An industrial robot is a general purpose, programmable machine possessing certain anthropomorphic characteristics.

Anthropomorphic characteristic of an industrial robot is its arm, that is used to perform various industrial tasks. Other human like characteristic are the robot s ability to respond to sensory inputs, communicate with other machines, and make decisions.

Robots can be substituted for humans in hazardous or uncomfortable work environments. Robot can perform its work cycle with consistency and repeatability that can not be attained by humans. Robots can be reprogrammed. Robots are controlled by computers.

The manipulator of an industrial robot is constructed of a series of joints and links. Robot anatomy is concerned with the types and sizes of these joints and links and other aspects of the manipulators physical construction.

A Joint of an industrial robot is similar to a joint in the human body. It provides relative motion between two parts of the body. Each joint or axis provides the robot a degree of freedom (DOF). In nearly all cases, only one degree of freedom is associated with a joint.

The no. of independent movements the wrist can perform in 3 dimensional space relative to robots base is called DOF of the robot.

Linear Joint (type L Joint): Relative movement between input and output link is a translational sliding motion, with axis of two links being parallel.

Orthogonal Joint (type O Joint): This is also a translational sliding motion, but the input and output links are perpendicular to each other.

Rotational Joint (type R Joint): This type provides rotational relative motion, with the axis of rotation perpendicular to the axis of input and output links.

Twisting Joint (type T Joint): This joint also carries rotary motion, but the axis of rotation is parallel to the axis of the two links.

Revolving Joint (type V Joint): In this joint type, the axis of the input link is parallel to the axis of rotation of the joint, and the axis of the output link is perpendicular to the axis of rotation.

Polar configuration: This configuration consists of a sliding arm (L joint) actuated relative to the body, that can rotate about a vertical axis (T Joint) and a horizontal axis (R joint).

Cartesian coordinate robot: Also known as rectilinear robot and x-y-z robot. It composed of three sliding joints, two of which are orthogonal.

Cylindrical configuration: This robot configuration consists of a vertical column, relative to which an arm assembly is moved up or down. The arm can be moved in or out relative to the axis of column.

Jointed-arm robot: This robot manipulator has the general configuration of a human arm. The jointed arm consists of a vertical column that swivels about the base (using T joint). At the top of the column is a shoulder joint (R joint), whose output link connects to an elbow joint (another R joint).

SCARA (Selective Compliance Assembly Robot Arm): This configuration is similar to the jointed arm robot except that the shoulder and elbow rotational axis are vertical. This type is mainly used for performing insertion tasks in assembly operations.

Robot wrist usually consists of 2 or 3 degrees of freedom. Figure shows an possible configuration for a 3 DOF wrist assembly. The 3 joints are defined as: (i) Roll, using a T joint to accomplish rotation about the robots arm axis. (ii) Pitch, which involves up and down rotation (using R joint). (iii) Yaw, which involves right and left rotation (using R joint). Note: A 2 DOF includes only roll and pitch joints (T & R joints).

The letter symbols for the 5 joint types (L, O, R. T and V) can be used to define a joint notation system.
Body and Arm
Polar Cylindrical Cartesian coordinate Jointed arm

Joint Notation
TRL TLO LOO TRR

SCARA

VRO

Point to point system: In this, robots movement is controlled from one point location in space to another. Each point is programmed into robots control memory and then played back during the work cycle. pick and place

Example:- Machine loading/unloading, activities, spot welding

Contouring system: In this robot have the capability to follow a closely spaced locus of points which describe a smooth compound curve.

Example:- Paint spraying, continuous welding

Work volume: The term work volume refers to the space within which the robot can operate. It is spatial region within which the end of the robots wrist can be manipulated. The work volume of an industrial robot is determined by its physical configuration, size and limits of its arm and joint manipulations. Precision of movement: The precision within which the robot can move the end of its wrist. It consists of following attributes:(i) Spatial resolution (ii) Accuracy (iii) Repeatability

Spatial resolution: The term Spatial resolution refers to the smallest increment of motion at the wrist end that can be controlled by robot. This is largely determined by the robots control resolution, which depends on its position control system and/or its feedback measurement system. Accuracy: The accuracy of the robot refers to its capability to position its wrist end at a given target within its work volume. Repeatability: This refers to the robots ability to position its wrist end back to a point in space that was previously taught. Weight carrying capacity: The weight carrying capacity of robot covers a wide range.

Robot joints are actuated by following types of drive system:Hydraulic : Used in large robots, and hydraulic system adds floor space required by robot. Advantages are mechanical simplicity, high strength, and high speed. Electric motor: Driven by electric motors (DC stepping motors or servomotor) Do not possess physical strength or speed as compared to hydraulic type. Accuracy and repeatability are better. Less floor space required. Pneumatic: Used in smaller robots. Used for simple operations such as pick and place operations.

