DJM6113

INDUSTRIAL AUTOMATION

CHAPTER 1
INTRODUCTION & BASIC CONCEPTS OF
AUTOMATION

LECTURER:
PUAN NURHANUM BINTI OMAR

STUDENT LEARNING OUTCOMES

At the end of this class, student should be able to:

1.1 Describe the concept of industrial automation.

 Definition of industrial automation.
 State the advantages & disadvantages.
 Identify types of automation.
 Describe the automation in production system.

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 “A robot is a re-programmable, multifunctional machine designed to
manipulate materials, parts, tools, or specialized devices, through
variable programmed motions for the performance of a variety of
tasks."
Robotics Industries Association

"A robot is an automatic device that performs functions normally

ascribed to humans or a machine in the form of a human."
Websters Dictionary

i. Robotics is the study of the design, construction and use of robots.

ii. The science and technology of robot, their design, manufacture, and
application.

iii. Robotics requires a working knowledge of electronics, mechanics and

software, and is usually accompanied by a large working knowledge of
many subjects.

iv. Although the appearance and capabilities of robots vary vastly, all robots
share the features of a mechanical, movable structure under some form of
autonomous control.

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Defined by ISO as an automatically controlled,
reprogrammable, multipurpose manipulator programmable
in three or more axes. The field of robotics may be more
practically defined as the study, design and use of robot
systems for manufacturing.

 The term robot derives from the Czech word robota, meaning forced
work or compulsory service, or robotnik, meaning serf.
 First used to describe fabricated workers in a fictional 1920s play
called Rossum’s Universal Robots by Czech author Karel Capek
(pronounced "chap'ek").
 The term 'robotics' refers to the study and use of robots and was
coined and first used by the Russian-born American scientist and
writer Isaac Asimov (1942). Asimov also created the ‘Three Laws of
Robotics’.
 in the early 1940’s MIT developed a numerically controlled (NC)
milling machine (the first NC machine tool)

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 • A robot may not injure a human being, or, through
inaction, allow a human being to come to harm

• A robot must obey orders given it by human beings, except

where such orders would conflict with the First Law.

• A robot must protect its own existence as long as such

protection does not conflict with the First or Second Law.

Asimov’s Laws of Robotics(1942)

 In 1961 George Devol created his patent for parts transfer machines. Joe
Engelberger teamed with Devol to form Unimation and was the first to
market robots. As a result, Engelberger has been called the 'father of
robotics.’
 The first industrial modern robot - the Unimate - developed by Devol and
Engelberger - was installed at GM (New Jersey) in 1961.

A Unimate employed more

profitably
A Unimate serves Devol and
Engelberger with a cocktail

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  Mobile Robotics moved into its own in 1983 when Odetics
introduced this six-legged vehicle which was capable of
climbing over objects.

 Repetitive tasks that robots  May be cheaper over the

can do 24/7. long term
 Robots never get sick or need  May be able to perform
time off. tasks that are impossible
 Robots can do tasks for humans
 Assisting the handicapped.
 considered too dangerous for
humans.
 Robots can operate
 Equipment to much higher
precision than humans.

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 Exploration
Robots are sent to explore dangerous places that humans are
unable to reach e.g., space mission, exploring volcano,
underwater exploration etc.

 Industry
Robots can do many things faster than humans plus they do not
have to be paid like a human e.g. assembly etc.

 Medicine
- There have been many advances in medical
technology in the recent years due to robots.
- Robots are more accurate & precise than
humans.

 Military & Police

- The military & police forces use robots to go
places where they might be injured or killed.
- They also use robots to find bombs and land
mines.

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  Humanoid robots can help to better understand humans.
 Humanoid robots are robots that are based on the overall
appearance of the human body.
 They can adapt to changes in their environment and themselves
and still reach given goals.

