https://www.youtube.com/watch?

v=7f7EhjRai_Y
 Scheme of Valuation
AUTOMATION AND ROBOTICS (20EC53I)
Q.
DESCRIPTION MARKS
NO
1a Any 10 benefits explanation 10*1m=10m

1b Explanation on Programmable Automation 10m

2a Benefits (Any 5) +Drawbacks (any 5) 5m+5m=10m

2b Explanation+ Benefits 10m

3a Quantity checking Sensors +Quality Checking Sensors 5m+5m=10m

3b Explanation about VFD function 10m

4a 5 different Sensors+5 equipment’s with Actuator 5m+5m=10m
4b List industrial Protocols+ Explanation for 4 Protocols 2m+4*2m=10m

5a Explanation about input malfunction+ output malfunction 5m+5m=10m

5b Block diagram+ Explanation 4m+6m=10m

6a 5 different actuators and their Advantages and disadvantages 5m*2=10m
6b i)Any 5 differences. +ii) Any 5 differences 5m+5m=10m

7a Types of Grippers(5m) +Criteria(5m) 5m+5m=10m

7b 5 different types of Robots with diagram 5m*2=10m

8a 5 Different Programming methods 5*2m=10m

8b Block diagram(3m)+Explanation 4m+6m=10m

9a i)Any 5 differences(5m)+ii) any 5 Significance(5m) 5m+5m=10m

9b Explanation for Robot path planning for AGV 10m

10a List of Advantages +Each Explanation 2m+8m=10m

10b Role of AI explanation 10m

SECTION I
1 a) Illustrate the benefits of automation in automobile industry. 10Marks
Benefits of Automation in automobile industry
1) Reduction in cost: Industrial automation helps improve productivity, quality and system
performance, which in turn reduces the operating expenses. However, the major advantage of
an industrial automation system is the reduction in manufacturing costs. Instead of a floor full
of workers, a few supervisors and key personnel can ensure that the systems are running
properly. Instead of a pile full of defective products or parts, a streamlined system can be
designed to have very few, if any, defective products.
2) Increase in productivity: These systems allow continuous mass production which can run
24/7. In simple words, automation systems will improve productivity because they never have
to take a break, go home, or stop running. Another benefit of automation system running is
that it frees up humans to do what they do best: The staff need not have to perform
monotonous job, they have the room to be creative and productive at work.
3) Enhances quality: By means of adaptive control and monitoring in different stages and
industrial processes, these industrial automation systems are useful in eliminating human
error, thus improving the quality of the products offered. If programmed correctly and without
any external interruptions, automated system will behave exactly as intended until the
program is changed or the system is turned off. Because there is very little, if any, room for
human interference, the chance for error is removed.
4) Precise results: Data automation is based on accurate data integration and connectivity.
When accurate information is used in the production process, you will get precise results. All
solutions help to get detailed data that can be analyzed using data analytics tools to get
accurate information to improve industrial processes.
5) Promotes industrial safety: Another huge benefit of automation is improved safety in the
workplace. Industrial automation keeps workers from going too close to the assembly lines,
thereby enhancing the safety of the workers. Thermal sensors continually check the
temperatures in the production area. In some cases, the thermal sensors can identify any spike
in temperature and send an alert. Immedi
6) ately after, certain precautions can be taken to ensure the safety of everyone on the production
floor.
7) Increase in human efficiency: The systems that a company implements to automate their
services will not only perform the tasks that a human being would do, but these automated
systems are capable of performing functions that exceed the capabilities of a real person.
8) Predictive maintenance: A huge benefit of industrial automation is that it helps in
monitoring and predictive maintenance. Production lines and the production floor can be
continuously monitored using sensors. These sensors track temperature, acoustics, time,
frequency, oil pressure, and other parameters related to the production process. If the sensors
detect any change in these parameters, they will immediately send an alert. the alert is
received, the technicians can immediately identify the cause of the change. If it is noted that
the changes in parameters may cause equipment problems or issues in the production process,
then immediate service or repairs can be done.
9) Industrial Communication: Without industrial communication, industrial automation can
be near impossible. The communication system helps monitor and operate entire production
lines, manage power distribution, and control machines. The most popular protocols for
industrial communication are Fieldbus, PROFIBUS, EtherCAT, EtherNET/IP, and CANopen.
Industrial communication allows for faster data analysis and real-time decision making.
10) Equipment Monitoring: An automated equipment monitoring system helps observe the
working condition of all the equipment in the manufacturing unit. Sensors, cameras, and
network can be used to observe the equipment from a far. The monitoring system also helps
 diagnose any issues in the equipment and do the necessary repairs and services. This
automated solution can be effectively used in petrochemical plants, manufacturing units, and
other industries where large and complex machines are used. The automated system enhances
safety, reduces the number of operators on the floor, and improves machine performance and
lifespan.
11) Production Traceability: Automating the entire production process can greatly help in
production tracing. Traceability is not only important in the food and beverage industry, but
also in other industries. Tracing helps increase the quality and value of your product and
facilitates mapping. Also, traceability makes root cause analysis more effective and aids
continuous development. Automation helps trace the entire life cycle of a product from the
raw material to the location where the final product is shipped. You will also have a clear
record of when and who did the product inspections, the assembly status, and the condition of
the machine when the product was processed.
b) A food processing industry having permanent automation was not able to meet the
demands of market supply due to slow production. Explain how programmable
