FLEXIBLE MANUFACTURING SYSTEMS AND LINE

BALANCING
What is Flexible Manufacturing System?

A flexible manufacturing system (FMS) is a form of flexible automation in which several

machine tools are linked together by a material-handling system, and all aspects of the system
are controlled by a central computer.

What are The Features of FMS?

An FMS is distinguished from an automated production line by its ability to process more
than one product style simultaneously. At any moment, each machine in the system may be
processing a different part type. FMS can let us make changes in production schedule in order
to meet the demands on different products.

Fundamental of Group technology and FMS

FMS is a highly automated GT Machine cell consisting of a group of processing workstations

(usually CNC Machine tool), interconnected by an automated material handling and storage
system and controlled by a distributed computer system.

The reason FMS is called Flexible is that capable of processing variety of different part style
simultaneously at the various workstation and the mix of part style and quantises of
production can be adjusted in response to changing demand pattern.

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The FMS is most suited for the mid-variety, mid-volume production range. An FMS relies on
the principles of group technology. No manufacturing system be completely flexible. There
is a limit to the range of parts or products that can be made in an FMS. Accordingly a flexible
manufacturing system is designed to produce parts within defined range of styles, sizes and
process. A more appropriate term for FMS would be flexible automated manufacturing
system. The use of the word "automated" would distinguish this type of production
technology from other manufacturing systems that are flexible but not automated, such as a
manned GT machine cell. The word "flexible" would distinguish it from other manufacturing
systems that are highly automated but not flexible, such as a conventional transfer line.
However, the existing terminology is well established.

Types of FMS
Each FMS is designed for a specific application that is a specific family of parts and process.
Each FMS is Custom-engineered and unique. FMS can be distinguished according to the
kind of operation they perform processing operation or assembly operation. An FMS is
usually designed to perform one or other but rarely both. A difference that is applicable to
machining systems is whether the system will process rotational parts or nonrotaional parts
Two other ways to classify flexible manufacturing system are by number of machines and
level of Flexibility.
Based on Number of Machine.

1. Single machine cell

2. Flexible manufacturing cell

3. Flexible manufacturing system

1. Single machine cell

A single machine cell consists of one CNC machining center combined with a parts storage
system for unattended operation , as in Figure Completed parts are periodically unloaded
from the parts storage unit, and raw workparts are loaded into it. The cell can be designedto
operate in a batch mode, a flexible mode, or a combination of the two. When operated in a
batch mode, the machine processes parts of a single style in specified lot sizes and is then
changed over to process a batch of the next part style. When operated in a flexible mode, the
system satisfies three of the four flexibility tests. It is capable of (1) processing different

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part styles, (2) responding to changes in production schedule, and (3) accepting new part
introductions. Criterion (4), error recovery, cannot be satisfied because if the single machine
breaks down, production stops.

2. Flexible manufacturing cell

A flexible manufacturing cell (FMC) consists of two or three processing work-stations

(typically CNC machining centers or turning centers) plus a parts handling system.

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 The parts handling system is connected to a load/unload station. The handling system
usually includes a limited parts storage capacity. One possible FMC is illustrated in
Figure A flexible manufacturing cell satisfies the four flexibility tests discussed
previously.

3. Flexible manufacturing System

It has four or more processing station connected mechanically by a common parts

handling system and electronically by a distributed computer system. Distinction between
FMS and FMC is the no of machine A FMC has two or three machine FMS has four or
More Machine

Based on Level of Flexibility

The two categories of flexibility are

– Dedicated

– Random order

1. Dedicated FMS

A dedicated FMS is designed to produce a limited variety of part styles, and the complete
universe of parts to be made on the system is known in advance. The part family is likely to
be based on product commonality rather than geometric similarity. The product design is

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considered stable, so the system can be designed with a certain amount of process
specialization to make the operations more efficient. Instead of being general purpose, the
machines can be designed for the specific processes required to make the limited part family,
thus increasing the production rate of the system. In some instances, the machine sequence
may be identical or nearly identical for all parts processed, so a transfer line may be
appropriate, in which the workstations possess the necessary flexibilty to process the different
parts in the mix. Indeed, the term flexible transfer line is some-times used for this case

