Subject: ROBOTICS ENGINEERING AND APPLICATIONS

Subject Code: ME 0002

Department of Mechanical Engineering
Note : Consider this PPT as reference only
.
5. INDUSTRIAL APPLICATIONS
Application of robots With examples.
Material handling Constraints,
Application Machine loading and unloading,
Assembly robot, assembly operation, RCC Devices, Benefits inspection robot,
used in Quality Control,
Welding robot, Features, sensors, Advantages
Painting Robot requirement , spray painting.
Mobile robot,
Micro robots
Recent developments in robotics- safety considerations.
5. INDUSTRIAL APPLICATIONS
Application of robots With examples.
Material handling Constraints,
Application Machine loading and unloading,
Assembly robot, assembly operation, RCC Devices, Benefits inspection robot,
used in Quality Control,
Welding robot, Features, sensors, Advantages
Painting Robot requirement , spray painting.
Mobile robot,
Micro robots
Recent developments in robotics- safety considerations.
OUT LINE OF V UNIT
Application of robots
Material transfer applications
Processing Applications
Assembly applications
Inspection applications
Welding robot, Features, sensors, Advantages
Painting Robot requirement , spray painting.
Mobile robot
Micro robots
Recent developments in robotics- safety considerations.
OUT LINE OF V UNIT
Application of robots
Material transfer applications
Processing Applications
Assembly applications
Inspection applications
Welding robot, Features, sensors, Advantages
Painting Robot requirement , spray painting.
Mobile robot
Micro robots
Recent developments in robotics- safety considerations.
Advantages , Disadvantages and shortcomings of Robots
Advantages :
Greater flexibility, reprogramability.
Reduced Costs.
Elimination of hazardous tasks.
Improved quality.
Improved productivity.
Greater response time to inputs than humans.
Accidents reduction.
Automation less susceptible to work stoppages.
Maximum capital intensive equipment in multiple work shifts.
Advantages , Disadvantages and shortcomings of Robots
Advantages :
Greater flexibility, reprogramability.
Reduced Costs.
Elimination of hazardous tasks.
Improved quality.
Improved productivity.
Greater response time to inputs than humans.
Accidents reduction.
Automation less susceptible to work stoppages.
Maximum capital intensive equipment in multiple work shifts.
Disadvantages :
Greater unemployment
Replacement if human labor.
Significant restraining cost for both unemployment and user of new technology.
Advertized technology does not always disclose some of the hidden disadvantages.
Payload to robot weight ratio is poor, often less tan 5 percent.
Robot structural configuration may limit joint movements.
Assembly dexterity does not match that of human beings, particularly where eye-
hand coordination is required .
Disadvantages :
Greater unemployment
Replacement if human labor.
Significant restraining cost for both unemployment and user of new technology.
Advertized technology does not always disclose some of the hidden disadvantages.
Payload to robot weight ratio is poor, often less tan 5 percent.
Robot structural configuration may limit joint movements.
Assembly dexterity does not match that of human beings, particularly where eye-
hand coordination is required .
shortcoming:
Today's robots:
1. Do not think independently
2. Do not adapt quickly to the changes in their environment.
3. Cannot react to unknown situations.
4. Are not creative or innovative.
5. Have no consciousness.
6. Cannot make complicated decisions.
7. Don not learn from mistakes
8. Have no human feelings.
shortcoming:
Today's robots:
1. Do not think independently
2. Do not adapt quickly to the changes in their environment.
3. Cannot react to unknown situations.
4. Are not creative or innovative.
5. Have no consciousness.
6. Cannot make complicated decisions.
7. Don not learn from mistakes
8. Have no human feelings.
APPLICATIONS OF ROBOTS
The various applications of robots include the following:
I. Industrial applications:
I. Material transfer applications
1. Part Placement
2. Palletizing and/or Depalletizing
3. Machine loading and/or unloading (Machine Tending)
a) Die casting machine
b) Plastic Molding
c) Forging and related operations
d) Machining operations (CNC)
e) Stamping press operations
4. Stacking and insertion operations
II.Processing Applications
1.Spot welding
2.Continues Arc Welding
3.Spray painting
4.Other Processing Operations
APPLICATIONS OF ROBOTS
The various applications of robots include the following:
I. Industrial applications:
I. Material transfer applications
1. Part Placement
2. Palletizing and/or Depalletizing
3. Machine loading and/or unloading (Machine Tending)
a) Die casting machine
b) Plastic Molding
c) Forging and related operations
d) Machining operations (CNC)
e) Stamping press operations
4. Stacking and insertion operations
II.Processing Applications
1.Spot welding
2.Continues Arc Welding
3.Spray painting
4.Other Processing Operations
III. Assembly applications
I. The assembly task
II. Peg in hole assembly
IV. Inspection applications
I. Sensor based inspection
II. Vision based inspection
III. Testing
Non industrial applications
I. Home sector
II. Health care
III. Service sector
IV. Agriculture and farms
V. Research and exploration
III. Assembly applications
I. The assembly task
II. Peg in hole assembly
IV. Inspection applications
I. Sensor based inspection
II. Vision based inspection
III. Testing
Non industrial applications
I. Home sector
II. Health care
III. Service sector
IV. Agriculture and farms
V. Research and exploration
I. Material Handling Applications
Robots are commonly used for shifting an object from one location to another.
This category includes the following:
1. Part Placement
2. Palletizing and/or depalletizing
3. Machine loading and/or unloading (Machine Tending)
4. Stacking and insertion operations
General considerations in robot material handling
In planning an application in which the robot will be used to transfer parts, load
machine, or other similar operations, there are several considerations that must be reviewed.
1. Part positioning and orientation
2. Gripper design
3. Minimum distances moved
4. Robot Work Volume
5. Robot weight capacity
6. Accuracy and repeatability
7. Robot Configuration, DOF, and control
8. Machine utilization problems
Robots are commonly used for shifting an object from one location to another.
This category includes the following:
1. Part Placement
2. Palletizing and/or depalletizing
3. Machine loading and/or unloading (Machine Tending)
4. Stacking and insertion operations
General considerations in robot material handling
In planning an application in which the robot will be used to transfer parts, load
machine, or other similar operations, there are several considerations that must be reviewed.
1. Part positioning and orientation
2. Gripper design
3. Minimum distances moved
4. Robot Work Volume
5. Robot weight capacity
6. Accuracy and repeatability
7. Robot Configuration, DOF, and control
8. Machine utilization problems
Material-handling(contd.)
1. Part Placement
The basic operation in this
category is the relatively simple
pick-and-place operation.
This application needs a low-
technology robot of the
cylindrical coordinate type.
Only two, three, or four
joints are required for most of
the applications.
Pneumatically powered
robots are often utilized.
1. Part Placement
The basic operation in this
category is the relatively simple
pick-and-place operation.
This application needs a low-
technology robot of the
cylindrical coordinate type.
Only two, three, or four
joints are required for most of
the applications.
Pneumatically powered
robots are often utilized.
Fig: Pick and place point
Pick point Place point
2. Palletizing and/or Depalletizing
The applications require robot to stack parts one on top of the other, that is to palletize
them, or to unstack parts by removing from the top one by one, that is depalletize them.
Example: Process of taking parts from the assembly line and stacking them on a pallet or vice
versa.
Many products are packaged in boxes of regular shape and stacked on standard
pallets for shipping. Robots are commonly used to palletize and depalletize boxes because they
can be programmed to move through the array of box positions layer after layer.
Although palletizing is more common than depalletizing, there is no major functional
difference in the manipulation requirements. Transport distances of several feet are common.
