BRE 501 Industrial

Robotics
Introduction
 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.
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
are processed 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.

(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 in
interconnecting work stations with material handling and
storage system.
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 mixtures of 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
(ii) To Decrease the Cost of Labour
(iii) To Minimize the Effect of Shortage of Labour
(iv) To Obtain High Quality of Products
(v) To Decrease the Manufacturing Lead Time
(vi) To upgrade the Safety of Workers.
Need for using robotics in industries:-
Industrial robot plays a significant role in automated
manufacturing to perform different kinds of applications.
1. Robots can be built a performance capability superior to those
of human beings. In terms of strength, size, speed, accuracy…
etc.
2. Robots are better than humans to perform simple and
repetitive tasks with better quality and consistence’s.
3. Robots do not have the limitations and negative attributes of
human works .such as fatigue, 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.
 Robot Anatomy
Anatomy means the scientific study of the structure of

human or animal bodies.

The robots are classified as:

Programmable/Reprogrammable purpose robots

Man controlled robots

Intelligent robots
Robots are used in manufacturing and assembly units
such 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. System integration and networking

4. Mechanical design

5. Mobility and navigation

6. Universal gripper

It has the following objectives:

1. To increase productivity

2. Reduce production life

3. Minimize labour requirement

4. Enhanced quality of the products

5. Minimize loss of man hours, on account of accidents.

6. Make reliable and high speed production.
Types of drive systems:-

1. Hydraulic drive

2. Electric drive

3. Pneumatic drive

Hydraulic drive:-
Hydraulic drive and electric drive arc the two main types of

drives used on more sophisticated robots.

Hydraulic drive is generally associated with larger robots.

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 and require
maintenance.
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.
Pneumatic drive:-
Pneumatic drive is generally reserved for smaller robots.
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
(ii) Machine loading and unloading
(iii) Processing operations like:
(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) Systems and integration and networking
(iv) Mechanical design
(v) Mobility and navigation (walking machines)
(vi) Universal gripper
(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.
Complete