2. Random order

A random-order FMS is more appropriate when the part family is large, there are substantial
variations in part configurations, new part designs will be introduced into the system and
engineering changes will occur in parts currently produced, and the production schedule is
subject to change from day to day. To accommodate these variations, the random-order FMS
must be more flexible than the dedicated FMS. It is equipped with general purpose machines
to deal with the variations in product and is capable of processing parts in various sequences
(random order). A more sophisticated computer control system is required for this FMS type

FMS COMPONENT

Several basic components of flexible manufacturing system

1. Workstations

2. Material handling and storage system

3. Computer control system

4. Manage and operate system

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1. WORKSTATIONS

The processing or assembly equipment used in a flexible manufacturing system depends on

the type of work accomplished by the system. In a system designed for machining operations,
the principal types of processing station are CNC machine tools. However, the FMS concept
is applicable to various other processes as well. Following are the types of workstations
typically found in a FMS

Load/Unload Stations
The load/unload station is the physical interface between the FMS and the rest of
the factory. It is where raw work parts enter the system and finished parts exit the system.
Loading and unloading can be accomplished either manually (the most common method) or
by automated handling systems. The load/unload station should be ergonomically designed to
permit convenient and safe movement of work parts.

Mechanized cranes and other handling devices are installed to assist the operator with
parts that are too heavy to lift by hand. A certain level of cleanliness must be maintained at
the workplace, and air hoses or other washing facilities are often used to flush away chips
and ensure clean mounting and locating points. The station is often raised slightly above floor
level using an' open-grid platform to permit chips and cutting fluid to drop through the
openings for subsequent recycling or disposal.

The load/unload station includes a data entry unit and monitor for communication
between the operator and the computer system. Through this system the operator receives
instructions regarding which part to load onto the next pallet in order to adhere to the
production schedule. When different pallets are required for different parts, the correct pallet
must be supplied to the station.

When modular fixturing is used, the correct fixture must be specified and the required
components and tools must be available at the workstation to build it. When the part loading
procedure has been completed, the handling system must launch the pallet into the system,
but not until then; the handling system must be prevented from moving the pallet while the
operator is still working. All of these conditions require communication between the
computer system and the operator at the load/unload station.

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Machining Stations

The most common applications of flexible manufacturing systems are machining operations.
The workstations used in these systems are therefore predominantly CNC machine tools.
Most common is the CNC machining center, in particular, the horizontal machining center.
CNC machining centers possess features that make them compatible with the FMS,
including automatic tool changing and tool storage, use of palletized work parts, CNC, and
capacity for DNC.

Machining centers can be ordered with automatic pallet changers that can be readily
interfaced with the FMS part handling system. Machining centers are generally used for non-
rotational parts. For rotational parts, turning centers are used; and for parts that are mostly
rotational but require multi-tooth rotational cutters (milling and drilling), mill-turn centers
can be used. In some machining systems, the types of operations performed are concentrated
in a certain category, such as milling or turning

For milling, special milling machine modules can be used to achieve higher
production levels than a machining center can manage. The milling module can be vertical
spindle, horizontal spindle, or multiple spindles. For turning operations, special turning
modules can be designed for the FMS. In conventional turning, the workpiece is rotated
against a tool that is held in the machine and fed in a direction parallel to the axis of work
rotation.

Parts made on most FMSs are usually nonrotational, but they may require some
turning in their process sequence. For these cases, the parts are held in a pallet fixture
throughout processing on the FMS, and a turning module is designed to rotate the single point
tool around the work

Other Processing Stations

The flexible manufacturing system concept has been applied to other processing
operations in addition to machining. One such application is sheet-metal fabrication, reported
in Winship. The processing workstations consist of press working operations such as
punching, shearing, and certain bending and forming processes.

