Industrial Robotics

Industrial Robotics
• Robot Anatomy and Related Attributes

• Robot Control Systems
• End Effectors
• Robot Programming
• Robot Accuracy and Repeatability
• Applications of Industrial Robots
Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper
Saddle River, NJ. All rights reserved.
Industrial Robot Defined
An automatically controlled, reprogrammable, multipurpose
manipulator programmable in three or more axes, which may be
either fixed in place or mobile for use in industrial automation
applications (ISO 8373)
• Why industrial robots are important:

– Robots can substitute for humans in hazardous work
environments
– Consistency and accuracy not attainable by humans
– Can be reprogrammed
– Robots are controlled by computers and can therefore be
connected to other computer systems
Robot Anatomy
• Manipulator consists of joints and links
– Joints (also called axes) provide relative motion
– Links are rigid members between joints
– Various joint types: linear and rotary
– Each joint provides a “degree-of-freedom”
– Most robots possess five or six degrees-of-freedom
• Robot manipulator consists of two sections:

– Body-and-arm – for positioning objects in the robot's
work volume
– Wrist assembly – for orienting objects
Robot Anatomy
Input/output links
Robot manipulator - a series of joint-link combinations
Types of Manipulator Joints
• Translational motion
– Linear joint (type L)
– Orthogonal joint (type O)
• Rotary motion
– Rotational joint (type R)
– Twisting joint (type T)
– Revolving joint (type V)
Translational Motion Joints
(a) Linear joint (type L)
(b) Orthogonal joint (type O)
Rotary Motion Joints
(c) Rotational joint (type R)
(d) Twisting joint (type T)
(e) Revolving joint (type V)
Robot Body-and-Arm Configurations
• Five common body-and-arm configurations for industrial
robots:
1. Articulated robot (aka jointed-arm robot)
2. Polar configuration
3. Selective Compliance Arm for Robotic Assembly
(SCARA)
4. Cartesian coordinate robot
5. Delta robot
• Function of body-and-arm assembly is to position an end
effector (e.g., gripper, tool) in space
Articulated Robot (Jointed-Arm)
• General configuration of a human arm
Polar Configuration
• Consists of a sliding arm (L joint) actuated relative to the

body, which can rotate about both a vertical axis (T joint)
and horizontal axis (R joint)
SCARA Robot
• SCARA = Selectively Compliant Assembly Robot Arm

• Similar to jointed-arm robot except that vertical axes are
used for shoulder and elbow joints to be compliant in
horizontal direction for vertical insertion tasks
Cartesian Coordinate Robot
• Consists of three sliding joints, two of which are

orthogonal
• Other names include gantry robot, rectilinear robot, and
x-y-z robot
It is commonly used
for overhead access to
load and unload
production machines
Delta Robot
• Consists of three arms attached
to an overhead base
• Each arm consists of two
rotational joints (type R), the
first of which is powered and the
second is unpowered
• All three arms are connected to
a small platform below, to which
an end effector is attached
• Used for high-speed movement
of small objects, as in product
packaging
Suggested Vidoe at
https://www.engineering.com/AdvancedManufacturing/ArticleID/166
51/The-What-Why-and-How-of-Delta-Robots.aspx
Wrist Configurations
• Wrist assembly is attached to end-of-arm
• End effector is attached to wrist assembly
• Function of wrist assembly is to orient end effector
– Body-and-arm determines global position of end
effector
• Two or three degrees of freedom:
– Roll
– Pitch
– Yaw
Wrist Configuration
• Typical wrist assembly has two or three degrees-of-
freedom (shown is a three degree-of freedom wrist)
Work Volume
Defined as the three-dimensional space within which the

robot can manipulate the end of its wrist
• Also known as work envelope
• Determined by:
– Number and types of joints
– Ranges of joints
– Physical sizes of links
Joint Notation Scheme
• Uses the joint symbols (L, O, R, T, V) to designate

joint types used to construct robot manipulator
• Separates body-and-arm assembly from wrist
assembly using a colon (:)
• Example: TLR : TR
Joint Notations for Five Arm-And-Body
Configurations
Configuration Notation Work Volume

