UNIVERSITI TEKNOLOGI MARA

FACULTY OF MECHANICAL ENGINEERING

Computer Integrated Manufacturing (CIM) –

MEM562 : Machine and System Control

WEEK 10:
 NUMERICAL CONTROL – Chapter 7
 INDUSTRIAL ROBOTS – Chapter 8
 PROGRAMMABLE LOGIC CONTROLLERS – Chapter 9

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NUMERICAL CONTROL
(Chapter 7)

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Numerical Control (Chapter 7)
 A form of programmable automation of a machine tool
(eg. drilling, milling, etc.) other equipment (non-machine
such as assembly, inspection).
 Generate a punched paper tape directly or to program in a
computer-typed language (Automatically Programmed
Tool) and process this source program off-line on a
computer, which translate it into a machine readable block
format program on punched paper tape. The NC machine
will read the tape and repeatedly use for every part
produced.

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Components of traditional NC
systems

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Computer Numerical Control
 Each NC machine comes with a computer (MCU).
 Features: storage of more than one part program, program
editing at the machine tool, communications interface, etc.
 CNC MCU: central processing unit, memory, I/O
interface, controls for machine tool axes and spindle
speed, sequence controls for other machine tool functions.
 CNC Software: operating system, machine interface &
application.

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Components of CNC

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Direct Numerical Control
 Direct numerical control (DNC) – control of
multiple machine tools by a single (mainframe)
computer through direct connection and in real
time
 1960s technology
 Two way communication
 Distributed numerical control (DNC) – network
consisting of central computer connected to
machine tool MCUs, which are computers (CNC)
 Present technology
 Two way communication
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General Configuration of a
Direct Numerical Control System

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Distributed Numerical Control
 Distributed numerical control (DNC) – network
consisting of central computer connected to
machine tool MCUs, which are computers (CNC)
 Present technology
 Two way communication

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General Configuration of a
Distributed Numerical Control System

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Distributed Numerical Control
Configuration (LAN)

Local area network (LAN)

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PROGRAMMABLE LOGIC
CONTROLLERS
(Chapter 9)

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PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)

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PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)
 Programmable logic controllers are the most widely used
electronic devices in the control of production and
assembly process in most automated factories due to its
simplicity and versatility.
 A programmable logic controller (PLC) is a user-friendly,
microprocessor-based, specialized computer carrying out
control functions of many types and levels of complexity
in industrial applications.

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PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)
A PLC system contains four main parts:
 CPU module (main processor)
 Input and Output modules (I/O modules)
 A power supply module
 Peripheral equipments

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PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)
 The first PLC systems evolved from conventional
computers in the mid 1970s and were mostly used in
automotive industry. Electronic programmable controller
has replaced relay-based, hard-wired electrical systems
 PLCs do majority of the control jobs. Whereas, PCs
handle most of the data and math functions.

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A PLC in an Automated System

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Parts of the PLCs
CPU Module:
This module
consists of a
central
processing
unit (CPU)
which acts as
the brain of
the system
and its
memory

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Parts of the PLCs
Power Supply Module:
 Power supply module provides power to the CPU and often provides
power to drive sensors and low power actuators connected to I/O
modules.

Peripheral Equipments:
 They are used for purposes such as preparing, storing and loading
control programs, system monitoring and even can be used for
communicating with other computers with which the PLC may be
networked.

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Parts of the PLCs
Various production equipment that can be connected to PLCs
include:
 Thermocouples
 Strain gauge
 Position encoder
 Servo valves
 Electrical motors
 Linear motors
 Stepping motors

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LADDER LOGIC DIAGRAMS
 PLC programming language is called Boolean instruction
language (or mnemonic code language). This language
involves four standardized mnemonic words: LOAD
(yes), AND, OR, NOT
 A Boolean statement is like:
If (a conveyor carries a box)
AND (the chute has no box)
THEN (turn the conveyor motor on)
In Boolean logic, terms TRUE or FALSE are main
parameters.

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LADDER LOGIC DIAGRAMS
 An example of an operation that is in the scope of a PLC
is controlling the operation of a robotic work cell, which
is interfaced with an automated material transportation
system using AGVs.
 When an AGV docks into position, the robot is required
to unload a processed part from the machine onto the
AGV and then pick up a new workpiece from the AGV
and load it onto the machine tool. This process can be
controlled using fairly simple logic that would be
implemented in the control program of a PLC.

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Ladder Logic Elements

 AND: Simply represents “and” operator in simple

logic. It is put between two statements when the
output is dependent on whether BOTH of the
statements are true or BOTH of the statements are
false. It is represented by the symbol:

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 Ladder Logic Elements
AND

In this AND gate logic, it can

be said that only if the
switches X1 and X2 change
their states form opened to
closed, the current can go to
the lamp.

