SKEM4153

ROBOT TECHNOLOGY FOR

AUTOMATION

CHAPTER 1
ROBOT APPLICATIONS IN
INDUSTRY

Prof. Dr. Shamsudin H.M. Amin

Ir. Dr. Mohd Ridzuan Ahmad
([email protected])
 Industrial Robot Definition
Industrial Robot can be defined as a general-
purpose, programmable machine possessing
certain anthropomorphic characteristics
• Hazardous work environments
• Repetitive work cycle
• Consistency and accuracy
• Difficult handling task for humans
• Multi shift operations
• Reprogrammable, flexible
• Interfaced to other computer systems
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INDUSTRIAL ROBOT
BY INDUSTRY Electrical and
electronics
9.90%
Autom otive
33.20%
Chem ical,
rubber and
plastics
9.40%
Machinery
4.30%

Metal
products
3.70%
Com m unicatio
Unspecified Food ns
25.00% 1.50% 2.50%
Other Precision and
9.70% optics
0.80%

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INDUSTRIAL ROBOT Dispensing Cutting,
BY APPLICATION and painting milling and
3.70% other
Assem bling processing
and 2.50%
dissassem bli Other
ng 7.90%
13.00%
Unspecified
8.60%
Welding and
soldering
28.90%
Handling of
materials and
processes
35.40%

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 Laws of Robotics

Isaac Asimov (a well known science

fiction writer) proposed three “Laws
of Robotics”:
• Law 1: A robot may not injure a human being or through
inaction, allow a human being to come to harm

• Law 2: A robot must obey orders given to it by human beings,

except where such orders would conflict with a higher order law

• Law 3: A robot must protect its own existence as long as such

protection does not conflict with a higher order law

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 History and Development of robots
and robotics system
• Joseph Engelberger (dubbed as the father of industrial robots)
and George Devol (known as the grandfather of industrial robots)
were the pioneers in the area of industrial robots and their
applications in the industry (started in 1951).

• The first industrial robot, a Unimate from Unimation, was installed in

1961 at a General Motor (GM) plant for unloading a die casting
machine.

• Most early installations were in automotive industries in the USA

and Japan (from 1980’s), particularly in the areas of:
– machine loading and material handling
– spot welding
– spray painting
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 History and Development of robots
and robotics system (cont.)
• Robots with greater precision, complex control algorithm and
advanced sensory capabilities begin to be built in the mid-70’s. In
1978, a PUMA (Programmable Universal Machine for Automation)
robot by Unimation was installed in a GM plant. Vision, tactile
sensing and intelligent control then become important research
topics.
• In the mid-80’s, there are 16,000 industrial robots in the USA alone
and 35% of them were in automotive assembly plants.
• In the US history, robot applications increased the productivity by
up to 30%, especially when the robots were integrated into an
automated system.
• In Japan, 60,000 industrial robots have been installed by the mid-
80’s. The Japanese government had a special program for
robotics and they are now the world leader in the usage of robots
in the industry. Japanese industries lead the American’s because
of their extensive use of robots in their plants.
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 DEALING WITH ISSUES OF INDUSTRIAL RELATION
When robots were first introduced, there was a lot of apprehension and
resistance coming from the labour work force. They were concerned that usage
of robots would mean loss of jobs as robots would be replacing humans in
carrying out industrial tasks. To allay those fears and resistance, in the USA, the
RIA (Robotics Industries Association) has put up the following promise for the
opponents of robot usage in the industry:
•Not to replace workers, only replace equipment.
•Use only for hazardous, boring, demoralizing, and repetitive
tasks.
•Only if it can result in shorter work week, higher pay, and
better working conditions for human.
Today, robots are seen as helping humans with hazardous tasks, repetitive and
boring tasks, making life more comfortable for humans. Robots are now widely
accepted at the work place as just like other pieces of equipment.

