INDUSTRIAL ROBOTICS AND CONTROL

ASSIGNMENT

Q) 1 Explain Industrial Internet of Things?

A) The industrial internet of things or ‘ IIoT’ is the use of smart
sensors and actuators to enhance manufacturing and industrial
processes.
Connected sensors and actuators enable companies to pick up on
inefficiencies and problems sooner and save time and money,
while supporting business intelligence efforts. In manufacturing,
specifically, IIoT holds great potential for quality control,
sustainable and green practices, supply chain traceability, and
overall supply chain efficiency.
WORKING OF IIOT
IIoT is a network of intelligent devices connected to form systems
that monitor, collect, exchange and analyse data. Each
industrial IoT ecosystem consists of:
 connected devices that can sense, communicate and store
information about themselves;
 public and/or private data communications infrastructure;
 analytics and applications that generate business information
from raw data;
 storage for the data that is generated by the IIoT devices; and
 people.
These edge devices and intelligent assets transmit information
directly to the data communications infrastructure, where it's
converted into actionable information on how a certain piece of
machinery is operating. This information can be used for predictive
maintenance, as well as to optimize business processes.
2) What is the use of bar code system in warehouse
automation?
A) A barcode is a visual, machine-readable representation of data –
it is essentially electronic data entry using a scanner. It is used
to automate data collection where hand recording is neither timely
nor cost effective.
Once you automate these processes, you’ll find that barcodes are
perfect for minimizing the human error, even eliminating it
altogether. The barcodes offer more efficient procedures for
picking the products, better planning for the arrival times of your
products, and easy tracking of the inventory flow.
Warehouse barcode labels allow you to tag each warehouse
location (using warehouse floor labels or hanging labels), rack, and
pallet and container with a label that can be easily scanned at any
time. This is useful for performing semi-automated cycle counts
and transferring inventory between departments or locations.

