restricted range of orientations • In other words, the dexterous workspace is a subset of the Reachable workspace
- 47. Robot ReachRobot Reach Work envelope Robot Endeffector Maximum reach Minimum reach Robot base D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 47
- 49. Classification of Manipulator 1. Cartesian coordinate robot system 2. Cylindrical robot system 3. Polar robot system 4. Pendulum robot system 5. Articulated or Jointed arm robot system a) Horizontal axis jointed arm b) Vertical axis jointed arm 6. Multiple joint robot system 49
- 50. Cartesian Coordinate Robot System (a) (c) (b) (a) Cartesian coordinate robot system (b) Gantry style (area gantry) (c) Rectangular work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Cartesian Coordinate Robot System 50
- 51. Cartesian Coordinate Robot System Animation 51
- 52. Cartesian Coordinate Robot System Animation 52
- 53. Cylindrical Robot SystemCylindrical Robot System D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R (a) Cylindrical robot system (b) Cylindrical work envelope 53
- 55. Polar Robot SystemPolar Robot System (a) Polar robot system (b) Spherical work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 55
- 57. Pendulum Robot SystemPendulum Robot System (a) Pendulum robot system (b) Partially spherical work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 57
- 59. Horizontal Axis Jointed ArmHorizontal Axis Jointed Arm (a) Horizontal axis robot system (b) Spherical work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 59
- 60. Horizontal Axis Jointed Arm 60
- 61. Horizontal Axis Jointed Arm Animation 61
- 62. Vertical Axis Jointed ArmVertical Axis Jointed Arm (a) Vertical axis robot system (b) Cylindrical work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 62
- 63. Vertical Axis Jointed Arm 63
- 64. Vertical Axis Jointed Arm Animation 64
- 65. Multiple Joint Robot SystemMultiple Joint Robot System (a) Spine robot system (b) Spherical work envelope D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 65
- 66. Multiple Joint Robot System Animation 66
- 67. Robot Motion 1. Point to point motion – The path has no importance. 2. Continuous path motion – The path taken is very important. 67
- 68. Trajectories 1. Path taken by the robot endeffector within the work volume is known as trajectory. 2. Trajectory planning. a) Joint interpolated trajectory planning. b) Cartesian path trajectory planning. 68
- 69. 5. ENDEFFECTORS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8 5. ENDEFFECTORS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8
- 70. Endeffectors 1. Endeffector is a device fixed to the wrist of the robot to do some sort of useful work. 2. A robot cannot work without an endeffector. 3. Endeffectors are broadly classified into two types, they are a) Grippers b) Tools 70
- 71. Kinds of Grippers Different kinds of grippers developed for specific kind of applications are 1. Mechanical grippers 2. Magnetic grippers 3. Vacuum grippers 4. Inflatable grippers 5. Adhesive grippers 6. Miscellaneous devices like hooks and scoops 71
- 72. Mechanical Grippers 1. Mechanical grippers have mechanical finger like provisions to grasp an object. 2. Fingers are provided with jaws for gripping the object. 3. Jaws are designed with suitable provisions for detaching them from the fingers. 4. Detachable jaw design helps us to replace worn out jaws and to fix different kind of jaws to the same gripper. 72
- 73. Types of Mechanical Grippers 1. Based on number of jaws a) Two jaw gripper b) Three jaw gripper 2. Based on finger movement a) Pivoted gripper b) Linear gripper 73
- 74. Two Jaw GripperTwo Jaw Gripper Jaw Gripper base D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 74
- 76. Three Jaw GripperThree Jaw Gripper Jaw Gripper Interface D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 76
- 78. Gripper with Articulated FingersGripper with Articulated Fingers Gripper interface Finger Joint D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 78
- 79. Gripper with Articulated Fingers Animation 79
- 80. Pivoted GripperPivoted Gripper Rotary motion Finger Pivot Gripper interface D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 80
- 82. Linear GripperLinear Gripper Linear motion Finger Gripper interface D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 82
- 84. Parallel Jaw Grippers Parallel Jaw Grippers (b) (a) (c) Fixed jaw Movable jaw (a) Pivoted type with both jaws movable (b) Linear type with both jaws movable (c) Linear type with one fixed jaw and one movable jaw (Vice type gripper) D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 84