New Techniques
 Walking robots
 Co-operating arms or AGV’s
 Biomedical engineering
 Teleoperation Wheeled mobile robots Legged robots
 Internet robotics
 Micro and nanorobotics

New Applications
 Tele-operated robotics (space, surgery)
 Service robots (teaching, retail, fast food outlets, bank Underwater robots
tellers, garbage collection, security guards, cleaning
vehicles etc…)
 UGV’s and UAV’s for hazardous environments

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 Industrial Robots
 Materials handling
 Welding
 Inspection
 Improving productivity
 Assembly process
 Laboratory applications
 Palletizing & Depalletizing
 Agricultural industry
 Food / bakery products
makings

Materials handling

Feeding the parquet grinding machine with a Handling bottles from the filling machine
pile of parquet blocks. into trays.

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 Materials handling

Arranging packets to be put into cardboard Arranging sacks from filling machine onto a
boxes. conveyor.

Materials handling

Handling particle boards (for furniture), Handling cheese with a vacuum gripper.
placing in cardboard packets.

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 Palletizing & Depalletizing

Palletising of cardboard boxes. Putting tubes into cardboard boxes and the boxes
onto pallets.

Welding

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 Food / bakery products makings

The robot takes the baking plates from the oven The robot unloads the baking plate.
trolley.

 Industry
The production of an economic good or service within
an economy.

 Automation
Automatic control.

 Industrial Automation
Making products under the control of computers and
programmable controllers.

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 Increased throughput or productivity

Improved quality or increased predictability of quality

Improved robustness (consistency), of processes or product

Increased consistency of output

Reduced direct human labor costs and expenses

Install automation in operations to reduce cycle time

Install automation where a high degree of accuracy is required

Replacing human operators in tasks that involve hard physical or

monotonous work

Replacing humans in tasks done in dangerous environments

Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.

Economic improvement (Japan, German, Korea)

Reduces operation time and work handling time significantly

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Causing unemployment and poverty by replacing human labor

Unpredictable/excessive development costs

High initial cost (Capital)

 Feedback control

 Sequential control

 Computer control

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Covers all the major cutting-edge technologies of production
automation and material handling, and how these technologies are
used to construct modern manufacturing systems.

 SME
 Enterprise level / sub contract
 Support raw material
- aluminium
- small part
- screw

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  QA/QC
 Quality, reject
 Part and end product
 Repair & rework, salvage, scrap
 Pass to production line

 Discipline of engineering
- research & development
- process
- machines
- tool & equipment
 Just in time (reduce in process) - kanban
 Lean manufacturing (eliminate waste)
 5S (sorting, straightening, systematic cleaning, standardize, sustain)
 Poka-yoke
 Jig (holding work and for guiding a machine tool to the work)

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 Transfer material from storage to production.

 Transfer product from machine / workplace to another workplace

 Advantages:
- higher productivity
- quality
- energy efficiency

 Robotic – arm robot

 Replace labour
- welding - improving productivity
- spray - laboratory application
- inspection - assembly process

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 STUDENT LEARNING OUTCOMES

At the end of this class, student should be able to:

1.2 Explain the basic concept of automation terminology

- Link and joint
- Orientation Axes
- Tool Centre Point (TCP)
- Speed
- Repeatability
- Settling Time
- Coordinates
- Degree of freedom (d.o.f)
- Position Axes
- Work Envelope/Workspace
- Payload
- Accuracy
- Control Resolution

 Link
- The connection of different manipulator joint.
- Rigid components that form a chain connected by joints.

 Each joints has two links : input & output link

 Input link allows the output link to move

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  Joint : - The integration of two or more link
- Each of these joints have a range over which it can be moved.

 Types : Rotational, Linear, Twisting, Orthogonal, Revolving

 Linear joint can be indicated by the letter L – joint.

 Two links should be in parallel axes.
 Translational and sliding movements.
 Telescoping mechanism and piston.
 The relative movement between the input link and the output link is a
linear sliding motion, with the axes of the two links being parallel.

