Automation, Production Systems, and Computer-

Integrated Manufacturing

Lecture 7:
Automation and Control Technologies
(Part III)

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any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 1
Edition, by Mikell P. Groover.
 Robot Anatomy and Related Attributes

o An industrial robot is defined as “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.
o Some of the qualities that make industrial robots commercially and technologically important:
• Robots can be substituted for humans in hazardous or uncomfortable work environments.
• A robot performs its work cycle with a consistency and repeatability that cannot be attained by humans.
• Robots can be reprogrammed. When the production run of the current task is completed, a robot can be
reprogrammed and equipped with the necessary tooling to perform an altogether different task.
• Robots are controlled by computers and can therefore be connected to other computer systems to
achieve computer integrated manufacturing.
o The robot’s anatomy affects its capabilities and the tasks for which it is best suited.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 2
Edition, by Mikell P. Groover.
 Joints and Links

o Links are the rigid components of the robot manipulator.

o The joints are to provide controlled relative movement between the input links and the output links.
o The five joint types are:
• Linear joint (type L joint).
• Orthogonal joint (type O joint).
• Rotational joint (type R joint).
• Twisting joint (type T joint).
• Revolving joint (type V joint, V from the “v” in revolving).

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 Common Robot Configurations
A robot manipulator can be divided into two sections: a body-and-arm assembly and a wrist assembly.
o Body-and-Arm Configurations: there are 5 * 5 * 5 = 125 possible combinations of joints that could be used
to design the body-and-arm assembly for a three-axis manipulator, and configurations are commonly
available in commercial industrial robots are: Articulated robot, Polar configuration, SCARA. Cartesian,
Coordinate robot, and Delta robot.
o Wrist Configurations.
• The robot’s wrist is used to establish the orientation of the end effector.
• Robot wrists usually consist of two or three joints that almost always consist of R and T type rotary joints.
o Work Volume: is defined as the three-dimensional space within which the robot can manipulate the end of its
wrist.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 4
Edition, by Mikell P. Groover.
Joint Drive Systems
Robot joints are actuated using any of three types of drive systems: (1) electric, (2) hydraulic, or (3) pneumatic.

Sensors in Robotics
Sensors used in industrial robotics can be classified into two categories:
o Internal sensors are components of the robot and are used to control the positions and velocities of the robot
joints.
o External sensors are external to the robot and are used to coordinate the operation of the robot with other
equipment in the cell.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 5
Edition, by Mikell P. Groover.
 Robot Control Systems
o The actuations of the individual joints must be controlled in a coordinated fashion for the manipulator
to perform a desired motion cycle.
o Robot controllers can be classified into four categories:
• Limited-Sequence Control: It can be utilized only for simple motion cycles, such as pick-and-
place operations.
• Playback with Point-to-Point Control: Playback control means that the controller has a
memory to record the sequence of motions in a given work cycle, as well as the locations and
other parameters (such as speed) associated with each motion, and then to subsequently play
back the work cycle during execution of the program.
• Playback with Continuous Path Control: A playback robot with continuous path control is
capable of greater storage capacity, and interpolation calculations.
• Intelligent Control: exhibits behavior that makes it seem intelligent.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 6
Edition, by Mikell P. Groover.
 End Effectors
The end effector is usually custom-engineered and fabricated for each different application.
o Grippers
Grippers are end effectors used to grasp and manipulate objects during the work cycle.
• Mechanical grippers, consisting of two or more fingers that can be actuated by the robot controller to open and
close on the work part .
• Vacuum grippers, in which suction cups are used to hold flat objects.
• Magnetized devices, for holding ferrous parts.
• Adhesive devices, which use an adhesive substance to hold a flexible material such as a fabric.
• Simple mechanical devices, such as hooks and scoops.
• Dual grippers, consisting of two gripper devices in one end effector for machine loading and unloading.
• Interchangeable fingers that can be used on one gripper mechanism.
• Sensory feedback in the fingers that provide the gripper with capabilities such as (1) sensing the presence of the
work part or (2) applying a specified limited force to the work part during gripping (for fragile work parts).
• Multiple-fingered grippers that possess the general anatomy of a human hand.
• Standard gripper products that are commercially available, thus reducing the need to custom-design a gripper for
each separate robot application.
o Tools
The robot uses tools to perform processing operations on the work part.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 7
Edition, by Mikell P. Groover.
 Applications of Industrial Robots
The applications of industrial robots can usually be classified into one of the following categories:
Material Handling Applications
o Material Transfer: the robot is to move parts from one location to another.
o Machine Loading and/or Unloading: the robot transfers parts into and/or from a production machine.
Processing Operations
o Spot Welding: two sheet metal parts are fused together at localized points of contact.
o Arc Welding: to provide continuous welds rather than individual spot welds at specific contact points.
o Spray Coating: Spray coating directs a spray gun at the object to be coated.
o Other Processing Applications: Drilling, routing, and other machining processes. Grinding, wire brushing, and similar
operations. Waterjet cutting. Laser cutting.
Assembly and Inspection
o Assembly: involves the combining of two or more parts to form a new entity, called a subassembly or assembly.
o Inspection: to inspect the work that is done.
Economic Justification of Industrial Robots
o Characteristics of Robot Applications. Hazardous work for humans. Repetitive work cycle. Difficult handling for humans.
Multishift operation. Infrequent changeovers. Part position and orientation are established in the work cell.
o Cycle Time and Cost Analysis. 𝑇𝑐 = 𝑇𝑜 + 𝑇ℎ + 𝑇𝑡
where 𝑇𝑐 = cycle time, min/pc; 𝑇𝑜 = time of the actual processing or assembly operation, min/pc; 𝑇ℎ = work part handling time,
min/pc; and 𝑇𝑡 = average tool handling time, min/pc.
©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 8
Edition, by Mikell P. Groover.
 Robot Programming
A robot program is a path in space to be followed by the manipulator, combined with peripheral actions that support the work
cycle.
Leadthrough Programming
The task is taught to the robot by moving the manipulator through the required motion cycle, simultaneously
entering the program into the controller memory for subsequent playback.
Robot Programming Languages
Textual programming languages for robots provide the opportunity to perform the following functions that
leadthrough programming cannot readily accomplish:
• Enhanced sensor capabilities, including the use of analog as well as digital inputs and outputs.
• Improved output capabilities for controlling external equipment.
• Program logic that is beyond the capabilities of leadthrough methods.
• Computations and data processing similar to computer programming languages.
• Communications with other computer systems.
o Motion Programming. Motion programming with robot languages usually requires a combination of textual statements and
leadthrough techniques.
o Interlock and Sensor Commands. The two basic interlock commands used for industrial robots are WAIT and SIGNAL.
Computations and Program Logic. Many robot languages possess capabilities for performing computations and data
processing operations that are similar to computer programming languages.
Simulation and Off-Line Programming
Permits the robot program to be prepared at a remote computer terminal and downloaded to the robot controller for execution
without interrupting production.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 9
Edition, by Mikell P. Groover.
 Robot Accuracy and Repeatability