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Also, flexible systems have been developed to automate the forging process. Forging is
traditionally a very labor intensive operation. The workstations in the system consist
principally of a heating furnace, a forging press, and a trimming station

Assembly

Some flexible manufacturing systems are designed to perform assembly operations. Flexible
automated assembly systems are gradually replacing manual labor in the assembly of
products typically made in batches. Industrial robots are often used as the automated
workstations in these flexible assembly systems

They can be programmed to perform tasks with variations in sequence and motion
pattern to accommodate the different product styles assembled in the system. Other examples
of flexible assembly workstations are the programmable component placement machines
widely used in electronics assembly.

Other Stations and Equipment

Inspection can be incorporated into a flexible manufacturing system, either by

including an inspection operation at a processing work-station, or by including a station
specifically designed for inspection. Coordinate measuring machines, special inspection
probes that can be used in a machine tool spindle, and machine vision are three possible
technologies for performing inspection on an FMS. Inspection is particularly important in
flexible assembly systems to ensure that components have been properly added at the
workstations.

In addition to the above, other operations and functions are often accomplished on a flexible
manufacturing system. These include cleaning parts and/or pallet fixtures, central coolant
delivery systems for the entire FMS, and centralized chip removal systems often installed
below floor level.

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 2. MATERIAL HANDLING AND STORAGE SYSTEM

The second major component of a FMS is its material handling and storage system. In this
section we discuss the functions of the handling system, material handling equipment
typically used in an FMS, and types of FMS layout.

Functions of the Handling System. The material handling and storage system in a
flexible manufacturing system performs the following functions

Allows random, independent movement of workparts between stations. Parts must be capable
of moving from any machine in the system to any other machine, in order to provide
various routing alternatives for the different parts and to make machine substitutions when
certain stations are busy.

Enables handling of a variety of workpart configuration& For prismatic parts (nonrotational

parts), this is usually accomplished by using modular pallet fixtures in the handling system.

The fixture is located on the top face of the pallet and is designed to accommodate different
part configurations by means of common components, quick-change features, and other
devices that permit a rapid build-up of the fixture for a given part.

The base of the pallet is designed for the material handling system. For rotational parts,
industrial robots are often used to load and unload the turning machines and to move parts
between stations

Provides temporary storage. The number of parts in the FMS will typically exceed the
number of parts actually being processed at any moment. Thus, each station has a small
queue of parts, perhaps only one part, waiting to be processed, which helps to maintain high
machine utilization.

Provides convenient access for loading and unloading workparts. The handling sys-tem
must include locations for load/unload stations.

Creates compatibility with computer control. The handling system must be under the direct
control of the computer system which directs it to the various workstations, load/unload
stations, and storage areas.

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Material Handling Equipment

The types of material handling systems used to transfer parts between stations in a FMS
include a variety of conventional material transport equipment, in-line transfer mechanisms,
and industrial robots.

The material handling function in a FMS is often shared between two systems:

1. a primary handling system and

2. a secondary handling system.

The primary handling system establishes the basic layout of the FMS and is responsible for
moving parts between stations in the system.

The secondary handling system consists of transfer devices, automatic pallet changers, and
similar mechanisms located at the workstations in the FMS. The function of the secondary
handling system is to transfer work from the primary system to the machine tool or other
processing station and to position the parts with sufficient accuracy and repeatability to
perform the processing or assembly operation

Other purposes served by the secondary handling system include (1) reorientation of the
workpart if necessary to present the surface that is to be processed, and (2) buffer storage of
parts to minimize work change time and maximize station utilization.

In some FMS installations, the positioning and registration requirements at the individual
workstations are satisfied by the primary work handling system. In these cases, there is no
secondary handling system.

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FMS Applications
• Flexible automation is applicable to a variety of manufacturing operations.

• FMS technology is most widely applied in machining operations.

• Other applications include sheet-metal press working, forging, and assembly. In this
section, we examine some of the applications using case study examples as
illustrations.

• Flexible Machining Systems. Historically, most of the applications of flexible

machining systems have been in milling and drilling type operations (nonrotational
parts), using CNC machining centers.