Articulated TRR Partial sphere
Polar TRL Partial sphere
SCARA VRO Cylindrical
Cartesian coordinate OOO Rectangular solid
Delta 3(RRu) Hemisphere
Joint Drive Systems
• Electric
– Uses electric motors to actuate individual joints
– Preferred drive system in today’s robots
• Hydraulic
– Uses hydraulic pistons and rotary vane actuators
– Noted for their high power and lift capacity
• Pneumatic
– Typically limited to smaller robots and simple material
transfer applications
Dynamic Response of Manipulator
• The drive system, position sensors (and speed sensors if used),
and feedback control systems for the joints determine the dynamic
response characteristics of the manipulator.
• The speed with which the robot can move to a programmed
position and the stability of its motion are important characteristics
of dynamic response in robotics.
• Motion speed refers to the absolute velocity of the manipulator at
its end-of-arm.
– Speed can be programmed into the work cycle so that different
portions of the cycle are carried out at different velocities.
• What is sometimes more important than speed is the robot’s
capability to accelerate and decelerate in a controlled manner.
• Other factors that influence speed of motion are the weight
(mass) of the object that is being manipulated and the
precision with which the object must be located at the end
of a given move.
• All of these factors are included in the speed of response,

which is the time required for the manipulator to move from
one point in space to the next.
– Speed of response is important because it influences

the robot’s cycle time, which in turn affects the
production rate in the application.
• Motion stability refers to the amount of overshoot and oscillation that
occurs in the robot motion at the end-of-arm as it attempts to move to
the next programmed location.
– More oscillation in the motion is an indication of less stability.
– The problem is that robots with greater stability are inherently
slower in their response, whereas faster robots are generally less
stable.
• Load carrying capacity depends on the robot’s physical size and
construction as well as the force and power that can be transmitted to
the end of the wrist.
– The net load-carrying capacity of the robot is obviously reduced
by the weight of the gripper. If the robot is rated at 10 kg and the
weight of the gripper is 4 kg, then the net weight carrying capacity
is reduced to 6 kg
Sensors in Robotics
Two basic categories of sensors used in industrial robots:
1. Internal - used to control position and velocity of the
manipulator joints
2. External - used to coordinate the operation of the robot
with other equipment in the work cell
– Tactile - touch sensors and force sensors
– Proximity - when an object is close to the sensor
– Optical – for proximity
– Machine vision - for inspection, parts identification and
guidance, and other uses
– Other sensors - temperature, voltage, etc.
Robot Control Systems
• The actuations of the individual joints must be controlled in a coordinated
fashion for the manipulator to perform a desired motion cycle.
• A hierarchical structure is used so that each joint has its own feedback
control system, and a supervisory controller coordinates the combined
actuations of the joints according to the sequence of the robot program
Hierarchical structure of a robot microcomputer controller
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
End Effectors
The special tooling for a robot that enables it to perform a

specific task
• Two types:
– Grippers – to grasp and manipulate objects (e.g.,
parts) during work cycle
– Tools – to perform a process, e.g., spot welding,
spray painting
Robot Mechanical Gripper
• A two-finger mechanical gripper for grasping rotational parts
Advances in Mechanical Grippers
• Dual grippers
• Interchangeable fingers
• Sensory feedback
– To sense presence of object
– To apply a specified force on the object
• Multiple fingered gripper (similar to human hand)
• Standard gripper products to reduce the amount of
custom design required
Robot Programming
A robot program can be defined as a path in space to be
followed by a manipulator, combined with peripheral actions that
support the work cycle
• Examples of peripheral actions:
– Opening and closing a gripper
– Performing logical decision making
– Communicating with other piece of equipment in the cell
Types of Robot Programming
• Leadthrough programming - work cycle is taught to robot by
moving the manipulator through the required motion cycle and
simultaneously entering the program into controller memory for
later playback
• Robot programming languages - uses textual programming
language to enter commands into robot controller
• Simulation and off-line programming – program is prepared at
a remote computer terminal and downloaded to robot
controller for execution without need for leadthrough methods
Leadthrough Programming
Two types:
1. Powered leadthrough
– Common for point-to-point robots
– Uses teach pendant to move joints to desired position
and record that position into memory
2. Manual leadthrough
– Convenient for continuous path control robots

