Industrial Automation

Industrial Automation is the use of control systems, such as computers, robotics, and
advanced information technologies, to operate machines, control processes, and manage
industrial operations with minimal or no human intervention. It aims to increase
productivity, enhance quality, reduce operational costs, and ensure safety in industrial
environments.

Key Characteristics of Industrial Automation:

1. High Efficiency:

o Automated systems work continuously without breaks, increasing production

rates.

2. Consistency and Precision:

o Machines are programmed to perform repetitive tasks with high accuracy,

reducing human error.

3. Cost Reduction:

o Automation minimizes labor costs and optimizes resource usage, leading to

cost savings.

4. Enhanced Safety:

o Dangerous and hazardous tasks can be handled by robots, protecting human

workers from harm.

5. Real-time Monitoring and Control:

o Automation systems can be monitored and adjusted in real time to optimize

performance and detect faults.

Types of Industrial Automation:

1. Fixed Automation (Hard Automation):

o Designed for mass production with a fixed sequence of operations.

o Example: Car manufacturing assembly lines.

 2. Programmable Automation:

o Suitable for batch production; processes can be reprogrammed for different

tasks.

o Example: CNC machines for different types of metal cutting.

3. Flexible Automation (Soft Automation):

o Allows for easy adaptation to different product types with minimal downtime.

o Example: Flexible Manufacturing Systems (FMS) that can switch between

different parts production seamlessly.

Robot Anatomy
Robot Anatomy refers to the physical construction and structural layout of a robot, including
its body, arm, and wrist. It describes the configuration and the relationship between
different parts that allow the robot to perform tasks. A typical robot consists of the following
main components:

1. Base:

o This is the foundation of the robot, which may be fixed or mobile.

o It provides stability and support to the entire robotic structure.

2. Manipulator Arm:

o It is the main structure that is used to perform operations.

o The arm consists of several segments called links connected by joints.

 o It usually has several degrees of freedom (DOF) to move in various directions.

3. Joints (Axial Movements):

o Joints are used to connect the links and provide motion.

o The main types of joints are:

▪ Linear Joints (Prismatic Joints): Provide straight-line motion.

▪ Rotational Joints (Revolute Joints): Allow the links to rotate about an

axis.

▪ Twisting Joints: Provide twisting motion between links.

▪ Revolving Joints: Enable links to revolve around a point.

4. End-Effector (Gripper or Tool):

o It is attached to the wrist of the manipulator and acts as the "hand" of the
robot.

o The end-effector can be a gripper, welding torch, spray gun, or any other tool,
depending on the application.

5. Wrist:

o It is located at the end of the arm and is responsible for the orientation of the
end-effector.

o The wrist has multiple degrees of freedom for precise control.

6. Controller:

o The controller is the brain of the robot, managing the movement and
operation of the arm and end-effector.

7. Sensors:

o These are used to provide feedback to the robot about its environment and
its own movements.

Application Example - Robotic Welding:

In robotic welding, the links and joints of the manipulator arm allow the robot to position
the welding torch accurately over the weld line.

• The rotational joints enable the torch to move around complex curves.

• The linear joints help in straight-line movement to cover long welding paths.
 • The end-effector, which in this case is the welding torch, precisely melts and fuses
metal parts.

• The wrist provides angular adjustment to keep the welding torch at the correct angle
during operation.

Robot Specifications
Robot specifications refer to the key performance and design characteristics that define
what a robot can do and how well it performs. These specifications help in choosing the
right robot for a particular task in industrial or service applications.

1. Spatial Resolution

• It is the smallest distance a robot can move within its work volume.

• Depends on:

o The controller’s resolution (how finely it can command movements).

o The position sensor’s resolution.

2. Accuracy

• Accuracy means how close the robot’s end-effector reaches the desired location.

• If you ask the robot to move to a point (say, 100 mm), and it reaches 98 mm, the
error is 2 mm. That’s a measure of low accuracy.
• High accuracy is essential in precision applications like surgery or semiconductor
handling.

3. Repeatability

• Repeatability is the robot’s ability to return to the same point again and again.

• Even if the robot isn’t very accurate, if it goes back to the same spot every time, it’s
considered highly repeatable.

• A robot can be repeatable but not accurate, which is still fine for tasks like spot
welding where exact position is less critical.

4. Compliance

• Compliance refers to the flexibility of the robot in different directions.

• Some flexibility is good in operations like assembly, where slight errors can be
absorbed.

• Helps to avoid damage during accidental contact.

5. Three-Degree-of-Freedom Wrist Assembly

• A robot wrist is the part after the arm that helps in orienting tools or grippers.