Stack heights usually do not exceed 5 ft. Payload weight can be in excess of 100 lb.
When standard servo-driven joint actuators are used accuracy and repeatability will
usually be far better than the required box positioning precision.
Palletizing typically requires four axes of controlled motion -three for translation and a
fourth for yaw to orient the box. Cylindrical coordinate robots are favored in palletizing
because they have large vertical lift and a compact footprint allowing more of the floor area in
the workspace for conveyors and pallets.
When larger workspace is needed gantry robots must be used. Continuous duty cycles
are not uncommon and robot power is important for maximizing throughput. The most
technically demanding aspect of system design is the gripper.
2. Palletizing and/or Depalletizing
The applications require robot to stack parts one on top of the other, that is to palletize
them, or to unstack parts by removing from the top one by one, that is depalletize them.
Example: Process of taking parts from the assembly line and stacking them on a pallet or vice
versa.
Many products are packaged in boxes of regular shape and stacked on standard
pallets for shipping. Robots are commonly used to palletize and depalletize boxes because they
can be programmed to move through the array of box positions layer after layer.
Although palletizing is more common than depalletizing, there is no major functional
difference in the manipulation requirements. Transport distances of several feet are common.
Stack heights usually do not exceed 5 ft. Payload weight can be in excess of 100 lb.
When standard servo-driven joint actuators are used accuracy and repeatability will
usually be far better than the required box positioning precision.
Palletizing typically requires four axes of controlled motion -three for translation and a
fourth for yaw to orient the box. Cylindrical coordinate robots are favored in palletizing
because they have large vertical lift and a compact footprint allowing more of the floor area in
the workspace for conveyors and pallets.
When larger workspace is needed gantry robots must be used. Continuous duty cycles
are not uncommon and robot power is important for maximizing throughput. The most
technically demanding aspect of system design is the gripper.
Vacuum grippers(fig) are popular for lifting boxes by their tops, but other more
complex gripping methods are sometimes needed. Payloads must be carefully positioned with
respect to the robots wrist and other links to balance gravitational and dynamic loading. Load
shifting during high acceleration moves can result in dropping or misallocating the box.
Palletizing position arrays are usually taught or programmed relative to a corner or
keystone box position as a reference so that the entire array can be shifted by redefining that one
position. Programs are simple and easily modified to adapt to changes in box dimensions.
Monitoring is done by checking the state of discrete proximity and vacuum sensors.
A proximity sensor mounted on a gripper will indicate if an object is at an expected location; or the
same simple proximity sensor may be used to stop the robot in the correct location to pick up a
box from a stack of unknown height when the top of the box is encountered.
Vacuum pressure switches are often used to verify acquisition by suction cup. A
simple proximity switch can be used to signal the presence of an expected package at the pick-up
point. With careful timing and additional sensor inputs, items can be transported to and from
moving conveyors.
Vacuum grippers(fig) are popular for lifting boxes by their tops, but other more
complex gripping methods are sometimes needed. Payloads must be carefully positioned with
respect to the robots wrist and other links to balance gravitational and dynamic loading. Load
shifting during high acceleration moves can result in dropping or misallocating the box.
Palletizing position arrays are usually taught or programmed relative to a corner or
keystone box position as a reference so that the entire array can be shifted by redefining that one
position. Programs are simple and easily modified to adapt to changes in box dimensions.
Monitoring is done by checking the state of discrete proximity and vacuum sensors.
A proximity sensor mounted on a gripper will indicate if an object is at an expected location; or the
same simple proximity sensor may be used to stop the robot in the correct location to pick up a
box from a stack of unknown height when the top of the box is encountered.
Vacuum pressure switches are often used to verify acquisition by suction cup. A
simple proximity switch can be used to signal the presence of an expected package at the pick-up
point. With careful timing and additional sensor inputs, items can be transported to and from
moving conveyors.
Fig: Palletizing/ Depalletizing of a robot
3. Machine loading and/or unloading: (Machine Tending)
These applications are material handling operations in which the robot is used to service a
production machine by transferring parts to and /or from the machine.
i.e., Robot transfers parts into and/or from a production machine.
Robots are commonly used for stock parts and load/unloading of finished parts on:
a) Die casting machine
b) Plastic Molding
c) Forging and related operations
d) Machining operations (CNC)
e) Stamping press operations
Testing machines
3. Machine loading and/or unloading: (Machine Tending)
These applications are material handling operations in which the robot is used to service a
production machine by transferring parts to and /or from the machine.
i.e., Robot transfers parts into and/or from a production machine.
Robots are commonly used for stock parts and load/unloading of finished parts on:
a) Die casting machine
b) Plastic Molding
c) Forging and related operations
d) Machining operations (CNC)
e) Stamping press operations
Testing machines
There are three possible cases:
Machine loading in which the robot loads parts into a production machine, but the
parts are unloaded by some other means.
Example: a press working operation, where the robot feeds sheet blanks into the
press, but the finished parts drop out of the press by gravity.
Machine loading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision or no
vision.
Example: Die casting, and plastic molding.
Machine loading and unloading that involves both loading and unloading of the
work parts by the robot. The robot loads a raw work part into the process and
unloads a finished part.
Example: Machine operation
.
There are three possible cases:
Machine loading in which the robot loads parts into a production machine, but the
parts are unloaded by some other means.
Example: a press working operation, where the robot feeds sheet blanks into the
press, but the finished parts drop out of the press by gravity.
Machine loading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision or no
vision.
Example: Die casting, and plastic molding.
Machine loading and unloading that involves both loading and unloading of the
work parts by the robot. The robot loads a raw work part into the process and
unloads a finished part.
Example: Machine operation
.
a) Die casting machine
It is manufacturing process in which
molten metal is forced into the cavity of mold
under high pressure.
The main die casting alloys are: zinc,
aluminium, magnesium, copper, lead, and
tin; although uncommon, ferrous die casting is
also possible.
Flash A thin web or fin of metal on
a casting which occurs at die partings(trimming
Operation).
The die-casting machines have
traditionally been tended by human operators.
The work tends to hot, repetitive, dirty, and
generally unpleasant for humans.
Unimate robot (1961).
Gripper design important.
Here robot is used to simple
load/unloading applications which is run by
programming.
a) Die casting machine
It is manufacturing process in which
molten metal is forced into the cavity of mold
under high pressure.
The main die casting alloys are: zinc,
aluminium, magnesium, copper, lead, and
tin; although uncommon, ferrous die casting is
also possible.
Flash A thin web or fin of metal on
a casting which occurs at die partings(trimming
Operation).
The die-casting machines have
traditionally been tended by human operators.
The work tends to hot, repetitive, dirty, and
generally unpleasant for humans.
Unimate robot (1961).
Gripper design important.
Here robot is used to simple
load/unloading applications which is run by
programming.
Fig: Robot at Die casting machine
Fig: Robot at plastic Molding Machine
b) Plastic Molding
It is a batch volume or high volume manufacturing
process used to make plastic parts to final shape and size.
The term plastic molding covers as number
of processes, including compression molding,
injection molding, thermoforming,
blow molding, and extrusion.
It is similar to die casting except for
the differences in materials being processed.
A thermoplastic material( small pallets/
granular form) is heated in a heating chamber to 200 to
300
O
C to transform it into semi fluid (plastic state) and
injected into the mold cavity under high pressure.
Important process parameters: temperature,
pressure, and the amount of material injected.
Here robots are used to remove (gravity/forced air
stream) the parts from the mold.
The robot design is simple than the die-casting robot.
Hooper
Fig: Robot at plastic Molding Machine
Fig: Robot at Blow Molding Machine
b) Plastic Molding
It is a batch volume or high volume manufacturing
process used to make plastic parts to final shape and size.