– Human programmer physical moves manipulator
through motion cycle and records cycle into memory
Suggested Video: https://www.youtube.com/watch?v=EA6pWwNI_wg
Leadthrough Programming Advantages
• Advantages:
– Can readily be learned by shop personnel
– A logical way to teach a robot
– Does not required knowledge of computer
programming
• Disadvantages:
– Downtime - Regular production must be interrupted to
program the robot
– Limited programming logic capability
– Not readily compatible with modern computer-based
technologies
World Coordinate System
Origin and axes of robot manipulator are defined relative to

the robot base
Tool Coordinate System
Alignment of the axis system is defined relative to the orientation

of the wrist faceplate (to which the end effector is attached)
Robot Programming Languages
Textural programming languages provide the opportunity to

perform the following functions that leadthrough
programming cannot readily accomplish:
• Enhanced sensor capabilities
• Improved output capabilities to control external equipment
• Program logic not provided by leadthrough methods
• Computations and data processing similar to computer
programming languages
• Communications with other computer systems
Motion Programming Commands
– MOVE P1
– HERE P1/LEARN P1 - used during leadthrough of
manipulator [Stored in format as 200, 150, 65, 0, 0, 0]
– MOVES P1 [Straight line interpolation]
– DMOVE(4, 125) [Delta or incremental move]
– APPROACH P1, 40 MM, MOVE P1 [will actuate gripper]
DEPART 40 MM
– DEFINE PATH123 = PATH(P1, P2, P3)
MOVE PATH123
– SPEED 75 (75% of the initial speed)
Interlock and Sensor Commands
• Input interlock:
WAIT 20, ON [Till the port 20 signal is ON]
• Output interlock:
– SIGNAL 10, ON [Switches On signal at output port 10]
– SIGNAL 10, 6.0 [Outputs a voltage level of 6 V to the
device from port 10]
• Interlock for continuous monitoring:
REACT 25, SAFESTOP [Subroutine]
Gripper Commands
• Basic commands
OPEN
CLOSE
• Sensor and and servo-controlled hands
CLOSE 25 MM
CLOSE 2.0 N
• Commands for tool type gripper also available
Computations and Program Logic
• Many robot languages possess capabilities for

performing computations and data processing operations
e.g. GO TO 150
and
IF (logical expression) GO TO 150
cause the program to branch to some other statement in
the program (e.g., to statement number 150 in the above
illustrations)
Simulation and Off-Line Programming
• In conventional usage, robot programming languages still
require some lost production time in order to define points in
the workspace that are referenced in the program
– They therefore involve on-line/off-line programming
• Advantage of true off-line programming is that the program
can be prepared beforehand and downloaded to the controller
with no lost production time
– Graphical simulation is used to construct a 3-D model of
the robot cell in which locations of the equipment in the cell
have been defined previously
Suggested VIDEO : https://blog.robotiq.com/what-are-the-

different-programming-methods-for-robots
Robot Accuracy and Repeatability
Three terms used to define precision in robotics, similar to
numerical control precision:
1. Control resolution - capability of robot's positioning system to
divide the motion range of each joint into closely spaced points
2. Accuracy - capability to position the robot's wrist at a desired
location in the workspace, given the limits of the robot's control
resolution
3. Repeatability - capability to position the wrist at a previously
taught point in the workspace
Robot Application Characteristics
General characteristics of industrial work situations that promote
the use of industrial robots
1. Hazardous work environment for humans
2. Repetitive work cycle
3. Difficult handling task for humans
4. Multishift operations
5. Infrequent changeovers
6. Part position and orientation are established in the work cell
Industrial Robot Applications
1. Material handling applications

– Material transfer – pick-and-place, palletizing
– Machine loading and/or unloading
2. Processing operations
– Spot welding and continuous arc welding
– Spray coating
– Other – waterjet cutting, laser cutting, grinding
3. Assembly and inspection
Arrangement of Cartons on Pallet
Robotic Arc-Welding Cell
Robot performs arc welding operation at one welding fixture
while worker changes parts at the other workstation

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Industrial Robotics

• Robot Anatomy and Related Attributes

• Why industrial robots are important:

• Robot manipulator consists of two sections:

Robot manipulator - a series of joint-link combinations

(a) Linear joint (type L)

(b) Orthogonal joint (type O)

(c) Rotational joint (type R)

(d) Twisting joint (type T)

(e) Revolving joint (type V)

• General configuration of a human arm

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

• SCARA = Selectively Compliant Assembly Robot Arm

• Consists of three sliding joints, two of which are

Defined as the three-dimensional space within which the

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

Configuration Notation Work Volume

• All of these factors are included in the speed of response,

– Speed of response is important because it influences

Hierarchical structure of a robot microcomputer controller

The special tooling for a robot that enables it to perform a

– Convenient for continuous path control robots

Origin and axes of robot manipulator are defined relative to

Alignment of the axis system is defined relative to the orientation

Textural programming languages provide the opportunity to

REACT 25, SAFESTOP [Subroutine]

• Commands for tool type gripper also available

• Many robot languages possess capabilities for

Suggested VIDEO : https://blog.robotiq.com/what-are-the-

1. Material handling applications

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