automation contribute to enhancing productivity.
10Marks
Industrial automation is a system that allows manufacturing companies to increase
productivity through computerized technologies. Programmable automation is one such
automated manufacturing system designed to accommodate batch processes and facilitate
changeover of products. Like any industrial automation process, programmable automation
features production equipment tooled with computer-controlled devices that control and
monitor a sequence of Industrial automation systems are systems designed to replace the
repetitive and mechanical tasks associated with one person and decisions made by them in the
manufacturing process. Intended to operate automatically to achieve output at a higher and
consistent level, automated devices can be programmed to control processes, but also have
the capability of making decisions during production processes.
Programmable automation utilizes an assortment of CNC (Computer Numerical Controlled)
machine tools, industrial robotic applications, and programmable logic controllers (PLC) that
work in real time. Operational efficiency is accomplished through the application of logical
programming commands with automation technologies that power equipment and machinery.
As an automated process, programmable automation:
Dramatically increases production and output .
Lowers associated costs.
Improves the work environment for employees by not only intellectually engaging them in
production
Removes humans from performing repetitive or hazardous tasks.
2 a) List the benefits and drawbacks of implementing automation in inventory management
of an industries. 10Marks
Inventory management refers to the supervision of flow of goods and materials from the
warehouse to the point of sale. An inventory management system can simplify the process
of ordering, storing and using inventory by automating end-to-end production, business
management, demand forecasting and accounting.
The benefits of automation is as follows:
 1) It makes the existing process of inventory management seamless.
2) It reduces the need for redundant tasks and contributes at several levels in a business.
3) Inventory management helps wholesalers, retailers and ecommerce business owners edit,
manage, and monitor their inventory in real time by using automated platform
4) The main benifit of inventory management comes in the cost reduction of the business and
making processes seamless so that key stakeholders can focus on more critical decisions for
their business rather than just getting involved in minute tasks related to inventory.
The advantages of automation for Inventory management are:
1) Automation helps save time
2) Automation ensures accurate inventory level (Real time data)
3) Automation improves the quality of delivery
4) Automation helps cut down on business costs
5) Automation reduces the risk for human error
The drawbacks of automation for Inventory management are:
1) Return on Investment (ROI)- Some automated services come with costs, so ROI has to be
considered before automating.
2) Complexity - Some tasks that are to be completed on daily basis tasks are complex, so
automating them may be difficult
3) Security –There are computer security-related problems like hacking attempts which needs
to be considered
4) Integration Compatibility - The platform chosen must be compatible with the existing
system in use.
5) Dependency on Technology: Relying heavily on automation can create vulnerabilities,
such as system failures or cyber-attacks, which could disrupt operations.
6) Job Displacement: Automation could potentially lead to job displacement for workers
involved in manual inventory management tasks, although it may also create new job
opportunities in technology and maintenance roles.
b) Illustrate with an example the implementation of industry 4.0 in any manual/semi
manual industry.
10Marks
An industry 4.0, or the “Fourth Industrial Revolution”, is widely used as the key for
manufacturers to unlock cost reductions and achieve new efficiencies. It has the potential to
centrally change the way manufacturers and industrial companies run their business. It means
using the power of the internet to link machines, sensors, computers, and people to boost
levels of data monitoring, processing, and analysis.
Industry 4.0 makes everything in your supply chain “smart” – from smart manufacturing and
factories to smart warehousing and logistics. But Industry 4.0 does not stop at the supply
chain. It inter-connects with back-end systems, like enterprise resource planning (ERP), to
give companies an unprecedented level of visibility and control.
 Ultimately, Industry 4.0 is a major part of any company’s digital transformation. It can be
implemented as follows:
1) For a company producing various products, intelligent workstations can be set up that which
can quickly switch between products as required
2) Adapt a technology to help the quick learning of manual work steps. Guiding assembly
steps, checking all assemblies via a 3D camera can be done.
3) Radio-frequency identification (RFID) of each single product can be used to ensure that
workers could pick only the necessary components for the new run
4) Each workstation can recognize employees via a Bluetooth tag and every step of the process
can be recorded and relayed to production operatives in real-time.
5) Technology can be used to ensure workers receive exact instruction tailored to their
qualification level and preferred language.
The benefits of implementing industry 4.0:
Radical improvements in productivity and automation: Businesses are making
datadriven decisions across their operations, improving forecast accuracy, supporting on-
time delivery, and building profit-optimized plans.
Flexible matter what the market or economy bring: Companies are shaping the future
digital supply chain based on state-of-the-art planning.
Confidence to explore new business models and seize opportunities quickly: Due to
Industry 4.0 solutions, businesses are reducing costs, improving market efficiency, and
connecting supply chains by sea, land, and air.
Green and sustainable solutions without sacrificing profitability: Customers are
becoming more efficient and cost-effective by going digital while meeting their
environmental objectives without compromising on other business goals, such as
profitability and scalability.