The term plastic molding covers as number
of processes, including compression molding,
injection molding, thermoforming,
blow molding, and extrusion.
It is similar to die casting except for
the differences in materials being processed.
A thermoplastic material( small pallets/
granular form) is heated in a heating chamber to 200 to
300
O
C to transform it into semi fluid (plastic state) and
injected into the mold cavity under high pressure.
Important process parameters: temperature,
pressure, and the amount of material injected.
Here robots are used to remove (gravity/forced air
stream) the parts from the mold.
The robot design is simple than the die-casting robot.
c) Forging related operations:
Forging is a metal working process in which metal is pressed or
hammered into the desired shape.
One of the oldest process.
It is most commonly used performed as a hot working process
in which the metal is heated to a high temperature prior to forging.
These operation includes
Die forging and
Upset forging. (High Volume production process, EX:)
Forging, especially hot forging operations, is one of the worst
industrial jobs for humans. The environment is noisy and hot, with
temperatures at the workplaces well above 100
O
F for hot forging.
The air in the forge shop is generally filled with dirt,
furnace fumes and lubricant mist & its repetitive.
The parts occasionally stick in the dies.
The gripper design :1. Resistance higher temperatures
2. Resist to impact loads
3. Accomodate substantial changes in shape
of the parts during the during successive hit in the forging cycle.
Video:
Gripper design is similar to die casting robot.
c) Forging related operations:
Forging is a metal working process in which metal is pressed or
hammered into the desired shape.
One of the oldest process.
It is most commonly used performed as a hot working process
in which the metal is heated to a high temperature prior to forging.
These operation includes
Die forging and
Upset forging. (High Volume production process, EX:)
Forging, especially hot forging operations, is one of the worst
industrial jobs for humans. The environment is noisy and hot, with
temperatures at the workplaces well above 100
O
F for hot forging.
The air in the forge shop is generally filled with dirt,
furnace fumes and lubricant mist & its repetitive.
The parts occasionally stick in the dies.
The gripper design :1. Resistance higher temperatures
2. Resist to impact loads
3. Accomodate substantial changes in shape
of the parts during the during successive hit in the forging cycle.
Video:
Gripper design is similar to die casting robot.
Fig: Robot at Forging Machines
Fig: Powerful tongs lift an ingot from the soaking pit where
it was thoroughly heated to the rolling temperature
Fig: Steel bloom enters the rolling mill
STAGE :1
STAGE :2
Robot
Gripper
Example: Robots used in Extrusion process
Fig: Powerful tongs lift an ingot from the soaking pit where
it was thoroughly heated to the rolling temperature
Fig: Structural shapes are rolled from blooms
on mills equipped with grooved rolls
Fig: Hot saw cuts rolled shapes to customer length
after delivery from the finishing rolling mill
STAGE :3
STAGE:4
Robot Tool (Grinding)
d) Machining Operation
Machining is a metal working process in which the shape of the part is changed by
removing excess material with a cutting tool.
Ex: Drilling , milling, shaping , planning and grinding.
Robots have been successfully utilized to perform the loading and unloading
functions in machining operations.
The robots is typically used to load a raw work part into the machine tool to unload
the finished part at the completion of the machining cycle.
The following robot features generally contribute to the success of the machine tool
load/unload applications.
1. Dual Gripper
2. Up to six joint motion
3. Good repeatability
4. Palletizing and depalletizing capability
5. Programming Features
d) Machining Operation
Machining is a metal working process in which the shape of the part is changed by
removing excess material with a cutting tool.
Ex: Drilling , milling, shaping , planning and grinding.
Robots have been successfully utilized to perform the loading and unloading
functions in machining operations.
The robots is typically used to load a raw work part into the machine tool to unload
the finished part at the completion of the machining cycle.
The following robot features generally contribute to the success of the machine tool
load/unload applications.
1. Dual Gripper
2. Up to six joint motion
3. Good repeatability
4. Palletizing and depalletizing capability
5. Programming Features
Robot
CNC Machine
Control System
Operator
Robot Work Cell
Fig: ABB IRB 6640 Machine Loading/Unloading Cell
Conveyor
system (Input /
Output)
e) Stamping Press operation
Stamping press operations are used to cut and form sheet metal parts. The process
is performed by means of die set held in machine too called stamping press(Fig).
The sheet metal stock used as the raw material in the process comes in several forms,
including coils, sheets and individual flat blank.
This application is often a dangerous one for human beings and so is ideally suited
for a robots.
Robots are being used for handling parts in press working operations, largely as a result
of the safety issue. The typical task performed by the robot is to load at the flat blanks into the
press for the stamping operation. There are variations in the way this can be done.
In forming operations, the robot can be used to hold the blank during the cycle so
that the formed part is readily removed from the press.
In the case of the many cutting operations, the robot loads the blank into the press, and
the parts fall though the die during the press cycle.
Another robot application in press working involves the transfer of parts of parts
from one press to another to form an integrated press working cell.
e) Stamping Press operation
Stamping press operations are used to cut and form sheet metal parts. The process
is performed by means of die set held in machine too called stamping press(Fig).
The sheet metal stock used as the raw material in the process comes in several forms,
including coils, sheets and individual flat blank.
This application is often a dangerous one for human beings and so is ideally suited
for a robots.
Robots are being used for handling parts in press working operations, largely as a result
of the safety issue. The typical task performed by the robot is to load at the flat blanks into the
press for the stamping operation. There are variations in the way this can be done.
In forming operations, the robot can be used to hold the blank during the cycle so
that the formed part is readily removed from the press.
In the case of the many cutting operations, the robot loads the blank into the press, and
the parts fall though the die during the press cycle.
Another robot application in press working involves the transfer of parts of parts
from one press to another to form an integrated press working cell.
Sheet
Robot End effector
Fig: Robot perform the machine loading/unloading task at a stamping press.
4. Stacking and insertion operation:
In the stacking process the robot places flat parts on top of each other, where the vertical
location of the drop-off position is continuously changing with cycle time.
In the insertion process robot inserts parts into the compartments of a divided carton.
stacking
Insertion
Fig: A robots in Stacking and Insertion operation:
Processing Operations
Robot performs a processing procedure on the part.
The robot is equipped with some type of process tooling as its end effector.
Manipulates the tooling relative to the working part during the cycle.
Industrial robot applications in the processing operations include:
1.Spot welding
2.Continues Arc Welding
3.Spray painting
4.Other Processing Operations (Metal cutting and deburring operations, drilling,
grinding, laser and water jet cutting, and riveting ,Rotating and spindle operations,
Adhesives and sealant dispensing).
The hazards of arc welding include: intense ultraviolet, visual band and radio
frequency radiation, toxic fumes, and noise. And Spray coating usually means spray painting, an
operation that is accomplished by an unhealthy work environment for humans and therefore
represents a good opportunity for robots.
II. Processing Operations
Processing Operations
Robot performs a processing procedure on the part.
The robot is equipped with some type of process tooling as its end effector.
Manipulates the tooling relative to the working part during the cycle.
Industrial robot applications in the processing operations include:
1.Spot welding
2.Continues Arc Welding
3.Spray painting
4.Other Processing Operations (Metal cutting and deburring operations, drilling,
grinding, laser and water jet cutting, and riveting ,Rotating and spindle operations,
Adhesives and sealant dispensing).
The hazards of arc welding include: intense ultraviolet, visual band and radio
frequency radiation, toxic fumes, and noise. And Spray coating usually means spray painting, an
operation that is accomplished by an unhealthy work environment for humans and therefore
represents a good opportunity for robots.