• FMS applications for turning (rotational parts) were much less common until
recently, and the systems that are installed tend to consist of fewer machines.

• For example, single machine cells consisting of parts storage units, parts loading
robots, and CNC turning centers are widely used today, although not always in a
flexible mode.

• Let us explore some of the issues behind this anomaly in the development of flexible
machining systems

• Flexible Machining Systems. Historically, most of the applications of flexible

machining systems have been in milling and drilling type operations (nonrotational
parts), using CNC machining centers.

• FMS applications for turning (rotational parts) were much less common until
recently, and the systems that are installed tend to consist of fewer machines.

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 • For example, single machine cells consisting of parts storage units, parts loading
robots, and CNC turning centers are widely used today, although not always in a
flexible mode.

• Let us explore some of the issues behind this anomaly in the development of flexible
machining systems

• Unlike rotational parts, nonrotational parts are often too heavy for a human operator
to easily and quickly load into the machine tool.

• Accordingly, pallet fixtures were developed so that these parts could be loaded onto
the pallet off-line using hoists, and then the part-on-pallet could be moved into
position in front of the machine tool spindle.

• Nonrotational parts also tend to be more expensive than rotational parts, and the
manufacturing lead times tend to be longer.

• These factors provide a strong incentive to produce them as efficiently as possible,

using advanced technologies such as FMSs.

• For these reasons, the technology for FMS milling and drilling applications is more
mature today than for FMS turning applications.

• Other FMS Applications. Press working and forging are two other manufacturing
processes in which efforts are being made to develop flexible automated systems.

FMS Benefits
A number of benefits can be expected in successful FMS applications.

The principal benefits are Increased machine utilization. Flexible manufacturing systems
achieve a higher average utilization than machines in a conventional batch production
machine shop. Reasons for this include

(1) 24 hour per day operation,

(2) automatic tool changing of machine tools,

(3) Automatic pallet changing at workstations,

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(4) queues of parts at stations, and

(5) dynamic scheduling of production that compensates for irregularities. It should be

possible to approach 80% to 90% asset utilization by implementing FMS technology [19].

Fewer machines required. Because of higher machine utilization, fewer machines

arerequired.

Reduction in the amount of factory floor space required. Compared to a job shop of
equivalent capacity, a FMS generally requires less floor area. Reductions in floor space
requirements are estimated to be 40% to 50%

Greater responsiveness to change. A flexible manufacturing system improves response

capability to part design changes, introduction of new parts, changes in production schedule
and product mix, machine breakdowns, and cutting tool failures. Adjustments can be made in
the production schedule from one day to the next to respond to rush orders and special
customer requests.

Reduced inventory requirements. Because different parts are processed together rather than
separately in batches, work-in-process is less than in a batch production mode. The inventory
of starting and finished parts can be reduced also, by a typical 60% to 80%.

Lower manufacturing lead times. Closely correlated with reduced work-in-process is the
time spent in process by the parts. This means faster customer deliveries.

Reduced direct labor requirements and higher labor productivity. Higher production
rates and lower reliance on direct labor mean greater productivity per labor hour with an FMS
than with conventional production methods. An FMS can result in labor savings of 30% to
50% .

Opportunity for unattended production. The high level of automation in a flexible

manufacturing system allows it to operate for extended periods of time without human
attention. In the most optimistic scenario, parts and tools are loaded into the system at the end
of the day shift, the FMS continues to operate throughout the night, and the finished parts are
unloaded the next morning.

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FMS PLANNING AND DESIGN ISSUES
The initial phase of FMS planning must consider the parts that will be produced by the
system. The issues are similar to those in cellular manufacturing. They include

Part family considerations. Any flexible manufacturing system must be designed to process
a limited range of part or product styles. The boundaries of the range must he decided. In
effect, the part family that will be processed on the FMS must be defined. The definition of
part families to be processed on the FMS can be based on product commonality as well as
part similarity.