SECTION II
3 a) illustrate the role of sensors in beverage company for the quantity and quality checking
of beverage filled in bottles. 10Marks
The sensors play a major role in the filling and checking processes in an industry. There are
many sensors used in this process along with the conveyor to move the bottles and PLC to
control them.
Types of sensors used to check the quantity of beverage filled:
1) Load Cells - Force Sensors Used in Bottle Filling Plant.
 Beverage manufacturers recognize that bottle overfilling can cause enormous production
losses. Hence, engineers and production managers need accurate sensor solutions that allow
for precise weight and load measurement and filling closed-loop control systems on
automatic filling machines.
 Though several methods and sensors for checking fill levels exist, the physical weight is the
most important process variable.
  An LSM Series Load Cell is mounted inline below a platform supporting a container being
filled.
 As the container is filled, the LSM series sensor weighs the fluid dispensed into the
container.
 The weight signal from the LSM series sensor is sent to an IDC305 Digital Controller (SPI
signal), IPM650 Digital Display (Amplified Analog Signal), or IAA series Analog Amplifier
(Amplified Analog Signal) to convert the signal and send it to a compatible PLC or micro
controller.
 The PLC or micro controller reads in the signal and shuts off the dispenser when the correct
weight of fluid is dispensed.
2) Using Ultrasonic Sensors to Detect Bottle Fill Levels  Ultrasonic sensors produce a
sound wave which reflects off of any surface in its path, identifying if there is a product
present or not and indicating its distance from the sensor.
3) Volumetric method (flow valve based on volume) :  The alternative solution is the
conventional volumetric automatic bottle filling machine (aka automatic liquid filling
machine), which controls the flow valve based on volume.
 The drawback of the volumetric method is that the material conditions can affect the final
weight.
Types of sensor used to check the quality of beverage filled :
 Infrared sensor detects the bottle, the conveyor motor stops to move and the dc pump will
start to flow the water to fill the bottle. After completing the filling operation, the dc pump
stops. Hence the conveyor motor starts to move and the bottle goes away from the dc pump.
 A pH sensor helps to measure acidity or alkalinity of the water with a value between 0-14.
 Turbidity sensor detects water quality by measuring the levels of turbidity, or the
opaqueness. This sensor has been modified to detect microbial contamination if any, present
in the liquids and beverages and uses light to detect suspended particles in water by
measuring the light transmittance and scattering rate.
 Color sensor: These sensors are the photoelectric devices that can emit light and detect the
color of reflected light from an object.
 Moisture sensor produces an output voltage according to the resistance, which by
measuring we can determine the moisture level.
 EyeSens BI Sensor: For the inspection of beverage bottles, EVT has come up with a vision
sensor especially for the beverage industry, the EyeSens BI (Bottle Inspect). This vision
sensor contains prefabricated programs to inspect bottles if the cap is closed, open, askew,
or missing.
b) How can the speed of a conveyor belt in a packaging industry be controlled by
interfacing a motor drive to a PLC.
10Marks
The present industrial world needs advancement in the field of technology to build better
automation process. The Motion control of the systems is one common scenario needed in all
the industries. Earlier Gear Boxes were used for control of machines and DC drives were
mostly used for variation of speed in industries for small scale applications only. With the
coming of AC Drives there is a major breakthrough in which motion control of large devices
 became comfortable. Conveyor is being greatly used in the Industrial processes. Hence
control of conveyor is of paramount need along with the PLC and VFD leading to work
automatically.
To incur an accurate controlling of a Conveyor, PLC ought to be interfaced with VFD Drive,
Personal computer and other equipment. Relay that is a switching device decides the
operation of VFD and Induction Motor. Variable frequency Drive (VFD) is being utilized in
the industry that can provide a control on various motor parameters. It finds its application in
the manufacturing process, machines, pumps, rolling mills etc. Thus, VFD when compared
with other starting and control methods is proved to be a better alternative. VFD raises the
productivity in terms of quality and product system efficiency thereby reducing the cost of
operation of the system.
Block Diagram.