Weld Defects/Imperfections
A welding defect is any flaw that compromises the usefulness of the finished weldment.
According to the ASME welding defect causes are broken down into the following
percentages:
45% poor process conditions,
32% operator error, Why Robots ?
12% wrong technique,
10% incorrect consumables and
5% bad weld grooves.
Weld Defects/Imperfections
A welding defect is any flaw that compromises the usefulness of the finished weldment.
According to the ASME welding defect causes are broken down into the following
percentages:
45% poor process conditions,
32% operator error, Why Robots ?
12% wrong technique,
10% incorrect consumables and
5% bad weld grooves.
Advantages of robotic welding Productivity
Productivity
Quality
Consumable costs
Labor
Safety
Flexibility
Floor space
Porosity
Arc Blow
Inclusions( Slag, Tungsten)
Incomplete Fusion
Undercut
Underfill
Overlap
Concavity
Convexity
Weld reinforcement
Spatters
Cracks
Weld Defects
Porosity
Arc Blow
Inclusions( Slag, Tungsten)
Incomplete Fusion
Undercut
Underfill
Overlap
Concavity
Convexity
Weld reinforcement
Spatters
Cracks
1.Spot welding
Process:
Applications:
Advantages:
Limitations:
Robots in spot welding process:
A welding gun is attached as the end effector to each robots wrist, and the robot is
programmed to perform a sequence of welds on the product as it arrives at the workstation.
Some robot spot welding lines operate with several dozen robots all programmed to
perform different welding cycles on the product.
Problem of Manual Spot welding
Fig: Spot welding in automobile industry
1.Spot welding
Process:
Applications:
Advantages:
Limitations:
Robots in spot welding process:
A welding gun is attached as the end effector to each robots wrist, and the robot is
programmed to perform a sequence of welds on the product as it arrives at the workstation.
Some robot spot welding lines operate with several dozen robots all programmed to
perform different welding cycles on the product.
Problem of Manual Spot welding
The robots used in spot welding must possess certain capabilities and features to perform the
process.
The robot must be relatively large. It must have sufficient payload capacity to readily
manipulate the welding gun for the application. The work volume must be adequate for the size
of the product.
The robot must be able to position and orient the welding gun in places on the
product that might be difficult to access. This might be result in the need for an increased
number of DOF.
The controller memory must have enough memory must have enough capacity to
accomplish the many positioning steps required fit eh spot welding cycle.
The benefits that result from automation (Robot) of the spot welding process by
means of robots are improved product quality, operator safety, better control over the production
operation.
Improved quality in the form of more consistent welds and better
repeatability in the location of the welds.
Improved safety results simply because the human is removed from a work
environment where there are hazards from electrical shocks and burns.
The robots used in spot welding must possess certain capabilities and features to perform the
process.
The robot must be relatively large. It must have sufficient payload capacity to readily
manipulate the welding gun for the application. The work volume must be adequate for the size
of the product.
The robot must be able to position and orient the welding gun in places on the
product that might be difficult to access. This might be result in the need for an increased
number of DOF.
The controller memory must have enough memory must have enough capacity to
accomplish the many positioning steps required fit eh spot welding cycle.
The benefits that result from automation (Robot) of the spot welding process by
means of robots are improved product quality, operator safety, better control over the production
operation.
Improved quality in the form of more consistent welds and better
repeatability in the location of the welds.
Improved safety results simply because the human is removed from a work
environment where there are hazards from electrical shocks and burns.
2. Continuous arc welding:
Arc welding is continues welding process as opposed to spot welding which might be
called discontinuous process.
Continuous arc welding is used to make long welded joints in which an airtight seal is
often required between the two pieces of metal which are being joined.
Introduction of welding
Different process
Problems for Robots in Arc Welding
Because of the hazards for human worker in continuous arc welding , it is logical to
consider industrial robots for the process. However, there are significant technical and
economical problems encountered in applying robots to arc welding.
Continuous arc welding is commonly used for in the fabrication industries.
Ex: Tanks, Pressure vessel and ship hulls. Human can position them selves into these areas more
than robots. (Why ?)
Technical problems:
1.The variation in the dimensions of the parts in a batch production job.
2.The variations in the edges and surfaces to be welded together. Instead of being straight and
regular, the edges are typically irregular.
Human welders are able to compensate for both of these variations by changing
certain parameters in the welding process. Industrial robots do not posses the sensing
capabilities, skills and judgment of human welders to make the components.
There are two approaches to compensate for these variations and irregularities in
robot welding applications:
1. Correct the stream production operations so that the variations are reduced the point
where they do not create a problem in the robot welding process.
2. Provide the robot with sensors to monitor the variations in the welding process and the
control logic to compensate for part variations and weld gap irregularities.
Problems for Robots in Arc Welding
Because of the hazards for human worker in continuous arc welding , it is logical to
consider industrial robots for the process. However, there are significant technical and
economical problems encountered in applying robots to arc welding.
Continuous arc welding is commonly used for in the fabrication industries.
Ex: Tanks, Pressure vessel and ship hulls. Human can position them selves into these areas more
than robots. (Why ?)
Technical problems:
1.The variation in the dimensions of the parts in a batch production job.
2.The variations in the edges and surfaces to be welded together. Instead of being straight and
regular, the edges are typically irregular.
Human welders are able to compensate for both of these variations by changing
certain parameters in the welding process. Industrial robots do not posses the sensing
capabilities, skills and judgment of human welders to make the components.
There are two approaches to compensate for these variations and irregularities in
robot welding applications:
1. Correct the stream production operations so that the variations are reduced the point
where they do not create a problem in the robot welding process.
2. Provide the robot with sensors to monitor the variations in the welding process and the
control logic to compensate for part variations and weld gap irregularities.
Fig: Technical problems in fabrication industries :
The Typical Robot Arc Welding Application:
Fig: Robot Arc Welding Cell
Features of the welding robot:
An robot that performs arc welding must possess certain features and
capabilities. Some of the technical considerations in arc welding applications are :
1. Work Volume and DOF
2. Motion Control system
3. Precision of motion
4. Interface with other systems
5. Programming
Sensors in Robotic Arc Welding:
The Robotic arc welding sensor systems considered here all designed to track the
welding joint and provide information to the robot controller to help guide the welding path.
The approaches used for this purpose divided into two basic categories :
1.Contact Arc Welding Sensors
2. Non- Contact Arc Welding Sensors
Arc Sensing systems
Vision-based systems
Fig: Joint tracking principle Fig: Sensor usage in SAW process
Advantages and Benefits of Robot arc welding
A Robot arc welding cell for batch production has the potential for achieving a
number of advantages over a similar manual operations. These advantages includes the
following:
1.Higher productivity
2.Improved safety and quality of Work Life
3.Greater QUALITY of product
4.Process rationalization
Robot Do not experience fatigue in the sense that human worker so.
A robot can continuous to operate during the entire shift without the need for
periodic rest breaks.
Improved safety and quality of work environment. Results from removing the
human operator from an uncomfortable . Fatigue and potentially dangerous work situations.
Greater product quality with greater accuracy and repeatability in robot arc welding
than manual arc welding.
Advantages and Benefits of Robot arc welding
A Robot arc welding cell for batch production has the potential for achieving a
number of advantages over a similar manual operations. These advantages includes the
following:
1.Higher productivity
2.Improved safety and quality of Work Life
3.Greater QUALITY of product
4.Process rationalization
Robot Do not experience fatigue in the sense that human worker so.
A robot can continuous to operate during the entire shift without the need for
periodic rest breaks.
