Automation and robotics

brief about automation and its types. Definition of Robotics and types of Robotics and how they are classified

1. AUTOMATION AND ROBOTICS BALAJI.K

2. AUTOMATION Automation can be explained as a process to create, control and monitor the applications of technology. Automation is the process of handling the operation of equipment such as processors, machinery, stabilization of ships, aircraft, boilers and many applications with minimum human efforts.

3. REASONS FOR AUTOMATION To increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or eliminate routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead lime To accomplish. processes that cannot be done manually To avoid the high cast of not automating

4. CLASSIFICATION OF AUTOMATION Base on hardware and software. Three main classification are : 1.Fixed (hard) automation – involve hardware only 2.Programmable automation – involve software only 3.Flexible automation – involve hardware and software

5. FIXED AUTOMATION Is a machine refer to totally hardware that can operate automatically without human interference. Examples – door with spring load – watch , gravity machine, water-wheel, animal/wind – wheel. Used in low and medium production manufacturing. Special machine for production process efficiency at higher number/rate of product. An Automatic machine and numerical control machine is an example of fixed automation because the inner construction and function can’t be change.

6. PROGRAMMABLE AUTOMATION Combination of hardware (machine) and software (programmable). Example – Production line assemble, Air condition, screen saver, traffic light, radiator Used when rate of production are small and there is a variation at the product. An equipments can be easily change their setup according to the product configuration needs after the first production is finish. More different/variety and unique product can be produce economically in small amount. One set of program to control the whole operation of product.

7. FLEXIBLE AUTOMATION Also known as “Flexible Manufacturing System(FMS)” and “Computer Integrated Manufacturing(CIM)”. Combination of hardware and software ( same as programmable) but can easily changed during the operation without waiting the whole operation completed. It can be programmed for different configuration product either at the beginning, middle or end of the production according to the production changes. But usually configuration product are limited compare to the programming automation. Allows combination of certain system. In flexible automation, different product can be made in the same time at the same manufacture system. Flexible Automation System mostly consist of series of workstation that is connected to the material operation and storage system, assembly line and control of operation of work by using a program for a different work station. Example – Automobile assemble line.

8. APPLICATIONS Major departments where automation is used in industries are: Transporting Working Packaging

9. ROBOTICS

10. ROBOTICS COINED Robot (a Slavic word for worker) was first introduced in 1921 in a play by the Czech playwright, Karel Čapek . The use of the word Robot was introduced into his play R.U.R. ( Rossum's Universal Robots) which opened in Prague in January 1921. The word 'robotics' was first used in Runaround, a short story published in 1942, by Isaac Asimov (born Jan. 2, 1920, died Apr. 6, 1992). I, Robot, a collection of several of these stories, was published in 1950.

11. ROBOTICS TIMELINE 1922 Czech author Karel Capek wrote a story called Rossum’s Universal Robots and introduced the word “ Rabota ”(meaning worker) 1954 George Devol developed the first programmable Robot. 1955 Denavit and Hartenberg developed the homogenous transformation matrices 1962 Unimation was formed, first industrial Robots appeared. 1973 Cincinnati Milacron introduced the T3 model robot, which became very popular in industry. 1990 Cincinnati Milacron was acquired by ABB

12. DEFINITION Defined by Robotics Industry Association (RIA) as “A re-programmable, multifunctional manipulator designed to move material, parts, tools or specialized devices through variable programmed motion for a variety of tasks” Law of Japan states that a robot is “All purpose machine equipped with a memory device (for handling) capable of replacing human labour for the automatic performance of tasks” Robert Schilling defines a robot as “a software controlled mechanical device that uses sensors to guide one or more of its end effectors through various programmed motions in a work space in order to manipulate physical objects”

13. CLASSIFICATION OF ROBOT Possible classification schemes are base on : 1.Anatomy (Body) 2.Control of movement 3.Kinematics /geometry structure 4.Energy source 5.Authority body 6.Industry/non industry 7.Technology level 8.Based on design 9.Application/job 10.By number of degree of freedom (gripper configuration)

14. BASED ON ANATOMY Arm Two arm Arm and leg Arm, leg and face Finger 2 fingers 3 fingers 5 fingers

15. BASED ON CONTROL OF MOVEMENT a) Limited sequence Robot b ) From point to point Robot c ) Continues Robot

16. LIMITED SEQUENCE ROBOT The movement of robot is limited in linear direction. Use of mechanical stop and limit switch to control the movement of manipulator. Difficult to fixed the stop point. The stop point on the path cannot be changed easily (only one stop point on a single path between the 2 point) Mechanical stop give a fixed position stop (repetition +/- 0.5mm). A dvantages : the cost is cheap 25% to 50%. Compare to others. This type of robot are used for casting, pressing and fixed movement. The robot not sophisticated. Disadvantages : 1) Control and movement are limited. 2) used longer time for setting machine.