PLC sequentially scans the input devices then it will update its memory and finally indicate
the status of its action in a PLC ladder logic. It exploits the output coil of it in order to change
condition of device at the output side. Then interfacing of VFD to the conveyor through
induction motor is exercised. By means of logic functions like Start, Reverse, Reset and Jog
the automatic control conveyor motor is accomplished. When Start is on the first relay gets
activated then the conveyor runs in forward direction. If Reverse action takes second relay
runs, then the conveyor is in reverse direction. Reset operation is performed when there
occurs error in execution then the conveyor doesn’t run and simultaneously the third relay
gets activated. The conveyor performs Jog operation when the Jog logic is being executed and
fourth relay is in action. Four inputs to PLC is given by push buttons. By then the Outputs
from PLC is fed to relays input. This will process inputs availing the logic given via ladder
program. It will then initiate output to VFD which upon performing its operation send signals
to the induction motor. Then, accordingly VFD control of speed and direction of the conveyor
is caused. For the speed control of the Conveyor if the frequency of the induction motor
which is connected to the conveyor then the speed of the conveyor can be easily regulated.
The following formula clearly depicts this control action.
4 a) Describe different Sensors and Actuators used in laptop packaging industry.
10Marks
In the laptop packaging industry, sensors and actuators play crucial roles in ensuring the
quality, efficiency, and safety of packaging processes. Some examples of sensors and
actuators commonly used in laptop industry:
 Sensors:
1. Pressure Sensors: Pressure sensors are used to monitor and control the pressure applied
during the packaging process, ensuring that the packaging materials are sealed properly
without damaging the laptop inside.
2. Temperature Sensors: Temperature sensors help monitor and control the temperature
conditions during packaging to prevent overheating or damage to the laptop components.
3. Humidity Sensors: Humidity sensors measure the moisture levels in the packaging
environment to prevent moisture-related damage to the laptops, especially during storage
and transportation.
4. Motion Sensors: Motion sensors detect any sudden movements or vibrations during
handling and transportation, helping to prevent damage to the laptops caused by impacts or
rough handling.
5. Proximity Sensors: Proximity sensors are used to detect the presence of laptops and
packaging materials at various stages of the packaging process, ensuring accurate
positioning and alignment.
6. Barcode Scanners: Barcode scanners are used to read and verify the barcodes on the
laptop packaging, ensuring accurate tracking and traceability throughout the supply chain.
7. Weight Sensors: Weight sensors measure the weight of the packaged laptops to ensure
compliance with shipping regulations and prevent under or overloading of packages.
Actuators:
1. Conveyor Systems: Conveyor systems use actuators to move laptops and packaging
materials along the production line, facilitating automated packaging processes and
improving efficiency.
2. Robotic Arms: Robotic arms equipped with actuators are used for precise handling and
positioning of laptops and packaging materials, especially in high-speed packaging
operations.
3. Sealing Machines: Sealing machines use actuators to apply heat, pressure, or adhesive to
seal the laptop packaging securely, protecting the laptops from external elements and
ensuring tamper-evident packaging.
4. Labeling Machines: Labeling machines use actuators to apply labels, stickers, or tags to
the laptop packaging, providing product information, branding, and tracking details.
5. Ejector Systems: Ejector systems use actuators to eject finished packaged laptops from
the production line onto conveyor belts or pallets for further processing or shipping.
6. Pneumatic Grippers: Pneumatic grippers are actuators used to grip, lift, and manipulate
laptops and packaging materials with precision and control, especially in robotic
packaging systems.
7. Filling Machines: Filling machines equipped with actuators are used to fill packaging
materials, such as air cushions or protective foam, to cushion and protect the laptops
during shipping.
b) What are the common industrial protocols used in automation industries, and explain any
4 protocols. 10Marks
 The Communication protocols is the way to trans-receive the data with a set of rules that
sends or receives between two or more devices.
 The communication protocol is the media or channel between two or more communicating
devices.
 By using the communication protocols, two devices can connect and communicate with each
other. Without communication protocol, devices can only be connected but not communicated.
 The communication protocols not only being to used expand the PLC network and Also its
used to expand number of IO devices by connecting additional modules (Expansion modules).
Most commonly used protocols with PLC in Beverage industry are:
 Modbus RTU
 EtherNet/IP and Ethernet TCP/IP
 Modbus TCP/IP
 Profibus
 Profinet Modbus RTU
 Modbus RTU is an open serial protocol derived from the Master/Slave architecture. It is a
widely accepted serial level protocol due to its ease of use and reliability.
 Modbus RTU is widely used within Industrial Automation Systems (IAS), Home
Automation, Building Management, Robotics etc.
 This protocol primarily uses an RS-232 or RS-485 serial interfaces for communications and
is supported by almost every commercial SCADA, HMI, OPC Server and data acquisition
software program in the marketplace.
EtherNet/IP and Ethernet TCP/IP  EtherNet/IP is an open application protocol,
maintained and distributed by ODVA. EtherNet/IP is used by Ethernet modules for several PLC’s
including Allen Bradley, Schneider Electric, and Omron. EtherNet/IP is an Ethernet adaptation of
the Control Information Protocol (CIP) in the same way that DeviceNet is a CAN adaptation of
CIP and ControlNet is a CTDMA adaptation of CIP.  EtherNet/IP I/O provides a mechanism of
deterministically sending data in both directions between a PLC and remote device. This data is
sent on an interval called the Requested Packet Interval (RPI). EtherNet/IP I/O is a very fast and
easy-to-use method of communication. It reduces the amount of ladder logic required for
communication, and communication occurs even when the PLC is in Program mode.
 Ethernet TCP/IP is responsible for the transmission of the packets, which are composed of
Modbus frames containing commands to read/write into the shared memory of a device.
Modbus TCP/IP  Modbus TCP/IP is a simple Modbus protocol running on Ethernet over a
TCP interface. Modbus is an application protocol that assigns the ways of managing and passing
data between various layers without being affected by the protocol used by the next immediate
layer.
PROFIBUS  PROFIBUS as process field bus, is a standard for fieldbus communication in
automation technology, which is extensively used by Siemens.
 Profibus communicates via a serial protocol behind which a complex machinery is housed
to transport the data reliably through an industrial environment.
  The PROFIBUS protocol is designed for high-speed communications with distributed I/O
devices (remote I/O).
 Profibus connection port look like DB-9 serial connector but protocol is totally different.
Profinet :  Profinet is process field net, is an Ethernet-based communication protocol. The
physical interface used for Profinet is a standard RJ-45 Ethernet jack.
 Profinet cables are easily recognizable by their green color.
 Due to its high-speed operation and a response time of less than 1 millisecond, Profinet is
ideal for high-speed applications.