o Control resolution refers to the capability of the robot’s positioning system to divide the range of the joint into
closely spaced points, called addressable points, to which the joint can be moved by the controller.
o Repeatability is a measure of the robot’s ability to position its end-of-wrist at a previously taught point in the
work volume.
o Accuracy is the robot’s ability to position the end of its wrist at a desired location in the work volume.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 10
Edition, by Mikell P. Groover.
 Discrete Process Control
Discrete process control systems deal with parameters and variables that are discrete and that change values at
discrete moments in time. It can be divided into two categories:
• Logic control, which is concerned with event-driven changes in the system.
• Sequence control, which is concerned with time-driven changes in the system.
Logic Control
A logic control system is a switching system whose output at any moment is determined exclusively by the values
of the current inputs. The basic elements of logic control are the logic gates AND, OR, and NOT.
Sequence Control
A sequence control system uses internal timing devices to determine when to initiate
changes in output variables.
• A timer is a device that switches its output ON or OFF at preset time intervals.
• A counter is a component used to count electrical pulses and store the results of the counting procedure.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 11
Edition, by Mikell P. Groover.
 Ladder Logic Diagrams
o Ladder logic diagram exhibits the logic as well as the timing and sequencing of the system.
o Symbols used in ladder diagrams for the common logic and sequence control components are presented
below.
o The ladder logic diagram is an excellent way to represent the combinatorial logic control problems in which the
output variables are based directly on the values of the inputs.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 12
Edition, by Mikell P. Groover.
 Programmable Logic Controllers
o PLC is a microcomputer-based controller that uses stored instructions in programmable memory to implement
logic, sequencing, timing, counting, and arithmetic functions through digital or analog input/output (I/O)
modules, for controlling machines and processes.
o PLCs are primarily associated with discrete manufacturing industries to control individual machines, machine
cells, transfer lines, material handling equipment, and automated storage systems.
o Advantages to use a PLC rather than conventional relays, timers, counters, and other hardwired control
components:
• Programming the PLC is easier than wiring the relay control panel.
• PLC can be reprogrammed, whereas conventional controls must be rewired.
• PLCs take less floor space than relay control panels.
• Reliability is greater, and maintenance is easier.
• PLC can be connected to computer systems more easily than relays.
• PLCs can perform a greater variety of control functions than relay-based controls.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 13
Edition, by Mikell P. Groover.
 Components of the PLC

The basic PLC components are the following: (1) processor, (2) memory unit, (3) power supply, and (4) I/O
module. (5) a programming device.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 14
Edition, by Mikell P. Groover.
PLC Operating Cycle
o A certain amount of time is required for the PLC processor to execute the user program during one cycle of
operation.
o The typical operating cycle of the PLC, called a scan, consists of three parts: (1) input scan, (2) program scan,
and (3) output scan.
Programming the PLC
o Programming is the means by which the user enters the control instructions to the PLC through the
programming device.
o The most basic control instructions consist of switching, logic, sequencing, counting, and timing.
o Three graphical languages and two text-based languages for programming PLCs:
(1) ladder logic diagrams, (2) function block diagrams, (3) sequential functions charts, (4) instruction list, and (5)
structured text.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 15
Edition, by Mikell P. Groover.
 Personal Computers and Programmable Automation Controllers

o Modern industrial control applications have evolved to include requirements in addition to logic and sequence
control: analog control, motion and servomotor control, arithmetic functions, matrix functions, data processing
and reporting, network connectivity and enterprise data integration.
o Two approaches to address the need for these additional requirements for industrial control: (1) personal
computers and (2) programmable automation controllers.
Personal Computers for Industrial Control
There are two basic approaches used in PC-based control systems: soft logic and hard real-time control.

Programmable Automation Controllers

A PAC is designed to be used in an industrial environment and to interface with the sensors and actuators whose
signals are typically binary, like a conventional PLC, but it also has capabilities that are usually associated with
personal computer applications.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 16
Edition, by Mikell P. Groover.
 Summary of this lecture

o We learnt about the hardware components and control technologies (Part III).
o In the next lecture, we will learn about material handling and identification.

©2015 Pearson Education, Inc., Upper Saddle River, NJ 07458. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in
any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth 17
Edition, by Mikell P. Groover.
 Multidisciplinary
The Control Systems Engineer knowledge & Skill Sets

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