The term product commonality refers to different components used on the same product.
Many successful FMS installations are designed to accommodate part families defined by this
criterion. This allows all of the components required to assemble a given product unit to be
completed just prior to beginning assembly

Processing requirements. The types of parts and their processing requirements determine
the types of processing equipment that will be used in the system.

In machining applications, nonrotational parts are produced by machining centers, milling

machines, and similar machine tools; rotational parts are machined by turning centers and
similar equipment.

Physical characteristics of the workparts. The size and weight of the parts determine the
size of the machines at the workstations and the size of the material handling system that
must be used.

Production volume. Quantities to be produced by the system determine how many machines
of each type will be required. Production volume is also a factor in selecting the most
appropriate type of material handling equipment for the system. After the part family,
production volumes, and similar part issues have been decided, design of the system can
proceed. Important factors that must be specified in FMS design include

Types of workstations. The types of machines are determined by part processing

requirements. Consideration of workstations must also include the load/unload station(s).

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Variations in process routings and FMS layout. If variations in process sequence are
minimal, then an in-line flow is most appropriate. For a system with higher product variety,a
loop is more suitable. If there is significant variation in the processing, a ladder layout or
open field layout are most appropriate.

Material handling system. Selection of the material handling equipment and layout are
closely related, since the type of handling system limits the layout selection. The material
handling system includes both primary and secondary handling systems

Work-in-process and storage capacity. The level of work-in-process (WIP) allowed in the
FMS is an important variable in determining utilization and efficiency of the FMS. If the WIP
level is too low, then stations may become starved for work, causing reduced utilization. If
the WIP level is too high, then congestion may result. The WIP level should be planned, not
just allowed to happen. Storage capacity in the FMS must be compatible with WIP level

Tooling. Tooling decisions include types and numbers of tools at each station, and the degree
of duplication of tooling at the different stations. Tool duplication at stations tends to
increase the flexibility with which parts can be routed through the system.

Pallet fixtures. In machining systems for nonrotational parts, it is necessary to select the
number of pallet fixtures used in the system.

Factors influencing the decision include levels of WIP allowed in the system and differences
in part style and size. Parts that differ too much in configuration and size require different
fixturing.

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 INTRODUCTION

The field of robotics has its origins in science fiction. The term robot was derived from the
English translation of a fantasy play written in Czechoslovakia around 1920. It took another
40 years before the modern technology of industrial robotics began. Today Robots are
highly automated mechanical manipulators controlled by computers. We survey some of
the science fiction stories about robots, and we trace the historical development of robotics
technology. Let us begin our chapter by defining the term robotics and establishing its place
in relation to other types of industrial automation.

Robotics: -
Robotics is an applied engineering science that has been referred to as a combination of
machine tool technology and computer science. It includes machine design, production
theory, micro electronics, computer programming & artificial intelligence.
OR

"Robotics" is defined as the science of designing and building Robots which are suitable for
real life application in automated manufacturing and other non-manufacturing
environments.

Industrial robot: -
The official definition of an industrial robot is provided by the robotics industries
association (RIA). Industrial robot is defined as an automatic, freely programmed, servo-
controlled, multi-purpose manipulator to handle various operations of an industry with
variable programmed motions.

Automation and robotics:-

Automation and robotics are two closely related technologies. In an industrial context, we
can dean automation as a technology that is concerned with the use of mechanical,
electronic, and computer-based systems in the operation and control of production
Examples of this technology include transfer lines. Mechanized assembly machines,
feedback control systems (applied to industrial processes), numerically controlled machine
tools, and robots. Accordingly, robotics is a form of industrial automation.

Ex:- Robotics, CAD/CAM, FMS, CIMS

Types of Automation:-
Automation is categorized into three types. They

are,1)Fixed Automation

2) Programmable Automation
3) Flexible Automation.