SECTION III
5 a) What steps should be included in a troubleshooting procedure for PLC
malfunctions in industrial settings.
10Marks
Troubleshooting Input Malfunctions, The steps taken can be summarized as follows:
 When input hardware is suspected to be the source of a problem, the first check is to see if
the status indicator on the input module illuminates when it is receiving power from its
corresponding input device (e.g., pushbutton, limit switch).
 If the status indicator on the input module does not illuminate when the input device is on,
take a voltage measurement across the input terminal to check for the proper voltage level.
 If the voltage level is correct, then the input module should be replaced.
 If the voltage level is not correct, power supply, wiring, or input device may be faulty.
 If the programming device monitor does not show the correct status indication for a
condition instruction, the input module may not be converting the input signal properly to the
logic level voltage required by the processor module. In this case, the input module should be
replaced.
 If a replacement module does not eliminate the problem and wiring is assumed to be
correct, then the I/O rack, communication cable, or processor should be suspected. The circuit of
Figure illustrates how to check for discrete input malfunctions
 Troubleshooting Output Malfunctions modules
 If the blown fuse indicator is not illuminated (fuse OK), then check to see if the output device
is responding to the LED status indicator.
 An output module s logic status indicator functions similarly to an input module s status
indicator
 When it is on, the status LED indicates that the modules logic circuitry has recognized a
command from the processor to turn on.
 If an output rung is energized, the module status indicator is on, and the output device is not
responding, then the wiring to the output device or the output device itself should be suspected.
 If, according to the programming device monitor, an output device is commanded to turn on
but the status indicator is off, then the output module or processors may be at fault.
 Check voltage at output; if incorrect, power supply, wiring, or output device may be faulty.
b) Design a PLC based system for controlling a baggage handling system for an airport
Luggage /baggage system considering four different destinations. 10 Marks
PLC based design for controlling a baggage handling system for an airport luggage/baggage
system is as shown in the below diagram. It has conveyer belts, sensors, security scanner, bar code
scanner, sensor to detect baggage jam.
Every luggage/baggage has a tag with a bar code which will be read by a scanner to route to
the appropriate baggage car/truck waiting to take its designated luggage/baggage load to an
awaiting flight.
First the baggage is loaded at the check-in counter. Next it is screened and routed through
security. Next the baggage is routed to the baggage car for the appropriate flight based on the
scanned bar code on the luggage tag. The system has sensors to detect baggage that is too close to
one another or that has caused a luggage jam. When an object is detected as too close, the system
will slow down the second piece of baggage to allow for more space; a detected jam will set off
an alarm. The system has a bar code scanning system to read the luggage/baggage tags so that the
system can route the baggage appropriately.
 A simple ladder logic program should be done to control the X-ray scanner, bar code scanner,
sensors for detecting jams and baggage items that are too close to each other and a mechanism to
push the baggage onto the final appropriate conveyor belt. An emergency stop and a motor
running the belt system denoting when the system is running, should also be available. For safety
purpose, a denoting when the system is running, stopped or off can be installed.