Improved safety and quality of work environment. Results from removing the
human operator from an uncomfortable . Fatigue and potentially dangerous work situations.
Greater product quality with greater accuracy and repeatability in robot arc welding
than manual arc welding.
Ex: Fanuc Robot (one case study Example)
Adaptive Pass Specific Welding Control:
Weld schedules Volts, Amps, WFS, Trim, Wave Control,
Travel Speed and Delay Time
Weave schedules Frequency, Amplitude, Right Dwell, Left Dwell and Angle
Multi-pass offsets X mm, Y mm, Z mm, Work Angle and Travel Angle
Run-in schedules Volts, Amps, WFS, Trim, Wave Control and Delay Time
Burn-back schedules Volts, Amps, WFS, Trim, Wave Control and Delay Time
Crater fill schedules Volts, Amps, WFS, Trim, Wave Control and Delay Time
Fig: Simulation of a welding Robot with Positioner
Work Fixture
Basic Flow Diagram of Adaptive Process
Fig: FANUC ARC Mate series robot integrated to
a Servo Robot MSPOT-90 laser joint scanner.
Sensor: Scans
the Weld Joint
Sensor Measures:
Gap, Area, Mismatch
User Defined Variables
Is the joint
within user
specified limits
Flag User Error:
Joint outside of
defined limits
No
Fig: FANUC ARC Mate series robot integrated to
a Servo Robot MSPOT-90 laser joint scanner.
Is the joint
within user
specified limits
Flag User Error:
Joint outside of
defined limits
Yes
Algorithm Calculates Changes:
Volts, Trim Wire Feed Speed
Travel Speed Weave Amplitude,
Frequency, Dwell TCP position
On-The-Fly Utility:
Adjusts the weld path and
process variables on the fly
Fig: Typical Weld Joints and Process Application
Automotive industries
BIW
Paint shop
Chassis assembly section
Spray coating :
Most products manufactured from metallic materials require some form of painted
finish before delivery to the customer. The technology for applying these finishes varies in
complexity from simple manual methods to highly sophisticated automatic techniques.
The common industrial coating techniques are divided into two categories:
1. Immersion and flow coating method .
Electro deposition
2. Spray coating method
Spray coating :
Most products manufactured from metallic materials require some form of painted
finish before delivery to the customer. The technology for applying these finishes varies in
complexity from simple manual methods to highly sophisticated automatic techniques.
The common industrial coating techniques are divided into two categories:
1. Immersion and flow coating method .
Electro deposition
2. Spray coating method
The spray coating methods, when accomplished manually, result in many
health hazards to the human operators. The hazards includes:
1. Fumes and mist in the air
2. Noise from the nozzle
3. Fire hazards
4. Potential cancer hazards
2. Robots in spray coating
The spray coating methods, when accomplished manually, result in many
health hazards to the human operators. The hazards includes:
1. Fumes and mist in the air
2. Noise from the nozzle
3. Fire hazards
4. Potential cancer hazards
2. Robots in spray coating
Fig: Spray coating Robot used in
painting of wind turbine.
General, the requirement of the robot for spray coating applications are the following:
1. Continuous path
2. Hydraulic drive.
3. Manual lead through program
4. Multiple program storage
Benefits of robot spray coating :
1. Removal of operators from hazardous environment
2. Lower energy consumption
3. Consistency of finish
4. Reduced coating material usage
5. Greater Productivity
General, the requirement of the robot for spray coating applications are the following:
1. Continuous path
2. Hydraulic drive.
3. Manual lead through program
4. Multiple program storage
Benefits of robot spray coating :
1. Removal of operators from hazardous environment
2. Lower energy consumption
3. Consistency of finish
4. Reduced coating material usage
5. Greater Productivity
Other Processing operations using Robots:
Fig: Robotic Rivet Insertion
Riveting gun
Fig: Robot for Plasma, laser and WJM
Fig: Robotic Rivet Insertion
Fig: Robot for Plasma, laser and WJM
Fig: Robots with Grinding Fig: Robots with polishing
Fig: WJMRobot
Fig: Milling Robot
Fig: Wire brushing Robot
Fig: Milling Robot
Fig: Drilling Robot
Assembly Operations:
The applications involve both material-handling and the manipulation of a
tool.
They typically include components to build the product and to perform
material handling operations.
Are traditionally labor-intensive activities in industry and are highly
repetitive and boring. Hence are logical candidates for robotic applications.
These are classified as:
Batch assembly: As many as one million products might be assembled.
The assembly operation has long production runs.
Low-volume: In this a sample run of ten thousand or less products
might be made.
The assembly robot cell should be a modular cell.
One of the well suited area for robotics assembly is the insertion of odd
electronic components.
Figure illustrates a typical overall electronic assembly operation.
Assembly Operations
Assembly Operations:
The applications involve both material-handling and the manipulation of a
tool.
They typically include components to build the product and to perform
material handling operations.
Are traditionally labor-intensive activities in industry and are highly
repetitive and boring. Hence are logical candidates for robotic applications.
These are classified as:
Batch assembly: As many as one million products might be assembled.
The assembly operation has long production runs.
Low-volume: In this a sample run of ten thousand or less products
might be made.
The assembly robot cell should be a modular cell.
One of the well suited area for robotics assembly is the insertion of odd
electronic components.
Figure illustrates a typical overall electronic assembly operation.
Fig: Robots in Engine
assembly Operations
Remote Center Compliance (RCC):
RCC is a mechanical device that facilitates automated assembly by preventing
peg-like objects from jamming when they are inserted into a hole with tight clearance.
In a naive design without an RCC, a robot might pick up a peg with its gripper, center
the peg over the hole and then push the peg along the axis of the hole.
If the peg is perfectly aligned and centered, it would then slide into the hole. However
if the peg's alignment or centering is slightly off, the peg contacts one side of the hole first and
the peg's tip experiences a lateral force.
As the robot's gripper is not perfectly stiff, the peg will tend to rotate about an axis in
the plane of the gripper's fingers, called the center of compliance. Such a rotation further
misaligns the peg, increasing the lateral force and causing more rotation, resulting in a jam that
prevents the insertion from being completed.
An RCC changes the way the peg responds to a lateral force at its tip. The RCC is
typically placed between the robot's wrist and the gripper, though it can be built in to the gripper
itself.
The RCC lets the gripper assembly move in the plane perpendicular to the peg's axis,
allowing the peg to rotate about an axis in the plane of the top of the hole, effectively moving the
center of compliance from the gripper to the hole.
With the RCC, the forces generated by any misalignment move the peg in a way that
corrects the problem, rather than exacerbate it.
RCC is a mechanical device that facilitates automated assembly by preventing
peg-like objects from jamming when they are inserted into a hole with tight clearance.
In a naive design without an RCC, a robot might pick up a peg with its gripper, center
the peg over the hole and then push the peg along the axis of the hole.
If the peg is perfectly aligned and centered, it would then slide into the hole. However
if the peg's alignment or centering is slightly off, the peg contacts one side of the hole first and
the peg's tip experiences a lateral force.
As the robot's gripper is not perfectly stiff, the peg will tend to rotate about an axis in
the plane of the gripper's fingers, called the center of compliance. Such a rotation further
misaligns the peg, increasing the lateral force and causing more rotation, resulting in a jam that
prevents the insertion from being completed.
An RCC changes the way the peg responds to a lateral force at its tip. The RCC is
typically placed between the robot's wrist and the gripper, though it can be built in to the gripper
itself.
The RCC lets the gripper assembly move in the plane perpendicular to the peg's axis,
allowing the peg to rotate about an axis in the plane of the top of the hole, effectively moving the
center of compliance from the gripper to the hole.