17. POINT TO POINT ROBOT The movement of robot is in linear direction. Can stop the axes at any point through the path. At the end of the tool will be programmed at sequence discrete points in the work space. No control for movement speed. Move at different speed and distance. Axes can reach the destination and stop before another axes. Usually used in industry environment where amount of work is zero and consistency between the movement of the outside object like ”conveyer” not needed.

18. CONTINUES CONTROL ROBOT The movement of robot is in any direction continuously. For complex workstation environment. Position and end tool must be controlled and Follow 3 dimension (3-D) space. Speed of movement action is different. Example : paint spray, welding works and application.

19. BASED ON KINEMATICS COORDINATE (MOVEMENT) Work space can be defined as space that robot manipulate (MOVE) a) C artesian Coordinate / Movement ( x,y,z ) b) Cylindrical Movement (Ø, r, z) c)Spherical Movement (Ø, R, Ø) d)SCARA Movement (Ø, Ø, Z) e)Revolute Movement (Ø, Ø, Ø)

20. BASED ON ENERGY SOURCES It is the energy source that makes the actuator or robot joint to move. Normally there is four categories : 1 ) Electrical Robot 2 ) Hydraulic Robot 3 ) Pneumatic Robot 4 ) Mechanical Robot

21. ELECTRICAL ROBOT Used electrical energy to move the motor. DC stepper motor, DC servomotor or AC servomotor , solenoid or plunger at the segment joint. Advantages : - Very popular, - low price, - clean, - silent and - easy to assemble. Avoided backlash ( slow response ) Easy to control or brake the circuit/operation

22. HYDRAULIC ROBOT Used hydraulic energy to move the actuator. Advantages :More powerful and response more faster then electrical robot. Used to manipulate high speed in range of huge payload. Disadvantages : Less clean and cleanliness is a important feature in assembling application.

23. PNEUMATIC ROBOT Both electrical and hydraulic robot usually use end tool from pneumatic power. Limited for robot network. In general, this robot is more cheaper and simple. But it quite hard to control and perform less dynamic then other robot.

24. BASED ON AUTHORITY BODY Japan Industrial Robot Association (JIRA) – divide into 6 class. Robotics Institute of America (RIA) – divide into 4 class (only consider class 3-6 as robots ) Association Francaise de Robotique (AFR) – divide into 4 class ( A to D )

25. JIRA (Japan Industrial Robot Association ) Class 1: manual handling device – a device with several DOF’s actuated by the operator. Class 2: fixed sequence robot – similar to fixed automation . Class 3: variable sequence robot – similar to programmable automation. Class 4: playback robot – the human performs tasks manually to teach the robot what trajectories to follow. Class 5: numerical control robot – the operator provides the robot with the sequence of tasks to follow rather than teach it. Class 6: intelligent robot – a robot with the means to understand its environment, and the ability to successfully complete a task despite changes in the surrounding conditions where it is performed.

26. RIA ( Robotics Institute of America ) Class 3: variable sequence robot – similar to programmable automation. Class 4: playback robot – the human performs tasks manually to teach the robot what trajectories to follow. Class 5: numerical control robot – the operator provides the robot with the sequence of tasks to follow rather than teach it. Class 6: intelligent robot – a robot with the means to understand its environment, and the ability to successfully complete a task despite changes in the surrounding conditions where it is performed.