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LADDER LOGIC DIAGRAMS
 Ladder logic diagrams and elements are graphical
representation of Boolean language.

A ladder logic program consists of horizontal rungs drawn

between two vertical rails.

Each rung contains instruction elements that examine

memory bits and contains at least one output element. If
the bit-examine elements on a simple rung is true then the
bits controlled by that rung’s output elements are turned
on.
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Ladder logic diagram and elements

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Advantages
 Greater flexibility, re-programmability
 Greater response time to inputs than humans
 Improved product quality
 Maximize capital intensive equipment in multiple work
shifts
 Accident reduction
 Reduction of hazardous exposure for human workers
 Automation less susceptible to work stoppages
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Disadvantages
 Replacement of human labor
 Greater unemployment
 Significant retraining costs for both unemployed and users of new
technology
 Advertised technology does not always disclose some of the hidden
disadvantages
 Hidden costs because of the associated technology that must be
purchased and integrated into a functioning cell. Typically, a
functioning cell will cost 3-10 times the cost of the robot.

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INDUSTRIAL ROBOTICS
(Chapter 8)

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Robotics Terminology

 Robot: An electromechanical device with multiple

degrees-of-freedom (DOF) that is programmable to
accomplish a variety of tasks.
 Industrial robot:The Robotics Industries Association
(RIA) defines robot in the following way:
 “An industrial robot is a programmable, multi-
functional manipulator designed to move materials,
parts, tools, or special devices through variable
programmed motions for the performance of a variety of
tasks”

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Robotics Terminology
 DOF degrees-of-freedom: the number of independent motions a
device can make. (Also called mobility)
 5 degrees-of -freedom

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Robotics Terminology
 Manipulator: Electromechanical device capable of interacting with
its environment.

 Anthropomorphic: Like human beings.

ROBONAUT (ROBOtic astroNAUT),

an anthropomorphic robot with two arms,
two hands, a head, a torso, and a stabilizing leg.

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Robotics Terminology
 End-effector: The tool, gripper, or other device
mounted at the end of a manipulator, for
accomplishing useful tasks.

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Robotics Terminology
 Workspace: The volume in space that a robot’s end-
effector can reach, both in position and orientation.

A cylindrical robots’ half workspace

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Robotics Terminology
 Position: The translational (straight-line) location of something.
 Orientation: The rotational (angle) location of something. A robot’s
orientation is measured by roll, pitch, and yaw angles.
 Link: A rigid piece of material connecting joints in a robot.
 Joint: The device which allows relative motion between two links in a robot.

A robot joint

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Robotics Terminology
 Kinematics: The study of motion without regard to forces.
 Dynamics: The study of motion with regard to forces.
 Actuator: Provides force for robot motion.
 Sensor: Reads variables in robot motion for use in control
 Speed
• The amount of distance per unit time at which the robot can
move, usually specified in inches per second or meters per
second.
• The speed is usually specified at a specific load or assuming that
the robot is carrying a fixed weight.
• Actual speed may vary depending upon the weight carried by
the robot.

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Robotics Terminology
 Load Bearing Capacity
• The maximum weight-carrying capacity of the robot.
• Robots that carry large weights, but must still be precise are expensive
 Accuracy
• The ability of a robot to go to the specified position without making a mistake.
• It is impossible to position a machine exactly.
• Accuracy is therefore defined as the ability of the robot to position itself to the
desired location with the minimal error (usually 25 mm).
 Repeatability
• The ability of a robot to repeatedly position itself when asked to perform a task
multiple times.
• Accuracy is an absolute concept, repeatability is relative.
• A robot that is repeatable may not be very accurate, visa versa.

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Robotics History
 1961: Unimate, the company of Joseph Engleberger and George Devoe, built the first
industrial robot, the PUMA (Programmable Universal Manipulator Arm).
 1966: The Stanford Research Institute creates Shakey the first mobile robot to know
and react to its own actions.
 1989: A walking robot named Genghis is unveiled by the Mobile Robots Group at
MIT

Unimate PUMA SRI Shakey

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Robotics History
 2000: Honda debuts new humanoid robot
ASIMO.