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Benefits of Industrial Robots Applications
(the following are the most common benefits)
Increased output rates.
Elimination of dangerous or undesirable jobs for
human.
Improved product quality.
Increased manufacturing flexibility.
Reduced material wastage.
Easier to compliance with standard regulations
e.g. OSHA
Reduced labor turnover.
Lower capital cost.
Controlled and faster inventory turnover.
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 MAN vs. ROBOT
HUMAN FACTORS GIVE RISE TO PROBLEMS
• Mental and Physical • Inconsistent Work
Fatigue Quality
• Interruptions due to • Unstable Production
personal problems
• Interactions with others • High Labour Turnover
• Easily affected by • Delay in Product
adverse conditions Delivery
• Always demand higher • Escalation in
pay production cost

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 HUMAN vs ROBOT
ROBOT ON THE OTHER HAND:
• Does not tire out
• Not emotional
• Does not take holidays
• Does not demand higher pay
• No Monday morning, Friday afternoon syndrome
• Does not argue with superiors
• Does not form Trade Unions

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 Table on Standards and Codes for industrial robots
Group Standard Subject ANSI/RIA = American National
Standards Institutes/Robotics
1. ANSI/RIA R1056-1986 American national standards for Industrial Association.
industrial robots and robot systems BSR/RIA = Bureau of
Standards Review/Robotics
2. BSR/RIA BSR/RIA R15- Proposed standard for industrial
Industrial Association.
06-19XX robots and robot systems
NIOSH = National Institute for
Occupational Safety and
3. ANSI/RIA R15.02-1990 American national standard human Health.
engineering design criteria for OSHA = Occupational Safety
hand-held robot control pendants and Health Administration.
4. OSHA Pub. 2254 Training requirements in standards AFOSH = Department of the
(revised) and training guidelines Air Force.

5. NIOSH Pub. 88-108 Safe maintenance guidelines for

robotics workstations
6. OSHA Pub. 8-1.3, Guidelines for robotics safety
1987
7. OSHA 29 CFR Control of hazardous energy
1910.147 source (lockout/tagout final rule)
8. AFOSH 127-12, 1991 Occupational safety machinery

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 Some Examples of Industrial Robot Applications
AEROSPACE TECHNOLOGY
Robots being use extensively especially for flexible aircraft
assembly– use fixtures for temporary fastening, the permanent
fastening must be drilled and parts dissembled for deburring and
cleaning, finally parts are reassembled and permanently fastened.
It was reported that, in many installation around the world in
Aircraft Manufacturing, the following improvements have
been achieved :
Reduced cost
Shorter cycle time
Improved control
Increased throughput and surge capability
Improved quality
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Examples of Industrial Robot Applications
POLISHING BUFFING

DEBURRING & POLISHING

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Examples of Industrial Robot Applications
MATERIAL HANDLING
Handling bottles from
the filling machine into
trays.

Feeding the parquet

grinding machine with
a pile of parquet
blocks.

Arranging packets
to be put into
cardboard boxes.

Arranging sacks
from filling machine
onto a conveyor.
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Examples of Industrial Robot Applications
PALLETISING & DEPALLETISING

Press brake
operation.

Palletising of
cardboard boxes.

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Examples of Industrial Robot Applications

WELDING

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Examples of Industrial Robot Applications

Waterjet Cutting

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 Examples of Industrial Robot Applications

Labelling application

Labelling of pallets. A sensor in the labelling

tool measure the surface of the pallet. The
robot controller calculates the exact position
of the labels. Standard labelling tool for up to
A3-size.Cycle time for two labels is about 15
seconds.
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 Examples of Industrial Robot Applications
APPLICATIONS IN AGRICULTURAL INDUSTRY

Motoman UP200 robot spot welds

Walking forest harvester prototype by
large agricultural equipment
Plustech Ltd., today part of John Deere
assemblies
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 Examples of Industrial Robot Applications
APPLICATIONS IN AGRICULTURAL INDUSTRY (cont. 1)

Cut-to-length (CTL) harvester made by

Ponsse Oy Ltd.

CTL Forwarded
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Examples of Industrial Robot Applications
APPLICATIONS IN AGRICULTURAL INDUSTRY (cont. 2)

MECANT walking machine by Halme et al. at TKK.