- 88. Gripping Techniques Grippers employ three types of gripping techniques to pick an object. 1. External gripping The object is gripped over its external surface. 2. Internal gripping The object is gripped over its internal surface. 3. Combinational gripping External and internal gripping techniques are combined for picking an object that has very large internal and external diameters. 88
- 89. Gripping TechniquesGripping Techniques D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R (a) External gripping (b) Internal gripping (c) Combinational gripping (b)(a) (c) 89
- 90. Locking Techniques The gripped object is held by the jaws using two different techniques. 1. Force locking All jaws in the gripper presses against the object to hold it firmly. 2. Positive locking The object is confined within the space formed in between the jaws so that the object rest in the jaws. 90
- 91. Locking TechniquesLocking Techniques (a) Force locking Object held by gripping force D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 91
- 92. Locking TechniquesLocking Techniques (b) Positive locking Object rests within the jaws Object rests on the jaws D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 92
- 93. Types of Jaws Different types of jaws are 1. Flat jaw 2. V – jaw 3. Circular jaw 4. Pivot joint swivel jaw 5. Ball and socket joint swivel jaw 93
- 94. Types of JawsTypes of Jaws (c) Circular jaw(a) Flat jaw (b) V – jaw D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 94
- 95. Types of JawsTypes of Jaws Pivot Ball in its socket (e) Ball and socket joint swivel jaw (d) Pivot joint swivel jaw D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 95
- 98. Contact Conditions 1. Contact condition achieved between the work piece and the jaw determines the loading force acting on it for holding it safely. 2. Different types of contact conditions are a) Point contact b) Line contact c) Multiple line contact d) Area contact 98
- 99. Contact ConditionsContact Conditions D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R (a) Point contact (b) Line contact (c) Area contact (a) (b) (c) 99
- 100. Gripper Mechanisms There are many different configuration for mechanical gripper design, some of them are 1. Linkage mechanism 2. Cam actuated mechanism 3. Rack and pinion mechanism 4. Worm and pinion mechanism 5. Lead screw mechanism 6. Cable and pulley mechanism 100
- 101. Linkage MechanismLinkage Mechanism (a) Pivoted grippers Pivot Hinge Hinge Actuator rod D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 101
- 104. Linkage MechanismLinkage Mechanism Links (b) Parallel jaw gripper Actuator rod D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 104
- 106. Cam Actuated Mechanism Jaw Cam Cam slot Parallel jaw gripper Cam follower Cam Actuated Mechanism D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 106
- 108. Rack and Pinion MechanismRack and Pinion Mechanism Fixed jaw Movable jaw Rack Rack Pinion Pinion Pinion Shaft (a) Pivoted type gripper Finger (b) Vice type gripper D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 108
- 109. Rack and Pinion Mechanism Animation 109
- 110. Rack and Pinion Mechanism Animation 110
- 111. Worm and Pinion MechanismWorm and Pinion Mechanism Worm gear Pinion Finger (a) Both jaws movable type (b) One fixed jaw type Fixed jawMovable jaw D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 111
- 112. Worm and Pinion Mechanism Animation 112
- 113. Worm and Pinion Mechanism Animation 113
- 114. Lead Screw MechanismLead Screw Mechanism Lead screw Nut Pivot Finger (a) Pivoted type gripper Hinge D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 114
- 116. Lead Screw MechanismLead Screw Mechanism Fixed jaw Movable jaw Left hand screw Nut Right hand screw Lead screw (b) Both jaws movable type (c) Vice type gripper D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 116
- 119. Magnetic Grippers 1. Magnetic grippers are used to lift ferrous objects especially ferrous sheet metal parts. 2. They produce very intense magnetic field to grasp the object. 3. Magnetic grippers are of two types, they are a) Permanent magnet grippers b) Electromagnetic grippers 119
- 120. Permanent Magnet Grippers 1. They use permanent magnets to produce the field required to grasp the object. 2. A mechanical stripping device is needed to release the object as the field produced by a permanent magnet cannot be stopped. 3. Permanent magnet gripper with a releasing mechanism is a modified version of magnetic chuck. 120
- 121. Permanent Magnet GripperPermanent Magnet Gripper Lead screw Carriage Permanent magnet grid Face plate Non magnetic spacers S N N S N S N S N S S N S N S N D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 121
- 123. Permanent Magnet Gripper Operation Animation 123
- 124. Electromagnetic Grippers 1. Electromagnets are used to grasp ferrous object. 2. Electromagnet is a device that becomes a magnet when electricity is applied to its windings, it loses its magnetism when power is turned OFF. 3. Force developed by an electromagnet is given as 124