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Industrial Robots

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Power Sources
 There are basically three types of power
sources for robots:
 Hydraulic drive
 Pneumatic drive
 Electrical drive

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Robotic Sensors
 Sensors provide feedback to the control systems and give
the robots more flexibility.
 Sensors such as visual sensors are useful in the building
of more accurate and intelligent robots.
 The sensors can be classified as follows:
 Position sensors
 Range sensors
 Velocity sensors
 Proximity sensors

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The Hand of a Robot: End-Effector
 The end-effector (commonly known as robot hand) mounted on the
wrist enables the robot to perform specified tasks. Various types of
end-effectors are designed for the same robot to make it more flexible
and versatile. End-effectors are categorized into two major types:
grippers and tools.
 Grippers are generally used to grasp and hold an object and place it at
a desired location.
 mechanical grippers
 vacuum or suction cups
 magnetic grippers
 adhesive grippers
 hooks, scoops, and so forth

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The Hand of a Robot: End-Effector
 At times, a robot is required to manipulate a tool to
perform an operation on a workpiece. In such applications
the end-effector is a tool itself
 spot-welding tools
 arc-welding tools
 spray-painting nozzles
 rotating spindles for drilling
 rotating spindles for grinding

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The Robotic Joints
A robot joint is a mechanism that permits
relative movement between parts of a robot
arm. The joints of a robot are designed to
enable the robot to move its end-effector
along a path from one position to another as
desired.

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The Robotic Joints
The basic movements required for a desired
motion of most industrial robots are:
 1. rotational movement: This enables the robot to
place its arm in any direction on a horizontal
plane.
 2. Radial movement: This enables the robot to
move its end-effector radially to reach distant
points.
 3. Vertical movement: This enables the robot to
take its end-effector to different heights.
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The Robotic Joints
These degrees of freedom, independently
or in combination with others, define the
complete motion of the end-effector. These
motions are accomplished by movements
of individual joints of the robot arm. The
joint movements are basically the same as
relative motion of adjoining links.
Depending on the nature of this relative
motion, the joints are classified as
prismatic or revolute.
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The Robotic Joints
 Prismatic joints (L) are also known as
sliding as well as linear joints.
 They are called prismatic because the cross
section of the joint is considered as a
generalized prism. They permit links to
move in a linear relationship.

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The Robotic Joints
Revolute joints permit only angular motion
between links. Their variations include:
 Rotational joint (R)
 Twisting joint (T)
 Revolving joint (V)

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The Robotic Joints
A rotational joint (R) is identified by its
motion, rotation about an axis
perpendicular to the adjoining links. Here,
the lengths of adjoining links do not change
but the relative position of the links with
respect to one another changes as the
rotation takes place.

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The Robotic Joints
A twisting joint (T) is also a rotational joint,
where the rotation takes place about an axis
that is parallel to both adjoining links.

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The Robotic Joints
A revolving joint (V) is another rotational
joint, where the rotation takes place about
an axis that is parallel to one of the
adjoining links. Usually, the links are
aligned perpendicular to one another at this
kind of joint. The rotation involves
revolution of one link about another.

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The Robotic Joints

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ROBOT CLASSIFICATION
Robots may be classified, based on:
 physical configuration
 control systems

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ROBOT CLASSIFICATION
Classification Based on Physical
Configuration:
 1. Cartesian configuration
 2. Cylindrical configuration
 3. Polar configuration
 4. Joint-arm configuration

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ROBOT CLASSIFICATION
Cartesian Configuration:
 Robots with Cartesian configurations consists
of links connected by linear joints (L). Gantry
robots are Cartesian robots (LLL).

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Cartesian Robots
A robot with 3 prismatic joints – the
axes consistent with a Cartesian
coordinate system.

Commonly used for:

• pick and place work
• assembly operations
• handling machine tools
• arc welding

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ROBOT CLASSIFICATION
Cylindrical Configuration:
 Robots with cylindrical configuration have
one rotary ( R) joint at the base and linear (L)
joints succeeded to connect the links.

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Cylindrical Robots

A robot with 2 prismatic joints and a

rotary joint – the axes consistent with a
cylindrical coordinate system.

Commonly used for:

• handling at die-casting machines
• assembly operations
• handling machine tools
•spot welding

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ROBOT CLASSIFICATION
Polar Configuration:
 Polar robots have a
work space of
spherical shape.
Generally, the arm is
connected to the base
with a twisting (T)
joint and rotatory (R)
and linear (L) joints
follow.

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ROBOT CLASSIFICATION
 The designation of the arm for this
configuration can be TRL or TRR.
 Robots with the designation TRL are also
called spherical robots. Those with the
designation TRR are also called
articulated robots. An articulated robot
more closely resembles the human arm.

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ROBOT CLASSIFICATION
Joint-arm Configuration:
 The jointed-arm is a combination of
cylindrical and articulated configurations.
The arm of the robot is connected to the
base with a twisting joint. The links in the
arm are connected by rotatory joints. Many
commercially available robots have this
configuration.
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ROBOT CLASSIFICATION

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Articulated Robots
A robot with at least 3 rotary
joints.

