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Chaapter-8 INDUSTRIAL ROBOTICS 7th Semester Mechanical Engineering CIM and Automation (06ME72) Chaapter-8 INDUSTRIAL ROBOTICS According to RIA (Robotics Industries Association) the definition of robot is “An industrial robot is a reprogrammable, multifunctional manipulator designed to move materials, parts, tools or special devices through variable programmed motions for the performance of a variety of tasks”. Over view of robots and future applications The four basic components of the robot system are o Manipulator o Sensors o Controller o Power conversion unit External power unit Teach Robot Computer Manipulator Pendent Controller Program Sensors storage disk / Internal / tape External Block diagram of an industrial robot HAREESHA N G Lecturer D B I T, Bangalore 1 7th Semester Mechanical Engineering CIM and Automation (06ME72) Manipulator: - The manipulator consists of a series of rigid members, called links, connected by joints. Motion of a particular joint causes subsequent links attached to it to move. The axes of motion of the robot arm can be either rotary or linear. The motion of the joint is accomplished by an actuator mechanism. The joints can be actuated by electric, hydraulic or pneumatic methods. The manipulator itself has three divisions a. The major linkages -- links like arm, shoulder and elbow, these link pairs grossly position the manipulator in space. The main frame is known as the “arm”. It consists of a sequence of mechanical links connected by joints. The function of the joint is to control the motion between the links b. The minor linkages – wrist components, these are associated with the fine positioning of the end effector i.e. they provide the ability to orient the end effector once the major linkages bring the manipulator close to the desired position. A typical wrist includes three joints, which provide three motions of roll, pitch and yaw. c. The end effector -- gripper or tool, it is mounted on the tool plate. It consists of particular mechanism needed at the end of the robotic arm to perform a particular task. Each of the joints of both arm and the wrist provides for one degree of freedom of motion of the robot end effector. It may be a tool, if the function is drilling or welding. It may be a gripper if the function is pick and place the objects. Sensors : - It is necessary to know the state of each joint (position, velocity and acceleration) for proper control of the manipulator. A sensory device must be incorporated into the joint- link pair to achieve proper control. Usually sensor is connected to the actuator’s shaft. Sensory devices may monitor position, speed, acceleration or torque. Touch and tactile sensors are used in grippers to gain information about whether the object is grasped or not. Vision sensor (TV camera, associated electronics and control) is used to locate a particular object in its field of view. Once found, it relays the coordinate of the object to the robot’s controller so that the robot can position its gripper over the object in order to pick it up. Controlle r: - The controller provides the intelligence to cause the manipulator to perform in the manner described by its user. The controller consists of: A memory to store data defining the positions (angles and lengths associated with the joints) of where the arm is to move and other information related to the proper sequencing of the system A sequencer that interprets the data stored in the memory and then utilizes the data to interface with other component of the controller. A computational unit that provides the necessary computations to aid the sequencer. An interface to obtain the sensory data into the sequencer. An interface to transfer sequencer information to the power conversion unit so that actuators can eventually cause the joints to move in the desired manner. An interface to ancillary equipment (like motors, valves and condition of limit switches) HAREESHA N G Lecturer D B I T, Bangalore 2 7th Semester Mechanical Engineering CIM and Automation (06ME72) Control unit for the user to use in order to demonstrate positions, to define the sequence of operations and control of the robot. (Control panel, teach pendent and simulator) Generally a computer is used as a controller in robots. It performs the task of controlling the robot with the help of specific software. Power conversion unit : - The power conversion unit contains the components necessary to take a signal from the sequencer (digital or analog) and convert it into a meaningful power level so that the actuators can move. Ex. For electric drive robots- electronic power amplifiers and power suppliers. For Hydraulic drive robots – compressor and control valves Classification and structure of Robotic system The classification of robot system can be done in many ways 1. According to Geometric configuration Cartesian Cylindrical Polar Jointed arm horizontal Jointed arm vertical Pendulum arm Multiple-joint arm 2. According to degrees of freedom: 3 Degrees of freedom 4 Degrees of freedom 6 Degrees of freedom 3. According to Drive Method: Electric drive Hydraulic drive Pneumatic drive 4. According to Control system : Open Loop System Closed Loop System 5. According to Programming Method On-line programming Off-line Programming 6. According to Intelligence level Operating Robot Sequence Control Robot (Fixed and Variable) Play back Robot (PTP and CP) Intelligent Robot 7. According to Function Assembly robot Welding robot Material Handling robot Painting robot 8. According to Application Education robot Industrial robot Military robot Marine robot HAREESHA N G Lecturer D B I T, Bangalore 3 7th Semester Mechanical Engineering CIM and Automation (06ME72) Space research robot Domestic robot 9. According Drive Transmission: Direct drive Indirect drive 10. According to purpose Single Purpose Multi Purpose Special purpose 11. According to Mobility: Stationary robot Mobile robot 12. According to path control system Point to Point Point-to-Point coordinated path Continuous path Work volume: - It refers to the space within which the robot can manipulate its wrist end. Work volume is determined by the following physical characteristics of the robot. The robot’s physical configuration - Determines the shape of the work volume The sizes of the body, arm and wrist components – Determines the size of the work volume The limits of the robot’s joint movements. – Determines the size of the work volume Horizontal Stroke Swing Vertical stroke Vertical Forward stroke and Backward stroke Rectangular work volume Cylindrical work volume 2.2 Robot Geometrical Configuration Configuration Work Volume Cartesian Rectangular Cylindrical Cylindrical Polar Spherical Joint-arm horizontal –axes Spherical HAREESHA N G Lecturer D B I T, Bangalore 4 7th Semester Mechanical Engineering CIM and Automation (06ME72) Joint-arm vertical-axes Cylindrical Pendulum arm Partial spherical Multiple-joint arm Spherical Cartesian or Rectangular co-ordinate Robots: The main frame of Cartesian/Rectangular coordinate robots has three linear axes of motion or coordinates. It has equal and constant resolution in all axes of motion throughout the work volume of the robot arm. It cannot reach objects on the floor. It has a rectangular work volume. Cartesian robot and Gantry robot with its work volume. Advantages:- 1. The linear movements allows for simpler controls. 2. These robots have high degree of mechanical rigidity, accuracy and repeatability due to their structure (spatial resolution is constant in all axes) 3. Large pay-load capacity. 4. Work-Volume region can be expanded easily. Disadvantages:- 1. The movement is limited to one direction at a time hence slower than other robots. 2. The robots cannot reach objects on the floor. 3. Large floor space for size of work-volume (Gantry) Applications:- Pick-and-place operations. Welding. Inspection. Surface finishing. Nuclear material handling Water Jet cutting. Loading of CNC Machines. Assembly and subassembly (St. Movements) Cylindrical coordinate Robots:- The main frame of cylindrical robot consists of two linear axes of motion and a rotary motion at the base. The resolution of the cylindrical robot is not constant and depends on the distance between the column and the gripper along the horizontal arm. It has inferior dynamic performance. Its work volume is hollow cylinder. HAREESHA N G Lecturer D B I T, Bangalore 5 7th Semester Mechanical Engineering CIM and Automation (06ME72) Advantages: 1. These robots are fast compared to Cartesian robots. 2. It is capable of carrying large payloads. 3. It has a good access to reach front and sides. 4. It has large work volume than rectangular robot. Disadvantages: 1. The overall mechanical stability is lower than Cartesian robot. 2. Repeatability and Accuracy are lower in the rotary movement and resolution is not constant. 3. It is not possible to reach above itself and around the obstacles. Applications: • Assembly • Coating • Conveyor pallet transfer • Die casting • General material handling • Foundry and forging • Investment molding • MACHINE loading and unloading • Meat packing • Pick and place Spherical or Polar coordinate Robots:- Spherical or Polar coordinate Robots consists of two rotary motions and one linear motion. It resembles turret of a military tank. It consists of a rotary base, an elevated pivot and a telescoping arm which moves in and out. The work envelope is a thick spherical shell. It has low resolution which varies with the arm length. Spherical or Polar coordinate Robot with work volume. Advantages: 1. It has better mechanical flexibility 2. It has easy access to points below base level. 3. These robots have good pay load capacity 4. Fast operation Disadvantages: 1. Overall mechanical stability is low 2. Low resolution compared to other two 3. Cannot reach around Obstacles Applications: • Glass handling • Heat treatment • Injection molding • MACHINE loading • Parts cleaning • Material handling • Stacking Jointed Arm Coordinate Robots:- HAREESHA N G Lecturer D B I T, Bangalore 6 7th Semester Mechanical Engineering CIM and Automation (06ME72) There are two types in this category 1.
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