• A 3 DOF wrist provides:

o Pitch: Up and down motion.

o Yaw: Side to side motion.

o Roll: Rotational movement around the axis.

• Mimics human wrist movement.

6. Joint Notation Scheme

• Used to describe robot arms and joints.

• Joints are coded as:

o L – Linear (prismatic joint)

o R – Rotational

o T – Twisting

o V – Revolving

• Example: A robot with L-R-R-T joints describes its motion type and configuration.

7. Speed of Motion

• Speed is how fast the robot moves.

• Expressed as:

o mm/sec (for linear movements)

o degrees/sec (for rotary joints)

• Important in operations like pick-and-place, where time-saving matters.

8. Payload

• The maximum weight the robot can carry at the wrist or end-effector.

• Includes the tool, gripper, and the object being handled.

• If the load is heavier than the payload, it can lead to positioning errors or even
damage the robot.
The Three Laws of Robotics
These laws were proposed by science fiction writer Isaac Asimov, and are widely referenced
in robotics to ensure ethical robot behavior.

Law 1:

A robot may not injure a human being, or, through inaction, allow a human to be harmed.

Explanation:

• A robot must never hurt a person directly (like hitting or damaging).

• Even doing nothing (inaction) is not allowed if it results in human harm.

• Example: If someone is about to fall, the robot must try to help or alert, not just
watch.

Law 2:

A robot must obey the orders given to it by human beings, except where such orders
would conflict with the First Law.

Explanation:

• The robot should follow human instructions.

• But if the instruction involves hurting someone, the robot must refuse.

• Example: If a person asks the robot to hit another person, the robot should say “NO”
due to Law 1.

Law 3:

A robot must protect its own existence as long as such protection does not conflict with
the First or Second Law.

Explanation:

• Robots can protect themselves from damage or destruction.

• But saving itself is not more important than saving a human or following a human's
safe command.
 • Example: A robot may move away from fire, but if a human is in danger, it must help
the person first—even if it gets damaged.

Parts of a Robot
A robot is made up of several parts that work together to perform tasks automatically. Each
part has a specific function. The major components of a typical robot are:

1. Power Source ( Page 50)

• Every robot needs a source of energy to function.

• It could be:

o Electrical (most common, e.g., batteries, power supply)

o Hydraulic (for heavy-duty robots)

o Pneumatic (for light, flexible movements)

• It powers the motors and controllers in the robot.

2. Controller ( Page 51)

• The brain of the robot.

• It processes the instructions and sends commands to the motors and actuators.

• Usually a microprocessor or microcontroller.

• Works with software and programming to control movement and logic.

3. Manipulator ( Page 51)

• This is the main body or the "arm" of the robot.

• It consists of links and joints, allowing it to reach and move objects.

• Its structure resembles a human arm, with shoulder, elbow, and wrist parts.
4. End Effector ( Page 52)

• The tool attached to the end of the robot arm.

• It interacts directly with the environment (e.g., picks up or welds parts).

• Examples:

o Grippers for holding items.

o Welding torches, spray guns, screwdrivers for specific tasks.

5. Actuators ( Page 52)

• Actuators are motors or mechanisms that move the robot.

• They convert energy from the power source into mechanical movement.

• Types include:

o DC/AC motors

o Hydraulic cylinders

o Pneumatic pistons

6. Sensors ( Page 52)

• Sensors allow the robot to sense its surroundings and adjust its actions.

• Types:

o Position sensors (like encoders)

o Force sensors

o Temperature sensors

• They give feedback to the controller for decision-making.

7. Interfaces ( Page 53)

• Connects the robot to external systems like computers or other machines.

• Useful for programming, data exchange, and remote control.

Need for Robots
The need for robots arises from the demand for efficiency, safety, and precision in various
tasks, especially in industries. Here are the key reasons:

1. To Handle Repetitive Tasks

• Robots are ideal for repetitive and boring tasks like assembly line work.

• They can do the same job continuously without fatigue or boredom.

2. To Improve Accuracy and Quality

• Robots work with high precision.

• They reduce human error, resulting in better product quality.

3. To Work in Hazardous Environments

• Robots can be used in dangerous places (like welding, space, or nuclear zones)
where human life is at risk.

• They can handle toxic chemicals, high heat, or radiation safely.

4. To Reduce Labor Cost

• Though expensive initially, robots help in long-term savings by replacing multiple

human workers and reducing human-related expenses.

5. To Increase Productivity

• Robots can work 24x7 without breaks, holidays, or sleep.

• This leads to high productivity in factories and manufacturing units.

6. To Perform Tasks Beyond Human Capability

• Robots can lift heavy objects, operate at micro or nano levels, and perform tasks that
are too small, fast, or complex for humans.