- 125. Attractive Force CalculationAttractive Force Calculation Input current Iron piece Air gap Soft iron core 𝑎 𝑎 Windings D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 125
- 126. Electromagnetic GripperElectromagnetic Gripper Gripper interface Electromagnet Gripper structure Electromagnet Flat ferrous object D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 126
- 127. Vacuum GripperVacuum Gripper Gripper interface Gripper structure Pressure line Suction cup Flat non porous object D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 127
- 128. Venturi NozzleVenturi Nozzle Pressurized air supply Exhaust Suction Nozzle Flow restrictor D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 128
- 130. Venturi Operated Suction Cup Animation 130
- 132. Adhesive GripperAdhesive Gripper Gripper interface Reel drive unit Tape reel Adhesive tape Tensioning roller Pressure plate Gripping area D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 132
- 133. Remote Centre Compliance device Animation 133 Remote Centre Compliance devices (RCC)
- 134. RCC – Lateral Error Animation 134
- 135. RCC – Angular Error Animation 135
- 136. Tools as Endeffector 1. To automate certain kind of manufacturing operations it needs a machine with human like dexterity and flexibility. 2. A robot is utilized to do that kind of job with machining tools as its endeffector. 3. The robot has the control over the tool attached to its wrist. 136
- 137. Widely used Tools Different kinds of tools used as endeffector are 1. Welding tools 2. Drilling tools 3. Milling cutters for light machining 4. Grinding wheels 5. Cutting tools 6. Riveting tools 7. Binding agent dispensers 8. Guns for surface coating and cleaning 137
- 138. Spot Welding ToolSpot Welding Tool Power cable C – Structure Electrode drive unit Movable electrode Fixed electrode Robot wrist D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 138
- 139. Rotating Tools Rotating Tools Drill bit Motor Drill chuck Motor Cutter adaptor Cutter Motor Grinding wheel Robot wrist (c) (a) (b) (a) Drilling tool (b) Milling cutter (c) Grinding wheel 139
- 140. Cutting Tools 1. Water jet cutting tools are employed with robots for cutting intricate parts. 2. The tool has a hard nozzle which delivers a high pressure water jet mixed with fine abrasive particles. 3. Abrasive particles impinging on the work piece makes a fine cut. 4. LASER is used for cutting intricate shapes and to drill fine holes. 5. High power Carbon dioxide LASER is used. 140
- 141. Riveting ToolRiveting Tool Pressure line Rivet driving mechanism Rivet head former C – Structure Robot wrist D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 141
- 142. Guns for Surface Coating and Cleaning 1. Painting guns are fitted to the robot wrist for spray painting. 2. The gun has a nozzle through which paint is delivered at optimal pressure for uniform coating at a consistent speed. 3. Blasting guns fitted to robots are used for cleaning surface deposits like scales and also for stripping older paint. 4. Sand blasting is used for this purpose. 142
- 143. Gun for Spray PaintingGun for Spray Painting Pressure line Nozzle Robot wrist D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 143
- 144. Criteria for Gripper Selection A gripper is selected for a specific application based on the following criteria 1. Material of the object either ferrous or non ferrous material. 2. Weight of the object. 3. Power needed to drive the gripper actuators. 4. Physical properties of the object like size, shape. 144
- 145. Criteria for Gripper Selection 5. Surface texture and porosity of the object. 6. Jaw opening and closing times. 7. Stroke length for jaw opening and closing. 8. Maximum gripping force delivered. 9. Maximum stress limits. 10. Dead weight of the gripper. These are various criteria that should be considered for selecting a gripper. 145
- 146. Criteria for Tool Selection 1. Tools are selected strictly based on the manufacturing technique employed to finish an operation. 2. A hole can be drilled using mechanical drill bit or by LASER, here the choice is made based on the cost and precision of the work to be done. 3. For some applications like spot welding there is no choice, a spot welding tool powerful enough in making the weld on the required work piece is selected. 146
- 147. 9. APPLICATIONS OF ROBOTS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8 9. APPLICATIONS OF ROBOTS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8
- 148. Applications of Robots 1. Material handling 2. Welding 3. Surface coating 4. Light machining 5. Assembling 6. Inspection and testing 7. Space exploration 8. Defence applications 9. Domestic applications 10. Medical applications 148