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(1) Fixed Automation:-

It is the automation in which the sequence of processing or assembly operations to be

carried out is fixed by the equipment configuration. In fixed automation, the sequence of
operations (which are simple) are integrated in a piece of equipment. Therefore, it is
difficult to automate changes in the design of the product. It is used where high volume of
production is required Production rate of fixed automation is high. In this automation, no
new products areprocessed for a given sequence of assembly operations.

Features:-

i) High volume of production rates,

ii) Relatively inflexible in product variety (no new products are

produced). Ex:- Automobile industries … etc.

(2) Programmable Automation:-

It is the automation in which the equipment is designed to accommodate various product

configurations in order to change the sequence of operations or assembly operations by
means of control program. Different types of programs can be loaded into the equipment
to produce products with new configurations (i.e., new products). It is employed for batch
production of low and medium volumes. For each new batch of different configured
product, a new control program corresponding to the new product is loaded into the
equipment. This automation is relatively economic for small batches of the product.
Features:-
i) High investment in general purpose,
ii) Lower production rates than fixed automation,
iii) Flexibility & Changes in products configuration,
iv) More suitable for batch production.
Ex:- Industrial robot, NC machines tools… etc.

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 (3) Flexible Automation:-
A computer integrated manufacturing system which is an extension of programmable
automation is referred as flexible automation. It is developed to minimize the time loss between
the changeover of the batch production from one product to another while reloading. The
program to produce new products and changing the physical setup i.e., it produces different
products with no loss of time. This automation is more flexible ininterconnecting work
stations with material handling and storage system.
It produces different products with no loss of time. This automation is more flexible in
inter-connecting work stations with material handling and storage system.

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Features:-
i) High investment for a custom engineering system.

ii) Medium Production rates

iii) Flexibility to deal with product design variation,

iv) Continuous production of variable

mixturesof products. Ex:- Flexible

manufacturing systems (FMS)

Advantages:-
1. High Production rates

2. Lead time decreases

3. Storing capacity decreases

4. Human errors are eliminated.

5. Labour cost is decreases.

Disadvantages:-
1. Initial cost of raw material is very high,

2. Maintenance cost is high,

3. Required high skilled Labour.

4. Indirect cost for research development & programming increases.

Reasons for implementation of automated systems in manufacture industries:-

The reasons for the implementation of automated systems in manufacturing industries are as
follows,
(i) To Increase the Productivity Rate of Labour
(ii) To Decrease the Cost of Labour
(iii) To Minimize the Effect of Shortage of Labour
(iv) To Obtain High Quality of Products
(v) A Non-automation nigh Cost is Avoided
(vi) To Decrease the Manufacturing Lead Time
(vii) To upgrade the Safety of Workers.

Need for using robotics in industries:-

Industrial robot plays a significant role in automated manufacturing to
performdifferent kinds of applications.

1. Robots can be built a performance capability superior to those of human beings. In

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terms of strength, size, speed, accuracy…etc.
 2. Robots are better than humans to perform simple and repetitive tasks
withbetter quality and consistence’s.

3. Robots do not have the limitations and negative attributes of human works .such
asfatigue, need for rest, and diversion of attention…..etc.
4. Robots are used in industries to save the time compared to human beings.
5. Robots are in value poor working conditions
6. Improved working conditions and reduced risks.

CAD/CAM & Robotics:-

CAD/CAM is a term which means computer aided design and computer aided
manufacturing. It is the technology concerned with the use of digital computers to
performcertain functions in design & production.

CAD:- CAD can be defined as the use of computer systems to assist in the creation
modification, analysis OR optimization of design.

Cam:- CAM can be defined as the use of computer system to plan, manage & control the
operation of a manufacturing plant, through either direct or in direct computer interface
with the plant’s production resources.

Specifications of robotics:-
1. Axil of motion

2. Work stations

3. Speed

4. Acceleration

5. Pay load capacity

6. Accuracy

7. Repeatability etc…

Overview of Robotics:-
"Robotics" is defined as the science of designing and building Robots which are suitable for
real life application in automated manufacturing and other non-manufacturing
environments.It has the following objectives,
1. To increase productivity

2. Reduce production life

3. Minimize labour requirement

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4. Enhanced quality of the products
5. Minimize loss of man hours, on account of accidents.