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 R–Joint
 Rotary motion
 Vertical to the arm axis
 This type provides a rotational
relative motion of the joints, with
the axis of the rotation
perpendicular the axes of the input
and output links.

 T-Joint
 makes twisting motion among the output and input link.
 the output link axis will be vertical to the rotational axis.
 The output link rotates in relation to the input link.
 This joint also involves rotary motion, but the axis of rotation is parallel to the axes
of the two links.

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 O-Joint
 similar to the linear joint
 output and input links will be moving at the right angles.
 This is also a linear sliding motion, but the input and output links are perpendicular
to each other during the move.

 V-Joint
 output link axis is perpendicular to the rotational axis
 the input link is parallel to the rotational axes
 output link spins about the input link
 the axis of the input link is parallel to the axis of rotation of the joint, and the
axis of the output links is perpendicular to the axis of rotation.

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 Number of axes or axes of motion.
 Modes in which a mechanical device or system can move.
 Number of degrees of freedom is equal to the total number of
independent displacements or aspects of motion.
 A machine may operate in two or three dimensions but have
more than three degrees of freedom.
 A robot arm has five to seven degrees of freedom.
 In a complex robot has two arms, the total.
 Number of degrees of freedom is doubled.
 Fully functional androids and multi-legged mobile.
 Robots can have more than 20 degrees of freedom.

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 Revolute Joint
1 DOF ( Variable - q)

Prismatic Joint
1 DOF (linear) (Variables - d)

Spherical Joint
3 DOF ( Variables - q1, q2, q3)

 Most robots are mounted on a

stationary base on the floor. We will
call it as robot base and its
connection to the first joint as link 0.

 It is the input link to joint 1, the first

in the series of joints used in the
construction of the robot. The output
link of joint 1 is link 1. Link 1 is the
input link to joint 2, whose output
link is link 2, and so on.

Diagram of robot construction showing

how robot is made up of a series of joint-
link combinations

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 How many degrees of freedom to the human body?

The human body contains 230 movable or slightly movable

joints, and if there are six degrees of freedom for each of
them it gives a total of 1380 DOF

compare to the human wrist

A - human (3 degree freedom)
B - robot (3 degree freedom)
C - robot (3 degree freedom; alternative design)

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  Arm sweep, shoulder swivel and elbow extension are examples of
position axes in the arm.
 Robot systems usually have at least 3 position axes in the arm.

 Definition:
- also called “end point”; the exact point of work on the effectors
 The TCP (Tool Center Point) is the mathematical point that your robot is
moving through space.
 When you store a point, you are basically storing information that records
the location of this mathematical point

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 The work envelope or work volume is defined as the space within which
the robot can manipulate the end of its wrist.
 The shape of work volume is determined by the type of robot
configuration.

 The work envelope of a cartesian robot is a rectangular prism.

 The work envelope of a cylindrical robot is a section of a cylinder and that
of revolute robot is a spherical section.

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a. Polar
b. Cylindrical
c. Cartesian
d. Jointed-Arm

 Term that refer to the space within which the robot can manipulate it wrist end.

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 Configure No. of axis Name of axis

Cartesian 3 X, Y, dan Z

Cylindrical 3 R, Z, dan 

Polar 3 R, , dan 

Jointed arm 6 B, S, E, R, P, dan Y

 Maximum rate the controller can move the TCP with the payload to a point.

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 Definition:
- maximum lifting capacity of the robot arm under operating
conditions

 Note:
- payload includes the weight of the tooling and the part to be lifted.

 Definition:
- one of the most important specifications, repeatability is the measure of
the variation that occurs during repeated returns to a point required
during a taught program.

 The point required is a manually taught point (using a teaching device).

 Repeatability is always specified by a vendor.

R R R

A A A

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 Accuracy is the measurement tolerance, or transmission of the instrument and
defines the limits of the errors made when the instrument is used in normal
operating conditions.

 A measure of how well the robot controller, arm and TCP respond to commands
from a remote terminal.