- 150. Robotic Spot WeldingRobotic Spot Welding Robot Spot welding endeffector Car frame Conveyor D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 150
- 152. Seam WeldingSeam Welding AC supply with timer Air tight seam weld Circular electrode Circular electrode Work piece D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 152
- 154. Robotic Spray PaintingRobotic Spray Painting Robot Spray gun Nozzle Car body D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Flexible cover(inside) 154
- 155. Robotic Machining Robots are used for light machining operations like 1. Fettling 2. Grinding 3. Deburring 4. Drilling 5. Riveting 155
- 156. Robotic FettlingRobotic Fettling Robot Grinding wheel Flash Work piece Work table attached with magnetic chuck Finished edge D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 156
- 157. Robotic DrillingRobotic Drilling Robot Drill chuck Drill bit Work piece with peculiar shape D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 157
- 158. PCB Assembly – SMD ComponentsPCB Assembly – SMD Components Lead Lead IC Copper pad PCB Soldered joint D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 158
- 159. Submarine Robotic VehicleSubmarine Robotic Vehicle Gripper Robotic arm Rudder PropellerHullLight Camera D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 159
- 160. Robot Installed in a Space ShuttleRobot Installed in a Space Shuttle Rocket nozzles Space shuttle Robotic arm Payload cargo Cargo bay D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 160
- 161. Bomb Disposal RobotBomb Disposal Robot Robotic arm Gripper High mounted camera Swivel for changing direction of view Antenna Radio transceiver Wheel Vehicle chassis D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 161
- 162. Operation of a Robotic Lawn MowerOperation of a Robotic Lawn Mower D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Turning point Perimeter path Lawn Magnetic strip Robotic lawn mower Building 162
- 163. 10. ROBOTIC MANUFACTURING SYSTEMS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8 10. ROBOTIC MANUFACTURING SYSTEMS D E S I G N A N D A P P L I C AT I O N S O F I N D U S T R I A L R O B OT S S A B A R I G I R I VA S A N . R I S B N 978-81-908268-0-8
- 164. Robotic Manufacturing Systems 1. Robots are designed to automate manufacturing operations that are monotonous and dangerous in nature. 2. The manufacturing cell that is serviced by one or more robots is known as robot work cell. 3. The robot work cell should have complete set of hardware, software and cell control system. 164
- 165. Structure of a Robot Work cell A robot work cell has the following equipments 1. Robots 2. Production machineries 3. Supply conveyor 4. Delivery conveyor 5. Cell controller 6. Communication peripherals 7. Protective barriers (Perimeter guard) 165
- 166. Structure of a Robot Work cell Structure of a Robot Work cell M1 M2 M3 M1, M2, M3 – Production machines Protective barrier Robot Control panel for manual override Cell access door Supply conveyor Delivery conveyor D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 166
- 167. Structure of a Robot Work cell Animation 167
- 168. Classification of Robot Work cell Based on Number of Robots 1. Single robot work cell a) Only one robot is employed to perform all operations. b) Machine interference can occur. c) Interference is caused due to imbalance in machine cycle and robot service times. 2. Multiple robot work cell a) More than one robot will be employed to perform all the required operation. b) Cell control system is employed to avoid collision. 168
- 169. Classification of Robot Work cell Based on the Position of Robots 1. Robot centered work cell. 2. Inline robot work cell. a) Intermittent part transfer b) Continuous part transfer 3. Mobile robot work cell a) Floor mounted rail system b) Overhead rail system 169
- 170. Robot Centered Work Cell Robot Centered Work Cell Machine 1 Machine 3 Machine 5 Machine 2 Machine 4 RobotSupply conveyor Raw materials Delivery conveyor Finished products D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 170
- 171. Robot Centered Work Cell Animation 171
- 172. Inline Robot Work CellInline Robot Work Cell Robot Work piece Moving production line D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 172
- 173. Inline Robot Work Cell Animation 173
- 174. Inline Robot Work Cell Animation 174
- 175. Robot Work Cell for Spot Welding (Inline work cell – Intermittent part transfer) Robot Work Cell for Spot Welding (Inline work cell – Intermittent part transfer) Robot Spot welding endeffector Car frameConveyor Robot D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 175