Commonly used for:

• assembly operations
• welding
• weld sealing
• spray painting
• handling at die casting or
fettling machines

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SCARA (Selective Compliance Articulated Robot
Arm) Robots

A robot with at least 2 parallel

rotary joints.

Commonly used for:

• pick and place work
• assembly operations

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Spherical/Polar Robots
A robot with 1 prismatic joint
and 2 rotary joints – the axes
consistent with a polar
coordinate system.

Commonly used for:

• handling at die casting or
fettling machines
• handling machine tools
• arc/spot welding

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ROBOT CLASSIFICATION
Classification Based on Control Systems:
 1. Point-to-point (PTP) control robot
 2. Continuous-path (CP) control robot
 3. Controlled-path robot

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Point to Point Control Robot (PTP):
 The PTP robot is capable of moving from one
point to another point.
 The locations are recorded in the control memory.
PTP robots do not control the path to get from
one point to the next point.
 Common applications include:
 component insertion
 spot welding
 hole drilling
 machine loading and unloading
 assembly operations

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Continuous-Path Control Robot (CP):
 The CP robot is capable of performing movements along the
controlled path. With CP from one control, the robot can stop
at any specified point along the controlled path.
 All the points along the path must be stored explicitly in the
robot's control memory. Applications Straight-line motion is
the simplest example for this type of robot. Some continuous-
path controlled robots also have the capability to follow a
smooth curve path that has been defined by the programmer.
In such cases the programmer manually moves the robot arm
through the desired path and the controller unit stores a large
number of individual point locations along the path in
memory (teach-in).

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Continuous-Path Control Robot (CP):
Typical applications include:
 spray painting
 finishing
 gluing
 arc welding operations

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Controlled-Path Robot:
 In controlled-path robots, the control equipment can generate
paths of different geometry such as straight lines, circles, and
interpolated curves with a high degree of accuracy. Good
accuracy can be obtained at any point along the specified
path.

 Only the start and finish points and the path definition
function must be stored in the robot's control memory. It is
important to mention that all controlled-path robots have a
servo capability to correct their path.

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Robot Reach
Robot reach, also known as the work
envelope or work volume, is the space of
all points in the surrounding space that can
be reached by the robot arm.
Reach is one of the most important
characteristics to be considered in selecting
a suitable robot because the application
space should not fall out of the selected
robot's reach.
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Robot Reach
 For a Cartesian configuration the reach is a
rectangular-type space.
 For a cylindrical configuration the reach is
a hollow cylindrical space.
 For a polar configuration the reach is part
of a hollow spherical shape.
 Robot reach for a jointed-arm configuration
does not have a specific shape.

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ROBOT MOTION ANALYSIS
In robot motion analysis we study the
geometry of the robot arm with respect to a
reference coordinate system, while the end-
effector moves along the prescribed path .

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ROBOT MOTION ANALYSIS
The kinematic analysis involves two different
kinds of problems:
 1. Determining the coordinates of the end-
effector or end of arm for a given set of joints
coordinates.
 2. Determining the joints coordinates for a given
location of the end-effector or end of arm.

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ROBOT APPLICATIONS
Loading/unloading parts to/from the machines
 The robot unloading parts from die-casting machines
 The robot loading a raw hot billet into a die, holding
it during forging and unloading it from the forging
die
 The robot loading sheet blanks into automatic presses
 The robot unloading molded parts formed in injection
molding machines
 The robot loading raw blanks into NC machine tools
and unloading the finished parts from the machines

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ROBOT APPLICATIONS
Welding:
 Spot welding: Widest use is in the automotive industry
 Arc welding: Ship building, aerospace, construction industries are
among the many areas of application.

Spray painting:
Provides a consistency in paint quality. Widely used in automobile
industry.

Assembly:
Electronic component assemblies and machine assemblies are two
areas of application.

Inspection

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ROBOT SELECTION
1. Size of class: The size of the robot is given by the maximum dimension
(x) of the robot work envelope.
 Micro (x < 1 m)
 Small (1 m < x < 2 m)
 Medium (2 < x < 5 m)
 Large (x > 5 m)

2. Degrees of freedom. The cost of the robot increases with the number of
degrees of freedom. Six degrees of freedom is suitable for most
works.

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ROBOT SELECTION
3. Velocity: Velocity consideration is effected by the robot’s arm structure.
 Rectangular
 Cylindrical
 Spherical
 Articulated

4. Drive type:
 Hydraulic
 Electric
 Pneumatic

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ROBOT SELECTION
5. Control mode:
 Point-to-point control (PTP)
 Continuous path control (CP)
 Controlled path control

6. Lift capacity:
 0-5 kg
 5-20 kg
 20-40 kg and so forth

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