 A time required for a component, circuit, device, instrument or system to

settle and remain at a given value once an input signal is received.

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 Control resolution is the smallest change in position that the feedback
device can sense.

 Absolute
 Relative

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 Welding
 Painting
 Ironing
 Assembly
 Pick and place
 Packaging
 Palletizing
 Product inspection
 Testing

a. ??? b. ???

c. ???

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1. Actuator
 A hardware device that produces motion or action created by a force or
torque in controlling machine or device
 It is also use to drive manipulator from one point to another.
 Example:
- Pneumatic or hydraulic cylinder
- Pneumatic or hydraulic motor
- Electric motor

2. End effectors
 A device or tool that's connected to the end of a robot arm. Its designed to
interact with environment.
 The structure of an end effectors and the nature of the programming and
hardware that drives it depend on the task the robot will be performing.
 End effectors used in manufacturing include:
- anti-collision sensors - cameras
- cutting tools - drills
- grippers - magnets
- sanders - screw drivers
- spray guns - vacuum cups
- welding guns

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 ???

3. Manipulator
 Is a device used to transfer materials without direct contact.
 Robot manipulators are created from a sequence of link and joint combinations.
 The links are the rigid members connecting the joints, or axes.
 The axes are the movable components of the robotic manipulator that cause
relative motion between adjoining links.
 Robotic manipulators can be divided into two sections, each with a different
function:
 Arm and Body - The arm and body of a robot are used to move and position
parts or tools within a work envelope. They are formed from three joints
connected by large links.
 Wrist - The wrist is used to orient the parts or tools at the work location. It
consists of two or three compact joints.

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1. Base rotation
2. Shoulder flex
3. Elbow flex
4. Wrist pitch
5. Wrist yaw
6. Wrist roll

Degree of Freedom ?

STUDENT LEARNING OUTCOMES

At the end of this class, student should be able to:

1.3 Explain the positioning concept of automation:

- Accuracy and repeatability
- Control resolution
- Payload

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* Repeatability or Accuracy ?
* Why robot manufacturers like to use
repeatability?

i. Point-to-point robots move from one point to another but cannot stop at arbitrary
intermediate points.
ii. Continuous point robots can move to a prescribed number of points along a path
and can stop at arbitrary intermediate points.
iii. Computed trajectory robots can move along a path specified algebraically.
iv. Servo-controlled robots have some means of sensing the current position and
feeding this sensed position back so that a prescribed path can be followed by
them.

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 Load carrying capacity varies greatly between robots.
 Specified when the arm is under its weakest position (arm fully extended).
 This includes the gripper/end-effector weight, the actual payload, and the tension
cable.
 Usually about 3-5% of total robot weight.
 For example, if rated payload is 6 kg, with end-effector of 2 kg, then the actual net
load it can pick-up is 4 kg.

1. Open loop control system

 Its also called non-servo robot. This type of control system doesn’t have any
sensor which the moves of arm are determine by limit switch.

 In normal condition, actuator moves with high velocity. While, other system
used limit sensor to control manipulator achieved the final point.

 The advantages of this system are easy to maintain and cheaper nevertheless
the disadvantages are limited application, complex programming and used
more time to finish a job.

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2. Close loop control system
 Called servo robot or linear system. The position and movement are controlled
by one sensor or more.
 Benefits of this system are to make sure the robot done a previous job before
continue next task, its also faster than open loop system, better flexibility and
accuracy.
 The weaknesses of this system are high cost to attach a sensor and need a high
skill to operate the system.

 Use in air pollution environment such as radiation, nuclear

reaction and chemical hazardous.
 Use in high temperature.
 Use in deep sea.
 Use in space station.

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 1. Welding
2. Paint spray
3. Assembly
4. Loading in machine
5. Test
6. Packaging
7. Product inspection

1. With the aid of sketch, explain the following terms.

a. Repeatability
b. Accuracy.
(6 marks)

2. Draw and explain the difference between open loop system and close
loop system.
(4 marks)

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