With the RCC, the forces generated by any misalignment move the peg in a way that
corrects the problem, rather than exacerbate it.
Peg=Dowel, Hook, Bolt, Nail
Peg
Hole
RCC
Robot wrist
Attachment ring
RCC
Gripper mechanism
Gripper fingers
Fig: Remote Center Compliance in operation Fig: Schematic of an RCC equipped robot
Inspection Operation:
Some inspection operation require parts to be manipulated, and other
applications require that an inspection tool be manipulated.
Inspection work requires high precision and patience, and human judgment
is often needed to determine whether a product is within quality
specifications or not.
Inspection tasks that are performed by industrial robots can usually be
divided into the following three techniques:
By using a feeler gauge or a linear displacement transducer known as a
linear variable differential transformer(LVDT), the part being measured
will come in physical contact with the instrument or by means of air
pressure, which will cause it to ride above the surface being measured.
By utilizing robotic vision, matrix video cameras are used to obtain an
image of the area of interest, which is digitized and compared to a
similar image with specified tolerance.
By involving the use of optics and light, usually a laser or infrared source
is used to illustrate the area of interest.
Inspection Operations
Inspection Operation:
Some inspection operation require parts to be manipulated, and other
applications require that an inspection tool be manipulated.
Inspection work requires high precision and patience, and human judgment
is often needed to determine whether a product is within quality
specifications or not.
Inspection tasks that are performed by industrial robots can usually be
divided into the following three techniques:
By using a feeler gauge or a linear displacement transducer known as a
linear variable differential transformer(LVDT), the part being measured
will come in physical contact with the instrument or by means of air
pressure, which will cause it to ride above the surface being measured.
By utilizing robotic vision, matrix video cameras are used to obtain an
image of the area of interest, which is digitized and compared to a
similar image with specified tolerance.
By involving the use of optics and light, usually a laser or infrared source
is used to illustrate the area of interest.
Fig: Robots in Inspection areas
MOBILE ROBOTS
Introductions:
A mobile robot is an automatic machine that is capable of movement in any given
environment.
Mobile robots have the capability to move around in their environment and are not fixed
to one physical location. In contrast, industrial robots usually consist of a jointed arm (multi-linked
manipulator) and gripper assembly (or end effector) that is attached to a fixed surface.
Mobile robots are a major focus of current research and almost every major university has
one or more labs that focus on mobile robot research. Mobile robots are also found in industry,
military and security environments. Domestic robots are consumer products, including entertainment
robots and those that perform certain household tasks such as vacuuming or gardening.
Classification
Mobile robots may be classified by:
The environment in which they travel:
Land or home robots are usually referred to as Unmanned Ground Vehicles (UGVs).
They are most commonly wheeled or tracked, but also include legged robots with two or
more legs (humanoid, or resembling animals or insects).
Aerial robots are usually referred to as Unmanned Aerial Vehicles (UAVs)
Underwater robots are usually called autonomous underwater vehicles (AUVs)
Polar robots, designed to navigate icy, crevasse filled environments
The device they use to move, mainly:
Legged robot : human-like legs (i.e. an android) or animal-like legs.
Wheeled robot.
Tracks.
Introductions:
A mobile robot is an automatic machine that is capable of movement in any given
environment.
Mobile robots have the capability to move around in their environment and are not fixed
to one physical location. In contrast, industrial robots usually consist of a jointed arm (multi-linked
manipulator) and gripper assembly (or end effector) that is attached to a fixed surface.
Mobile robots are a major focus of current research and almost every major university has
one or more labs that focus on mobile robot research. Mobile robots are also found in industry,
military and security environments. Domestic robots are consumer products, including entertainment
robots and those that perform certain household tasks such as vacuuming or gardening.
Classification
Mobile robots may be classified by:
The environment in which they travel:
Land or home robots are usually referred to as Unmanned Ground Vehicles (UGVs).
They are most commonly wheeled or tracked, but also include legged robots with two or
more legs (humanoid, or resembling animals or insects).
Aerial robots are usually referred to as Unmanned Aerial Vehicles (UAVs)
Underwater robots are usually called autonomous underwater vehicles (AUVs)
Polar robots, designed to navigate icy, crevasse filled environments
The device they use to move, mainly:
Legged robot : human-like legs (i.e. an android) or animal-like legs.
Wheeled robot.
Tracks.
APPLICATIONS
The robots have potential application in areas where a vehicle or a mechanic
automatic system may exist
Areas of application:
Support to medical services SERVICE ROBOTS
Transportation of food, medication, medical exams,
Automation of pharmacy service
Automatic cleaning of (large) areas
Supermarkets, airports, industrial sites
Glass cleaning
Domestic vacuum-cleaner
Client support
Museum tours, exhibitions guides
Agricultural
Fruit and vegetable picking, fertilization, planting
Forests
Cleaning, fire preventing, tree cutting
APPLICATIONS
The robots have potential application in areas where a vehicle or a mechanic
automatic system may exist
Areas of application:
Support to medical services SERVICE ROBOTS
Transportation of food, medication, medical exams,
Automation of pharmacy service
Automatic cleaning of (large) areas
Supermarkets, airports, industrial sites
Glass cleaning
Domestic vacuum-cleaner
Client support
Museum tours, exhibitions guides
Agricultural
Fruit and vegetable picking, fertilization, planting
Forests
Cleaning, fire preventing, tree cutting
Hazard Environments
Inspection of hazard environments (catastrophic areas, volcano's,
nuclear power plants, oil tanks)
Inspection of gas or oil pipes, and power transmission lines
Oil tank cleaning
Construction and demolishing
Space
Space exploration
Remote inspection of space stations
Military
Surveillance vehicles
Monitoring vehicles
Material Handling
AGVs Automated guided vehicle
SGVs Self-Guided Vehicle
LGVs Laser Guided Vehicles
Safety
Surveillance of large areas, buildings, airports, car parking lot
Hazard Environments
Inspection of hazard environments (catastrophic areas, volcano's,
nuclear power plants, oil tanks)
Inspection of gas or oil pipes, and power transmission lines
Oil tank cleaning
Construction and demolishing
Space
Space exploration
Remote inspection of space stations
Military
Surveillance vehicles
Monitoring vehicles
Material Handling
AGVs Automated guided vehicle
SGVs Self-Guided Vehicle
LGVs Laser Guided Vehicles
Safety
Surveillance of large areas, buildings, airports, car parking lot
Civil Transportation
Inspection of airplanes, trains,
Elderly and Handicapped
Assistance to handicapped or elderly people, helping in transportation, health care,
Entertainment
Robot Dog
Aibo Robot dog from Sony
Telepresence
Civil Transportation
Inspection of airplanes, trains,
Elderly and Handicapped
Assistance to handicapped or elderly people, helping in transportation, health care,
Entertainment
Robot Dog
Aibo Robot dog from Sony
Telepresence
Planetary Robotics P
Fig: NASA JPL Rovers
Robotic Antarctic Meteorite Search (RAMS)
Autonomous Helicopter Project
Components of a Mobile Robot
Example:
MICRO ROBOTS
In the field of robotics, a microrobot is defined as a miniaturized robotic system,
making use of micro- and, possibly, nanotechnologies. Generally speaking, many terms such as
micro-mechanisms, micro-machines and micro-robots are used to indicate a wide range of
devices whose function is related to the concept of operating at a small scale.
The prefix micro in (almost) its strict sense, in order to address components,
modules and systems with sizes in the order of micrometers up to few millimeters. Therefore,
with the term microrobot it will be considered a robot with a size up to few millimeters, where
typical integrated components and modules have features in the order of micrometers and have
been entirely produced through micro mechanical and microelectronic mass-fabrication and
mass-assembly processes. Hence, the entire robot is completely integrated in a stack of
assembled chips.