Limited sequence control: This is most elementary control type. It can be utilized only for simple motion cycles such as pick and place operations. It is usually implemented by setting limits or mechanical stops for each joint and sequencing the actuation of the joints to accomplish the cycle. Playback with point to point control: Playback control means that the controller has a memory to record the sequence of motions in a given work cycle as well as the locations and other parameters associated with each motion and then to subsequently play back the work cycle during the execution of program. In PTP type, individual positions of robot arm are recorded into memory.

Playback with continuous path control : Continuous path robots have the same play back capacity as the playback with point to point control. The difference between PTP and continuous path is same as that of NC machine. Intelligent robots:Intelligent robots have the capability to Interact with its environment. Make a decision when things go wrong during work cycle. Communicate with humans. Make computations during motion cycle. Respond to advanced sensor inputs. In addition to above they possess playback capability for both PTP or continuous control. These features require (i) high level of computer control (ii) advanced programming language.

End effector is usually attached to the robots wrist. End effector enables the robot to accomplish a specific task.

Categories of end effector: Grippers Tools

Grippers: Grippers are end effectors used to grasp and manipulate objects during the work cycle. The objects are usually workparts that are moved from one location to another. Machine loading and unloading applications fall into this category. Types of grippers used: Mechanical Grippers:- consisting of 2 or more fingers that can be actuated by robot controller to open and close to grasp the work part. Vacuum Grippers:- consists of suction cups used to hold flat objects. Magnetized devices:- for holding ferrous parts. Adhesive devices:- adhesive substance is used to hold a material. Simple mechanical devices:- such as hooks. Mechanical grippers are the most common gripper type.

Tools: Tools are used in applications where the robot must perform some processing operation on the work part. Examples of tool used: Spot welding gun Arc welding tool Spray painting gun Rotating spindle for drilling, grinding etc. Assembly tool (e.g automatic screw driver) Water jet cutting tool

Internal sensors: Used for controlling position and velocity of various joints of the robot. These sensors form a feedback control loop with robot controller. Examples are potentiometers and optical encoders.
External sensors: Used for coordinating the operation of the robot with other equipment in the cell. Examples are limit switches.

Commonly used sensors: Tactile sensors:- Used to determine whether contact is made between sensor and other object. Tactile sensor can be divided into 2 categories:(i) Touch Sensors:- Only indicates that contact has been made with the object. (ii) Force Sensors:- Used to indicate magnitude of force with object. Proximity sensors:- Indicate when an object is close to the sensor. Optical sensors:- Used for detecting presence or absence of object. Other sensors:- These include devices for measuring temperature, fluid pressure, electric voltage, current and various other physical properties.

Hazardous work environment for humans e.g spray painting, continuous arc welding and spot welding and forging operations. Repetitive work cycle Difficult handling for human beings Material handling operations such as material transfer, machine loading and unloading. Processing operations such as spot welding, continuous arc welding, spray coating, drilling, grinding and water jet cutting & laser jet cutting etc. Assembly and inspection operations.

Manual method: Used for simpler robots. This method involves setting mechanical stops, switches or relays in the robots control unit. Used for low technology robots having short work cycle.
Walk through method: In this method, programmer manually moves the robots arm and hand through motion sequence of the work cycle. Each movement is recorded into memory for subsequent play back during production.

Leadthrough method Off-line programming

Leadthrough method: This method makes use of a teach pendant to power drive the robot through its motion sequence. The teach pendant is usually a small hand-held devices with switch to control the robots physical movements. Each motion is recorded into memory for future play back. Most popular programming method. Off-line programming: This method involves the operation of robot program offline, in a manner similar to NC part programming.

Most commonly used languages are The VALTM Language The MCL language The VALTM Language: This language was developed by Victor Scheinman for the PUMA robot, an assembly robot. Hence, VAL stands for Victors Assembly language. It is basically an off-line language but various point locations used in work cycle are defined through lead through. VAL statements are divided in two categories: (i) Monitor commands (ii) Programming instructions

(i) Monitor commands:- are the set of administrative instructions that direct the operation of robot system. Functions performed by monitor commands: Preparing the system for the user to write programs for PUMA. Defining points in space. Commanding PUMA to execute program. Listing programs on CRT. (ii) Programming instructions:- are a set of statements used to write robot programs. Program in VAL direct the sequence of motions of PUMA.

The MCL Language: MCL stands for machine control language and was developed by McDonnell-Douglas Corporation under contract to US Air Force ICAM program. Language is based on the APT NC language, but is designed to control a complete manufacturing cell, including a cell with robots.