- 176. Mobile Robot Work Cell – Floor Mounted Rail System Mobile Robot Work Cell Floor Mounted Rail System Machine 1 Machine 2 Carriage Robot Floor mounted rail D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 176
- 177. Mobile Robot Work Cell – Floor Mounted Rail System Animation 177
- 178. Mobile Robot Work Cell – Overhead Rail System Mobile Robot Work Cell Overhead Rail System D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R Machine 1 Machine 2Supply conveyor Delivery conveyor Overhead rail RobotCarriage 178
- 179. Mobile Robot Work Cell – Overhead Rail System Animation 179
- 180. Safety Considerations 1. Safety is of paramount importance in any industrial operation. 2. The robot should be protected from damaging itself and injuring humans while in action. 3. Everything in the cell should be maintained well and checked for safe operation so that no mishap occurs. 180
- 181. Potential Hazards for Safety 1. Oil leaks in hydraulic robots and pressure loss in pneumatic robots. 2. Broken power cables. 3. Poor maintenance. 4. Poor quality of components. 5. Software errors. 6. Uncoordinated robot motion with the production machine. 181
- 182. Potential Hazards for Safety 7. Careless attitude of workers. 8. Unauthorized entry of workers into the cell. 9. Careless attitude of management. 182
- 183. Protective Measures 1. Providing multi tier security system. 2. Intruder alarm and glowing sign boards should be provided. 3. The robot should be stopped on detecting an intruder. 4. Protective barriers like wire mesh or guard railings should be provided. 5. Robots should be clearly visible and painted in bright colours. 183
- 184. Protective Measures 6. Cell access doors should get automatically locked while the robot is in action. 7. Control panel for manual override should be provided. 8. Emergency stop switch should be clearly visible and should be within easy reach. 9. Dormant state of the robot should be indicated by visible light signals. 184
- 185. Protective Measures 10. Unwanted objects should not be left inside the cell. 11. High quality components should be used. 12. Painting robots should be given proper covering. 13. Robot should be stopped if any of the sensor fails. 14. Adequate training and safety awareness should be imparted to the workers. 185
- 186. Economic Considerations 1. Robots are expensive equipments hence cost is an important factor to be considered while robotizing the production facility. 2. Robot costs a) Initial investment b) Operating cost c) Earnings and savings d) Miscellaneous costs 186
- 187. Cost Comparison 1. Before robotizing, other production process should be considered to arrive an optimal conclusion. 2. Earnings made for certain production volume should be compared with manual production and fixed automation. 3. Only when substantial cost benefits are realized it will be a profitable business. 187
- 188. Cost Comparison ChartCost Comparison Chart Cost per unit Production volume Graph plotted against logarithmic scale on both the axes. B1, B2, B3 – Break even points B1 B2 B3 Robotic production Manual production Fixed automation D E S I G N A N D A P P L I C A T I O N S O F I N D U S T R I A L R O B O T S S A B A R I G I R I V A S A N . R 188
- 189. Cost Estimation Two simple techniques for making estimates of earnings to justify robotization are 1. Payback period method 2. Return on Investment method 189
- 190. Payback Period Method 1. The investor calculates the payback period to recoup the money spent on robots. 2. Payback period is the time in years required to take back the money spent as investment and expenditure on robots. 3. Payback period is given as 4. The robot has salvage value after payback period. 190
- 191. Return on Investment Method 1. The investor calculates the rate of return from the robotic operations. 2. Rate of return is the percentage of investment earned per year. 3. The actual rate of return should be greater than the expected rate of return only then the business will be profitable. 191
- 192. Robot Selection 1. A robot is selected by considering its various operational parameters. 2. The features of a robot required to do the required operations are determined in advance using results of the study made by the Industrial Engineering department. 3. The robot should meet the required criteria so that it can perform all the operations effectively to which it is intended for. 192
- 193. Robot Selection Criteria 1. Precession – Accuracy, resolution and repeatability. 2. Speed. 3. Payload. 4. Type of drive system. 5. Programming methods. 6. Memory capacity. 7. Number of Degrees of Freedom. 193
- 194. Robot Selection Criteria 8. Power interface. 9. Communication interface. 10. Availability of standard endeffectors. 11. Cost, the most important deciding factor. 194
- 195. Thank you the Presentation NTTF