In addition to automated scanning, barcodes provide a few unique

benefits that are important for warehouse operations:
 Faster order processing speed
 Reduced clerical and operating costs
 Fewer errors
 Greater inventory and cycle count accuracy
 Excellent scalability for future expansions
 A professional and organized warehouse layout
The use of a barcode system also makes it possible to develop a
perpetual inventory control system by monitoring real-time data
and using a centralized warehouse management system. These
software platforms also allow you to link important information,
such as product size and weight, to each unique barcode.
3) What are the welding parameters to be set in welding power
source?
A) The four important parameters are the welding current, wire
electrode extension, welding voltage and arc travel speed. These
parameters will affect the weld characteristics to a great extent.
Because these factors can be varied over a large range, they are
considered the primary adjustments in any welding operation.
 FEED:
In a wirefeed operation (i.e., MIG or flux-cored welding), the
wire electrode is held farther away from the joint than in stick
welding. That’s because the arc is more concentrated, and thus
capable of burning through metal. Variations in the ESO or
CTWD affect the amount of the current going into the joint,
regardless of the wire speed setting on the machine.
 WELDING CURRENT:
The welding current is the electrical amperage in the power
system as the weld is being made. It is usually read from the
power source meter, but a separate ammeter is often used.
 TORCH ANGLE:
Angle – There are two torch angles to remember when welding.
The first is the work angle, which is the relationship between the
joint and the torch (or rod). Ideally, you’ll hold your torch
perpendicular, or 90 degrees, to the joint. The big exception to
the rule is T-joints, where the work angle varies between 30 to
50 degrees. The second angle used in welding is the travel
angle. This is the relationship between the torch and line of
travel. In order to see the joint and puddle, the welder may tip
the rod up to 10 degrees in the direction of travel, or sometimes
against the direction of travel.
  WIRE ELECTRODE ENTENSION:
Wire extension or “stick-out” is the distance between the last
point of electrical contact, usually the end of the contact tip, and
the end of the wire electrode.
 WELDING VOLTAGE:
It should be re-emphasized that the voltage setting directly
controls the arclength. In addition, a certain range is required to
maintain arc stability at any given welding current level.
 ARC TRAVEL SPEED:
The arc travel speed is the linear rate that the arc moves along
the workpiece. This parameter is usually expressed as inches or
meters per minute. Three general statements can be made
regarding the arc travel speed:
1)   As the material thickness increases, the travel speed must be
lowered.
2)   For a given material thickness and joint design, as the
welding current is increased, so is the arc travel speed. The
converse is also true.
3)   Higher welding speeds are attainable by using the forehand
welding technique.
 LENGTH OF ARC:
How close to the work plates the welder holds the arc of a wire
or welding electrode can affect the amount of current and heat
going into the joint. Held close to the work plates, the current
and heat in the weld remains high. Held farther away, the
electrode produces less heat and more spatter.
4) Can you explain the parts of arc welding work cell layout?
A) In arc welding work cell, the equipment we use are Robot,
controller, welding gun, teach pendent, frames, workpiece, welding
gun/Torch cleaner. Description of equipment is as follows:
1. Robot: The robot we are using here is hollow robot and feed
wires are in the load area which connects to the welding torch
from the back side of the robot.
2. Controller: Controller used here is IRC5. The IRC5 is a multi-
robot controller with PC tool support that optimizes the robot
performance for short cycle times and precise movements.
This controller is also practically maintenance free and is
available in multiple variants to deliver cost-effective
performance customized for need.
3. Welding Gun: A welding gun is a portable device used to
achieve semi-automatic or automatic welds on pieces of metal.
4. Teach Pendent: Teach pendent is used for moving robot in
manual or auto mode. It is also used for making programming.
5. Frames: Frames are used to define the area of robot where
robot will work at its maximum reach.
6. Workpiece: An object being worked on with a tool or machine.
7. Torch Cleaner: Torch cleaner is used to remove slag from the
torch which gets deposited on torch during the welding
operation.
5) What are the arc welding commands used in program?
A) Arc Welding commands that are mostly/always used in
programs are as follows:
 ArcC: Set Torch for circular path.
 ArcL: Set Torch for linear path.
 ArcCStart: Welding on for circular movement.
 ArcCEnd: Welding off for circular movement.
 ArcLStart: Welding on for linear movement.
 ArcLEnd: Welding off for linear movement.
 ArcMoveJ: Move rapidly to welding start point and no
welding action.
6) What are Industrial Robots? Explain the various types of
Industrial Robots.
A) 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.
Mainly, Industrial Robots are of 6 types:
a. CARTESIAN ROBOTS:
Cartesian robots, which are also called linear robots or gantry
robots, are industrial robots that work on three linear axes that use
the Cartesian Coordinate system (X, Y, and Z), meaning they move
in straight lines on 3-axis (up and down, in and out, and side to
side). Cartesian robots are a popular choice due to being highly
flexible in their configurations, giving users the ability to adjust the
robot’s speed, precision, stroke length, and size.
b. CYLINDRICAL ROBOTS:
Cylindrical Robots have a rotary joint at the base and a prismatic
joint to connect the links. The robots have a cylindrical-shaped
work envelop, which is achieved with rotating shaft and an
extendable arm that moves in a vertical and sliding motion.
Cylindrical Robots are often used in tight workspaces for simple
assembly, machine tending, or coating applications due to their
compact design.
c. SPHERICAL ROBOTS:
Spherical robots have an arm with two rotary joints and one linear
joint connected to a base with a twisting joint. The axes of the
robot work together to form a polar coordinate, which allows the
robot to have a spherical work envelope. These robots are
commonly used for die casting, injection moulding, welding, and
material handling.

d. SCARA ROBOTS:

SCARA is an acronym that stands for Selective Compliance

Assembly Robot Arm or Selective Compliance Articulated Robot
Arm. SCARA Robots function on 3-axis (X, Y, and Z), and have a
rotary motion as well. SCARA Robots excel in lateral movements
and are commonly faster moving and have easier integration than
Cartesian Robots. Typically, SCARA robots are used for assembly
and palletizing, as well as bio-med application.

e. ARTICULATED ROBOTS:

Articulated Robots mechanical movement and configuration

closely resembles a human arm. The arm is mounted to a base with
a twisting joint. The arm itself can feature anywhere from two
rotary joints up to ten rotary joints which act as axes, with each
additional joint or axis allowing for a greater degree of motion.
Most Articulated Robots utilize four or six-axis. Typical
applications for Articulated Robots are assembly, arc welding,
material handling, machine tending, and packaging.

f. PARALLEL ROBOTS:

Parallel robots possess three arms connected to a single base,

which is mounted above the workspace. These Robots work in a
dome-shape and can move both delicately and precisely at high
speeds due to each joint of the end effector being directly
controlled by all three arms. Delta/Parallel Robots are often used
for fast pick and place applications in the food, pharmaceutical,
and electronic industries.

SUBMITTED BY Golla Vara Prasad ( GU-2018-3221)