6. Make reliable and high speed production.

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The robots are classified as,
Programmable/Reprogrammable
purpose

robots
*Tele-operated, Man controlled robots

*Intelligent robots.

Robots are used in manufacturing and assembly

unitssuch as,

1. Spot or arc welding

2. Parts assembly

3. Paint spraying

4. Material, handling

5. Loading and unloading

The feature and capabilities of the robots are as follows,

1. Intelligence

2. Sensor capabilities

3. Telepresence

4. Mechanical design

5. Mobility and navigation

6. Universal gripper
7. System integration and networking.

Types of drive systems:-

1. Hydraulic drive

2. Electric drive

3. Pneumatic drive

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1. Hydraulic drive:-
Hydraulic drive and electric drive arc the two main types of drives used on
moresophisticated robots.

Hydraulic drive is generally associated with larger robots, such as the Unimate 2000
series. The usual advantages of the hydraulic drive system are that it provides the robot
with greater speed and strength. The disadvantages of the hydraulic drive system are
that it typically adds to the floor space required by the robot, and that a hydraulic
system is inclined to leak on which is a nuisance.

This type of system can also be called as non-air powered cylinders. In this system, oil is
used as a working fluid instead of compressed air. Hydraulic system need pump to
generate the required pressure and flow rate. These systems are quite complex, costly
andrequire maintenance.

2. Electric drive:-

Electric drive systems do not generally provide as much speed or power as hydraulic
systems. However, the accuracy and repeatability of electric drive robots are usually
better. Consequently, electric robots tend to be smaller. Require less floor space, and their
applications tend toward more precise work such as assembly.

In this System, power is developed by an electric current. It required little

maintenance and the operation is noise less.

3. Pneumatic drive:-

Pneumatic drive is generally reserved for smaller robots that possess fewer degrees
offreedom (two- to four-joint motions).

In this system, air is used as a working fluid, hence it is also called air-powered cylinders.
Air is compressed in the cylinder with the aid of pump the compressed air is used to
generate the power with required amount of pressure and flow rates.

Applications of robots:-
Present Applications of Robots:-

(i) Material transfer applications

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(ii) Machine loading and unloading
(iii) Processing operations like,

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 (a) Spot welding

(b) Continuous arc welding

(c) Spray coating
(d) Drilling, routing, machining operations
(e) Grinding, polishing debarring wire brushing

(g) Laser drilling and cutting etc.

(iv) Assembly tasks, assembly cell designs, parts mating.
(v) Inspection, automation.

Future Applications of Robots:-

The profile of the future robot based on the research activities will include the following,

(i) Intelligence

(ii) Sensor capabilities

(iii) Telepresence

(iv) Mechanical design

(v) Mobility and navigation (walking machines)
(vi) Universal gripper
(vii) Systems and integration and networking

(viii) FMS (Flexible Manufacturing Systems)

(Ix) Hazardous and inaccessible non-manufacturing environments

(x) Underground coal mining

(xi) Fire fighting operations
(xii) Robots in space
(xiii) Security guards
(xiv) Garbage collection and waste disposal operations

(xv) Household robots

(xvi) Medical care and hospital duties etc.

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Classification of Robots (or) Classification by co-ordinate system and

control system:-Co-ordinate systems:-

Industrial robots are available in a wide variety of sizes, shapes, and physical configurations.
The vast majority of today’s commercially available robots possess one of the basic
configurations:
I. Polar configuration

2. Cylindrical configuration
3. Cartesian coordinate configurable
4. Jointed-arm configuration

1. Polar configuration:-

The polar configuration is pictured in part (a) of Fig. It uses a telescoping arm that can be
raised or lowered about a horizontal pivot The pivot is mounted on a mta6ng base These
various joints provide the robot with the capability to move its arm within a spherical
space, and hence the name “spherical coordinate” robot is sometimes applied to this type.
A number of commercial robots possess the polar configuration.