Due to its size, the capabilities of the single unit are limited and, consequently, micro-
robots need to work in very large groups, or swarms, to significantly sense or affect the
environment. Main inspiration for the swarm concept is bio-mimetic: nature offers plenty of
examples of swarms (e.g., insects) capable of efficiently accomplish tasks, as surface exploration
looking for food, for example.
MICRO ROBOTS
In the field of robotics, a microrobot is defined as a miniaturized robotic system,
making use of micro- and, possibly, nanotechnologies. Generally speaking, many terms such as
micro-mechanisms, micro-machines and micro-robots are used to indicate a wide range of
devices whose function is related to the concept of operating at a small scale.
The prefix micro in (almost) its strict sense, in order to address components,
modules and systems with sizes in the order of micrometers up to few millimeters. Therefore,
with the term microrobot it will be considered a robot with a size up to few millimeters, where
typical integrated components and modules have features in the order of micrometers and have
been entirely produced through micro mechanical and microelectronic mass-fabrication and
mass-assembly processes. Hence, the entire robot is completely integrated in a stack of
assembled chips.
Due to its size, the capabilities of the single unit are limited and, consequently, micro-
robots need to work in very large groups, or swarms, to significantly sense or affect the
environment. Main inspiration for the swarm concept is bio-mimetic: nature offers plenty of
examples of swarms (e.g., insects) capable of efficiently accomplish tasks, as surface exploration
looking for food, for example.
Miniaturization allows a reduction of the required resources and, potentially, even
better performances. Micro- and nanotechnologies have demonstrated the capability to
fabricate and assembly different types of micro and nano-devices in micro-systems, creating
advanced micro-instruments for specific applications.
The concept of miniaturization and integration of devices and systems brings
mainly to the following advantages:
- Required resources (mass, volume, power, etc.) are dramatically reduced.
- Integrated Micro-Electro-Mechanical-Systems (MEMS) and Nano-Electro-Mechanical-
Systems (NEMS) can substitute many discrete components and devices.
- The system is produced with batch processes, and so with mass fabrication; this implies
costs reduction and possible redundancy of critical parts in order to achieve higher reliability
during operation.
- Performances for cost and mass unit are higher, that means it is possible to decrease the cost
of the whole system, or at given overall costs, increasing performances.
- Small facilities are requested to test the system.
Miniaturization allows a reduction of the required resources and, potentially, even
better performances. Micro- and nanotechnologies have demonstrated the capability to
fabricate and assembly different types of micro and nano-devices in micro-systems, creating
advanced micro-instruments for specific applications.
The concept of miniaturization and integration of devices and systems brings
mainly to the following advantages:
- Required resources (mass, volume, power, etc.) are dramatically reduced.
- Integrated Micro-Electro-Mechanical-Systems (MEMS) and Nano-Electro-Mechanical-
Systems (NEMS) can substitute many discrete components and devices.
- The system is produced with batch processes, and so with mass fabrication; this implies
costs reduction and possible redundancy of critical parts in order to achieve higher reliability
during operation.
- Performances for cost and mass unit are higher, that means it is possible to decrease the cost
of the whole system, or at given overall costs, increasing performances.
- Small facilities are requested to test the system.
APPLICATIONS
Bio-Medical
-flow along human arteries to find out bad bacteria
-scatter antibodies in human bodies to promote immunity
-sometimes sent to explore dangerous caves or tiny long tubes.
Space applications
In space terminology, however, the term micro (and nano)
rover, probe or satellite currently addresses a category of
relatively small systems, with a size ranging from a few to several tens of
centimeters, not necessarily including micro-
and nanotechnologies (except for microelectronics).
Military
Security and safety technology
APPLICATIONS
Bio-Medical
-flow along human arteries to find out bad bacteria
-scatter antibodies in human bodies to promote immunity
-sometimes sent to explore dangerous caves or tiny long tubes.
Space applications
In space terminology, however, the term micro (and nano)
rover, probe or satellite currently addresses a category of
relatively small systems, with a size ranging from a few to several tens of
centimeters, not necessarily including micro-
and nanotechnologies (except for microelectronics).
Military
Security and safety technology
APPLICATIONS
RECENT DEVELOPMENTS IN ROBOTICS
Recent developments in robotics-
New Techniques
walking robots
co-operating arms or AGVs
biomedical engineering
teleoperation
Internet robotics
micro and nanorobotics
New Applications
Teleported robotics (space, surgery)
service robots (teaching, retail, fast food outlets, bank
tellers, garbage collection, security guards, cleaning
vehicles etc etc)
UGVs and UAVs for hazardous environments
New Techniques
walking robots
co-operating arms or AGVs
biomedical engineering
teleoperation
Internet robotics
micro and nanorobotics
New Applications
Teleported robotics (space, surgery)
service robots (teaching, retail, fast food outlets, bank
tellers, garbage collection, security guards, cleaning
vehicles etc etc)
UGVs and UAVs for hazardous environments
Robug III
Robug III is the latest concept design at the University of Portsmouth; it is the
next generation Robug. It will be slightly smaller than Robug IIs but will still be quite large
for a climbing robot. It will have eight four-jointed legs and be capable of climbing
vertical surfaces. It will also be teleoperated, but will include more on-board sensing
features and better surface adhesion than Robug IIs. Interest in the Robug project continues
only because of the work done in wall climbing and surface adhesion .
Remember high viscosity at Small scales makes a
corkscrew Motion of propulsion far more
Effective.
Swimming robotics bugs
Bugs that walk on water
The Defense Advanced Research Projects Agency (DARPA) is an agency of the United
States Department of Defense responsible for the development of new technologies for use by
the military. DARPA has been responsible for funding the development of many technologies
which have had a major effect on the world, including computer networking, as well as NLS,
which was both the first hypertext system, and an important precursor to the contemporary
ubiquitous graphical user interface.
The Cheetah robot is the fastest legged robot in the World, surpassing 29 mph, a new land speed
record for legged robots. The previous record was 13.1 mph, set in 1989 at MIT.
The Cheetah robot has an articulated back that flexes back and forth on each step, increasing its
stride and running speed, much like the animal does. The current version of the Cheetah robot
runs on a high-speed treadmill in the laboratory where it is powered by an off-board hydraulic
pump and uses a boom-like device to keep it running in the center of the treadmill. The next
generation Cheetah robot, WildCat, is designed to operate untethered. WildCat recently entered
initial testing and is scheduled for outdoor field testing later in 2013.
Cheetah robot development is funded by DARPA's Maximum Mobility and Manipulation
program.
CHEETAH - Fastest Legged Robot
The Cheetah robot is the fastest legged robot in the World, surpassing 29 mph, a new land speed
record for legged robots. The previous record was 13.1 mph, set in 1989 at MIT.
The Cheetah robot has an articulated back that flexes back and forth on each step, increasing its
stride and running speed, much like the animal does. The current version of the Cheetah robot
runs on a high-speed treadmill in the laboratory where it is powered by an off-board hydraulic
pump and uses a boom-like device to keep it running in the center of the treadmill. The next
generation Cheetah robot, WildCat, is designed to operate untethered. WildCat recently entered
initial testing and is scheduled for outdoor field testing later in 2013.
Cheetah robot development is funded by DARPA's Maximum Mobility and Manipulation
program.
BigDog - The Most Advanced Rough-Terrain Robot on Earth
BigDog is a rough-terrain robot that walks, runs, climbs
and carries heavy loads.