27. AFR (The Association Francaise de Robotique) Type A: Handling devices with manual control to telerobotics Type B: Automatic handling devices predetermined cycles Type C: Programmable, servo controlled robot with continuous point-to-point trajectories Type D: Same as type C, but with the capability to acquire information from its environment

28. BASED ON INDUSTRIAL / NON INDUSTRIAL Non industrial robot use in home,school,field , for personal,education , army,medical,hobby , showcase and promote Industrial robot in manufacturing, welding, cutting, formatting, assembling, heavy works,painting

29. NON-INDUSTRIAL ROBOT Example of non-industrial robot : Micro flying copter nuvo asimo REUTERS PIC 2003 Robot WL-16

30. INDUSTRIAL ROBOTS Industrial robots is more complex. Consist of some subsystem that operate together to perform function that have been determined. Main importancy in the subsystem for the robot is kinematic, control system and driver. Robots are used in a wide range of industrial applications. The earliest applications were in materials handling, spot welding, and spray painting. Robots were initially applied to jobs that were hot, heavy, and hazardous such as die casting, forging, and spot welding.

31. There are many different device types that perform similar functions. For example: –Manual manipulator. A manipulator worked by a human operator. –Fixed-sequence robot. A manipulator that performs successive steps of a given operation; its instructions cannot be easily changed. –Variable-sequence robot. A manipulator similar to the fixed-sequence robot, but its instructions can be changed easily.

32. – Playback robot. A manipulator that can reproduce operations originally executed under human control. –Numerically controlled (NC) robot. A manipulator that can perform a sequence of movements which is communicated by means of numerical data. –Intelligent robot. A robot that can itself detect changes in the work environment by means of sensory perception and adjust its movements accordingly.

33. BASED ON MOVEMENT The robot classification based on movement can be divided into two class : 1. Static Robot (still) 2. Dynamic Robot (moving)

34. STATIC ROBOT These robots just stand at it’s place and still moving to do work with it’s arm. These robot known as automatic control. Doing same work reputably. For example : screw installation. These robot are suitable to do task that is bored in the industrial. Can be reprogrammed to do other task.

35. Example of Stationary Robots : 1. Forging robot. 2. Assembling installation. 3. Blocking rod for car park. 4. Robotic Arm

36. DYNAMIC ROBOT The base of robot can travel along the track or rail either on the floor or overhead mount. This robot work at several place and can move/walk by itself. The movement using wheel, foot or rail. The tasks that have been done by robot needs to make it move from one place to another place. The workspace maybe danger , difficult or wide. Dynamic robot is divide into 3 types : 1. Walking robots. 2. Rolling robots. 3. Sliding robots.

37. BASED ON TECHNOLOGY This classification same as computer. According to the level of technology used. The factor are number of axes, payload, cycle time, accuracy, control and actuation. The tree levels of technology are : 1. Low level technology 2. Medium level technology 3. High level technology

38. LOW TECHNOLOGY ROBOTS Used in industrial for simple job like machine loading and unload ( doing same sequence of job in a particular time) . The task can’t be change during working - fixed control. The axes of movement are between two to four Non servo controlled robots. Need mechanical stop at the end of each axes of travel. The axes motion are generally up/down, reach and rotate gripper. Stop after finish the job/task and repeat back .

39. Payload (load capacity) that manipulator can position is at the end of effectors this weight is measure at the center of wrist flange of the robot. The maximum of weight can range from 3-13.6 Kg. The time taken for robot to move from one location to other (cycle time) depend on payload and length manipulator arm must travel. For low technology robot have very high cycle time from 5–10 second. The accuracy ( how closely a robot can position its payload to a given programmed point) related to the repeatability for LTR is very high (0.050 – 0.024 millimetre .

40. MEDIUM TECHNOLOGY ROBOTS Primarily for picking and placing and loading and unloading More sophisticated than low-technology robots (more movement) Have a large work cell. Its mean axis travel is grater Have a three, five to six axes (Degree of freedom) of motion (up/down, reach, rotation, band, roll, yaw (rotational) Have a grate payload able to handle weight from 68 -150 kg.

41. The cycle time form reach axis from 25 to 65 centimeter take 1secont to execute . Rotation 150 cm/sec. The accuracy is not as good as LTR because of increased number of axes Capable to repeating their position data to meet the requirement of the job. For 0.2 mm to 1.3mm Microprocessor used to control the robot system Can be control by manually, all the position and movement can be recorded and stored

42. HIGH TECHNOLOGY ROBOTS Used for multi purpose job such as material handling, press, transpiring, painting, sealing, spot welding and arc welding. Have an axes form six to nine to 16 or more almost same as human movement The payload about the same ad medium-technology robot around 68-150 kg. The cycle time also same as MTR in additional every axes have their own cycle time. The accuracy and repeatability is the garters, by used of feed back data from 1-0.4 mm. Can perform well although the object is not at the correct position by use of sensor and microprocessor high bit 16-31 bps ).

