Module 9: Industrial Robotics and Flexible Automation
1. Industrial Robotic Systems
• Definition: Robotic systems used in manufacturing for tasks such as welding, painting,
assembly, and material handling.
• Components:
o Manipulator (robot arm)
o End-effector (tooling)
o Controllers and actuators
o Sensors (vision, force, proximity)
• Design Considerations:
o Payload capacity
o Accuracy and repeatability
o Workspace volume
o Degrees of freedom (DoF)
• Implementation Phases:
1. Task analysis and feasibility study
2. Robot selection and integration
3. Programming and calibration
4. Testing and validation
2. Flexible Automation
• Definition: Automation system capable of adapting to changes in product types or
configurations with minimal reprogramming or tooling changes.
• Key Characteristics:
o Quick changeover
o Programmability
o Integration with sensors and control systems
• Benefits:
o Customization of products
o Lower downtime
o Adaptability to varying demand
3. System Integration in Flexible Manufacturing Systems (FMS)
• FMS: A system that combines CNC machines, robots, AGVs, and control software into a
unified, flexible production system.
• Integration Aspects:
o Communication protocols (e.g., OPC UA)
o Real-time data acquisition and monitoring
o Centralized control using SCADA/PLC
o Digital twins and simulation models
4. Robotic Arms and Human-Robot Collaboration
• Collaborative Robots (Cobots):
o Designed to work safely alongside humans without fencing.
o Features: force sensing, soft end-effectors, speed limiting.
o Programming methods: hand-guiding, teach pendants, graphical interfaces.
• Human-Robot Interaction (HRI):
o Focuses on shared workspaces, trust, safety, and ergonomics.
o Effective HRI enhances productivity and reduces cognitive load on operators.
5. Case Studies in Flexible Automation
• Automotive:
o Robotic welding, painting, and assembly.
o Use of AGVs for parts delivery.
o BMW and Tesla using FMS for varied models on a single line.
• Electronics:
o Precision placement of components using SCARA robots.
o High-mix, low-volume manufacturing.
o Example: Foxconn's deployment of cobots for iPhone assembly.