BigDog is powered by an engine that drives a hydraulic
actuation system.
BigDog has four legs that are articulated like an
animals, with compliant elements to absorb shock and
recycle energy from one step to the next.
BigDog is the size of a large dog or small mule; about 3
feet long, 2.5 feet tall and weighs 240 lbs.
BigDog is a rough-terrain robot that walks, runs, climbs
and carries heavy loads.
BigDog is powered by an engine that drives a hydraulic
actuation system.
BigDog has four legs that are articulated like an
animals, with compliant elements to absorb shock and
recycle energy from one step to the next.
BigDog is the size of a large dog or small mule; about 3
feet long, 2.5 feet tall and weighs 240 lbs.
RiSE: The Amazing Climbing Robot
RiSE is a robot that climbs vertical terrain such as walls, trees and fences.
RiSE uses feet with micro-claws to climb on textured surfaces.
RiSE changes posture to conform to the curvature of the climbing surface and its
tail helps RiSE balance on steep ascents. RiSE is 0.25 m long, weighs 2 kg, and travels
0.3 m/s.
SandFlea
Leaps Small Buildings in a Single Bound
Sand Flea is an 11 pound robot that drives
like an RC car on flat terrain, but can jump
30 ft into the air to overcome obstacles. That
is high enough to jump over a compound
wall, onto the roof of a house, up a set of
stairs or into a second story window.
The robot uses gyro stabilization to stay level
during flight, to provide a clear view from
the onboard camera, and to ensure a smooth
landing. Sand Flea can jump about 25 times
on one charge. Boston Dynamics is
developing Sand Flea with funding from the
US Armys Rapid Equipping Force (REF).
SandFlea
Leaps Small Buildings in a Single Bound
Sand Flea is an 11 pound robot that drives
like an RC car on flat terrain, but can jump
30 ft into the air to overcome obstacles. That
is high enough to jump over a compound
wall, onto the roof of a house, up a set of
stairs or into a second story window.
The robot uses gyro stabilization to stay level
during flight, to provide a clear view from
the onboard camera, and to ensure a smooth
landing. Sand Flea can jump about 25 times
on one charge. Boston Dynamics is
developing Sand Flea with funding from the
US Armys Rapid Equipping Force (REF).
Atlas - The Agile Anthropomorphic Robot
Atlas is a high mobility, humanoid robot designed
to negotiate outdoor, rough terrain. Atlas can walk
bipedally leaving the upper limbs free to lift, carry,
and manipulate the environment.
In extremely challenging terrain, Atlas is strong and
coordinated enough to climb using hands and feet,
to pick its way through congested spaces.
Articulated, sensate hands will enable Atlas to use
tools designed for human use. Atlas includes 28
hydraulically-actuated degrees of freedom, two
hands, arms, legs, feet and a torso
Atlas - The Agile Anthropomorphic Robot
Atlas is a high mobility, humanoid robot designed
to negotiate outdoor, rough terrain. Atlas can walk
bipedally leaving the upper limbs free to lift, carry,
and manipulate the environment.
In extremely challenging terrain, Atlas is strong and
coordinated enough to climb using hands and feet,
to pick its way through congested spaces.
Articulated, sensate hands will enable Atlas to use
tools designed for human use. Atlas includes 28
hydraulically-actuated degrees of freedom, two
hands, arms, legs, feet and a torso
Robots that fly, walk and hop.
Safety considerations
Safety: Method and technique used for avoiding accidents.
Includes the usual considerations of man, machine and workstations, environment,
and the interface behavior, but it must also consider software.
Causes of accidents
Engineering deficiency
Lack of proper procedures
Inadequate programming
How ?
Emergency stop switches must appear on the control panel and also be added to
the pendant used in the teach mode where the operator or programmer may be
moving in the robots work envelope.
Comprehensive instruction and operation procedures must also be incorporated
through training programs.
Causes of accidents
Engineering deficiency
Lack of proper procedures
Inadequate programming
How ?
Emergency stop switches must appear on the control panel and also be added to
the pendant used in the teach mode where the operator or programmer may be
moving in the robots work envelope.
Comprehensive instruction and operation procedures must also be incorporated
through training programs.
Safety Guidelines
The unexpected robot movements are the concern of employees for obtaining further
guidelines on robotics safety.
Researchers have developed many guidelines pertaining to safety issues in robots.
Following guidelines are for safe use of robots in a production environment:
1. If the robot is not moving, do not assume it is not going to move.
2. If the robot is repeating pattern, do not assume it will continue.
3. Always be aware of where you are in relationship to the possible positions that the
robot may reach.
The unexpected robot movements are the concern of employees for obtaining further
guidelines on robotics safety.
Researchers have developed many guidelines pertaining to safety issues in robots.
Following guidelines are for safe use of robots in a production environment:
1. If the robot is not moving, do not assume it is not going to move.
2. If the robot is repeating pattern, do not assume it will continue.
3. Always be aware of where you are in relationship to the possible positions that the
robot may reach.
Safety guidelines (contd.)
4. Be aware if there is power actuators. Indicator lights will be on when there is power to the
actuators.
5. Teaching, programming, servicing, and maintenance are the only authorized reasons for
entry into the work envelope.
6. Before activating power to the robot, employees should be aware of what it is programmed
to do, that all safeguards are in place, and that no foreign materials are present with in the
work envelope.
7. Notify supervision immediately when an unexpected interruption to the normal robot work
cycle occurs.
8. Report any missing of defective safeguard to supervision immediately. Check all safeguards
at the beginning to each shift.
4. Be aware if there is power actuators. Indicator lights will be on when there is power to the
actuators.
5. Teaching, programming, servicing, and maintenance are the only authorized reasons for
entry into the work envelope.
6. Before activating power to the robot, employees should be aware of what it is programmed
to do, that all safeguards are in place, and that no foreign materials are present with in the
work envelope.
7. Notify supervision immediately when an unexpected interruption to the normal robot work
cycle occurs.
8. Report any missing of defective safeguard to supervision immediately. Check all safeguards
at the beginning to each shift.
Applications
S.N
o
Feature Part loading
and unloading
Material
handling
Spot Welding Arc Welding Spray Coating Electric Assembly
1 Structure Polar,
Cylindrical
jointed arm
Jointed adaptable
robot arm
Polar, Jointed
adaptable robot
arm
Polar, Modular
Cartesian with
adaptable
jointed arm
Jointed arm with
adaptable robot
arm
Jointed adaptable
Cartesian modular
robotic arm
2 Degree of
freedom
4-5 multiple
arms
3-5 5-6 5-6 6 or More 3-6
3 Drive
System
Electronic
Servo motors
(for heavy
loads)
Servo motors Electric stepper
Motors
Direct drive
Servo motors
Hydraulic
Actuators
Stepper Motors
and direct drives
Summary of Features and applications of Future industrial robots
Electronic
Servo motors
(for heavy
loads)
4 Program Programmable
Automation
control (PAC)
Programmable
Automation
control (PAC)
Programmable
logic
controllers(PLCs)
Programmable
logic
controller(PLC)
Programmable
logic
controllers(PLCs)
Programmable
Automation with
controller Area
Network(CAN)
5 Control
System
Micro
controllers and
motion
controllers
with vision
Motion
Controllers With
sensor
technology
Micro controller
with changeable
functions
Continuous
path motion
controllers with
sensors
technology
Continuous path
motion
controllers
Micro controllers
nodes with sensors
and end effectors
with vision
6 Nature of
task
Complicated
and safe
environments
Safe/hazardous
complicated
Simple and safe Complicated
and unsafe
Simple and unsafe Complicated and
safe