2. Cylindrical configuration:-

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The cylindrical configurable, as shown in fig, uses a vertical column and a slide that can be
moved up or down along the column. The robot arm is attached to the slide so that it cm
he moved radially with respect to the column. By routing the column, the robot is capable
of achieving a work space that approximation a cylinder.

3. Cartesian coordinate configurable:-

The cartesian coordinate robot, illustrated in part Cc) of Fig, uses three perpendicular
slides to construct the x, y, and z axes. Other names are sometimes applied W this
configuration, including xyz robot and rectilinear robot, By moving the three slides relative
to one another, the robot is capable of operating within a rectangular work envelope.

4. Jointed-arm configuration:-

The jointed-arm robot is pictured in Fig. Its configuration is similar to that of the human
arm. It consists of two straight components. Corresponding to the human forearm and
upperarm, mounted on a vertical pedestal. These components are connected by two
rotary joints corresponding to the shoulder and elbow.
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Control systems:-
With respect to robotics, the motion control system used to control the movement of
theend-effector or tool.

1. Limited sequence robots (Non-servo)

2. Playback robots with point to point (servo)

3. Play back robots with continuous path control,

4. Intelligent robots.

Limited sequence robots (Non-servo):-

Limited sequence robots do not give servo controlled to inclined relative positions of the
joints; instead they are controlled by setting limit switches & are mechanical stops. There is
generally no feedback associated with a limited sequence robot to indicate that the desired
position, has been achieved generally thin type of robots involves simple motion as pick &
place operations.

Point to point motion:-

These type robots are capable of controlling velocity acceleration & path of
motion, from the beginning to the end of the path. It uses complex control programs,
PLC’s (programmable logic controller’s) computers to control the motion.

The point to point control motion robots are capable of performing motion cycle that
consists of a series of desired point location. The robot is tough & recorded, unit.

Continuous path motion:-

In this robots are capable of performing motion cycle in which the path
followed by the robot in controlled. The robot move through a series of closely
spacepoint which describe the desired path.

Ex:- Spray painting, arc welding & complicate assembly operations.

Intelligent robots:-
This type of robots not only programmable motion cycle but also interact with its
environment in a way that years intelligent. It taken make logical decisions based on sensor
data receive from the operation.

There robots are usually programmed using an English like symbolic language
not like a computer programming language.

Precision of movement (or) parameters of robot:-

The preceding discussion of response speed and stability is concerned with the
dynamicperformance of the robot. Another measure of performance is precision of the
robot's movement. We will define precision as a function of three features:
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1. Spatial resolution
2. Accuracy

3. Repeatability

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These terms will be defined with the following assumptions.

1) The definitions will apply at the robot’s wrist end with no hand attached to the wrist.
2) The terms apply to the worst case conditions, the conditions under which the robot's precision will be at its
wont. This generally means that the robot’s arm is fully extended in the case of a jointed arm or polar
configurable.
3) Third, our definitions will he developed in the context of a point-to-point robot.

1. Spatial resolution:-

The spatial resolution of a robot is the smallest increment of movement into which the robot can
divide its work volume. Spatial resolution depends on two factors: the system's control resolution and the
robot's mechanical inaccuracies. It is easiest to conceptualize these factors in terms of a robot with 1 degree
of freedom.

2. Accuracy:-

Accuracy refers to a robot's ability to position its wrist end at a desired target point within the work
volume. The accuracy of a robot can be denned in terms of spatial resolution because the ability to achieve a
given target point depends on how closely the robot can define the control increments for each of its joint
motions.

3. Repeatability:-

Repeatability is concerned with the robot's ability to position its wrist or an end effector attached to its
wrist at a point in space is known as repeatability. Repeatability and accuracy refer to two different aspects of
the robot’s precision. Accuracy relates to the robot's capacity to be programmed to achieve a given target
point. The actual programmed point will probably be different from the target point due to limitations of
control resolution Repeatability refers to the robot’s ability to return to the programmed point when
commanded to do so.

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