43. COMPARISON OF PAYLOAD

44. ARTIFICIAL INTELLIGENCE Officially born in 1956 at Dartmouth University – Marvin Minsky , John McCarthy, Herbert Simon Intelligence in machines Internal models of the world Search through possible solutions Plan to solve problems Symbolic representation of information Hierarchical system organization Sequential program execution

45. BASED ON DESIGN First Generation Robot Fixed sequence program Take and placed task – Blind and deaf dan ( no sense ) Less ability to make decision. Bight control is open. Upgrade : ( Sophisticated robot ) the ability will be upgraded. Some action control by sense. Can know when something happen but cannot rectify. Closed control bight have been introduced.

46. Second generation robot: Have a coordinate control between manipulator and eye sensor ( under progress testing) New ability : Mobility Voice recognization command. Have touch foresee. Multi arm action with hand to hand coordination arm that is flexible. Microprocessor intelligence Multi robots in crowd-swarm action. Can make decision.

47. Third generation robot Move faster, more robustly Have an AI (Non-physical, “disembodied thinking) to operate on their own for example discrete part assembly Make a decision to commit a deference job/task Only need a few information to do their job/task. Be able to learn a new thing without reprogram Cybernetics - Biologically inspired robot control New types of robot control: Reactive, hybrid, behavior-based

48. BASED ON JOB OR TASK There is various job or task that can be done by a robot such as : 1. Bomb destroyer 2. Searching and communicate 3. Searching victim in disaster 4. Seaching for Information - temperature - enemy - on planet Mars 5. Simple assembling – push, pull 6. Lifting and place 7. Entertain/ Hobby/ Friend/ to serve ( waiter) / player 8. Observe and guard (security guard) 9. Assembling line in manufacturing There is many ways to categorize the robot . Some are based on job or task. Some are based on work

49. ROBOT COMPONENTS 1. Manipulator or Rover : Main body of robot ( Links, Joints, other structural element of the robot ) 2. End Effecter : The part that is connected to the last joint hand) of a manipulator. 3. Actuators : Muscles of the manipulators (servomotor, stepper motor, pneumatic and hydraulic cylinder). 4. Sensors : To collect information about the internal state of the robot or To communicate with the outside environment.

50. 5. Controller : Similar to cerebellum. It controls and coordinates the motion of the actuators. 6. Processor : The brain of the robot. It calculates the motions and the velocity of the robot’s joints, etc. 7. Software : Operating system, robotic software and the collection of routines.

51. ROBOT COMPONENTS EXAMPLES Main components are : Manipulator : Main body (Links, Joints etc ) End effector : Welding Torch, Paint spray gun etc Actuators : servo motors,stepper motors,cylinders etc Sensors : Vision, Touch, Speech synthesizers etc Controller : receives data from PC and controls the actuators Processor: calculates motions of joints@speeds Software : OS, Appliaction s/w

52. SENSORS Sensors provide awareness of the environment by sensing things . Sensors are the core of robots . It is the system that alerts the robots.. Sensing can be in different forms like- Light Sound Heat Chemicals Force Object proximity Physical orientation/position Magnetic & Electric Fields Resistance

53. END EFFECTOS In robotics, an end effector is the device at the end of a robotic arm, designed to interact with the environment. End effectors may consist of a gripper or a tool. The gripper can be of two fingers, three fingers or even five fingers.

54. ACTUATORS Locomotion Manipulation

55. ACTUATORS Locomotion- Legs Wheels Other exotic means

56. ACTUATORS Manipulations- Degrees of freedom independently controllable components of motion Arms convenient method to allow full movement in 3D more often used in fixed robots due to power & weight even more difficult to control! due to extra degrees of freedom Grippers may be very simple (two rigid arms) to pick up objects may be complex device with fingers on end of an arm probably need feedback to control grip force

57. Hydraulic Motor Stepper Motor Pneumatic Motor Servo Motor Pneumatic Cylinder DC Motor

58. CONTROLLER Provide necessary intelligence to control the manipulator/mobile robot Process the sensory information and compute the control commands for the actuators to carry out specified tasks

59. THANK YOU