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Examples of Industrial Robot Applications

APPLICATIONS IN AGRICULTURAL INDUSTRY (cont. 3)

Macadamia nut sorter with camera (tomato, broccoli, apple sorters)

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 Examples of Industrial Robot Applications
APPLICATIONS IN CONSTRUCTION INDUSTRY

Large scale pipe manipulator

Concrete panel installation robot

(courtesy Fujita Research)

Large manipulator system

(courtesy Shimizu Corp.)
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 Examples of Industrial Robot Application
APPLICATIONS IN CONSTRUCTION INDUSTRY (cont.1)

Concrete surface finishing robot

Autonomous Excavator Robot

Teleoperated concrete spraying robot

(courtesy MEYCO Equipment)
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 Examples of Industrial Robot Applications
APPLICATIONS IN CONSTRUCTION INDUSTRY (cont.2)

Teleoperated pothole patching robot Concrete block laying robot

Hard rock automated drilling robot

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Examples of Industrial Robot Applications
APPLICATIONS IN FOOD/BAKERY PRODUCTS MAKINGS

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 Examples of Industrial Robot Applications
What else?
ROBOT PACKAGING
PRINTED CIRCUIT BOARD’S COMPONENT INSERTION
PHARMACEUTICAL MANUFACTURING
APPLICATIONS IN TEXTILE INDUSTRY

APPLICATIONS IN BRICK INDUSTRY

APPLICATIONS IN GLASS INDUSTRY

PRINTING & PUBLISHING INDUSTRY

And Many More!
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 AN APPROACH ON
INSTALLATION OF ROBOTS

A logical sequence of steps to implement a robotic

program in its operations:

Initial familiarization with the technology

Plant survey to identify potential applications
Selection of the applications
Selection of the robot
Detailed economic analysis and capital authorization

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 ROBOT INSTALLATION PROCEDURE

1. PLANNING
Introduction
Task Force
Master and Detail Schedule
Documents Preparation
Material Preparation
Tool Preparation
Layout Preparation
Job Sharing
Safety Meeting
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 ROBOT INSTALLATION PROCEDURE
2. INSTALLATION
Measurements
Material Orientation
Electrical Wiring
Mechanical Fitting
Accessories
Robot Tool Fitting
Alignment
Safety Fence
Robot Programming
PLC Programming
Discussion, Problem Sheet, Reporting, Dress-up
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 ROBOT INSTALLATION PROCEDURE

3. INSPECTION 4. TRIAL
Static, Dynamic, Manual, auto operation
Electrical, Mechanical, Sequence Check
Safety Inspection Low/High Speed
Inspection Sheet & Accuracy Check and confirmation
Robot Inspection Quality and Cycle-time confirmation
Up-date standard operation

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 ROBOT INSTALLATION PROCEDURE
5. MODIFICATION AND RETRIAL
Immediate and Long-term Action
Scheduling
Retrial
Overall Confirmation
6. ENDURANCE TEST
Reliability, Variance Test
Problem Detection
Performance Test
Safety Test

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ROBOT INSTALLATION PROCEDURE

7. TRAINING 8. FINAL REPORT

Operators, Technical report &
Supervisors, documentation
Engineers,
Managers

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 TEXT AND REFERENCE BOOKS
Textbook:
1. James A. Rehg: Introduction to Robotics in CIM
Systems. Fifth Edition, Prentice-Hall. 2003.

Reference book:
1. Mikell P. Groover: Automation, Production Systems,
and Computer Integrated Manufacturing, Second
Edition. 2004.
2. Mikell P. Groover, Mitchell Weiss, Roger N. Nagel,
Nicholas G. Odrey: Industrial Robotics: Technology,
Programming, and Applications, McGraw-Hill. 1986.
3. Farid M. L. Amirouche: Computer-Aided Design and
Manufacturing. Prentice-Hall.
4. Richard K. Miller, Industrial Robot Handbook. Van
Nostrand Reinhold, N.Y. (1987).
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