6 a) Explain advantages and disadvantages of different types of actuators used in

pharmaceutical industry. 10Marks
Types of Actuators:
1.Actuators are basically classified into the following two types based on their movement. 
Translational  Rotational It is possible to convert one form of actuation to another. For example,
translational motion is converted into rotational and vice versa by suitably designing the
interfacing components around the actuator. Rack and pinion, gears, pulleys, lead screw and nut,
and cams can be used as interfacing components.
2. Actuators can be classified into the following types based on the type of energy.
1. Electrical
2. Electromechanical
3. Electromagnetic
4. Hydraulic
5. Pneumatic
Electrical Actuators: An actuator obtaining electrical energy from the mechanical system is
called electric actuators. Electric actuators are generally referred to ad being those where an
electric motor drives the robot links through some mechanical transmission i.e. gears.
Electrical actuators comprise the following:
1. Drive system: DC motor, AC motor, Stepper motor
2. Switching Device: a. Mechanical switch: Solenoids, Relays
b. Solid-state switch: Diodes, Thyristor, Transistors
 Advantages of Electrical Actuators:
 High power conversion efficiency.
 The widespread availability of power supply.
 No pollution of the working environment.
 The basic drive element in an electric motor is usually lighter than that for fluid power.
 Structural components can be lightweight.
 The drive system is well suited to electronic control.
Disadvantages of Electrical Actuators:
1. A larger and heavier motor must be used which is costly.
2. Poor dynamics response.
3. Compliance and wear problems are causing inaccuracies.
4. Conventional gear-driven creates a backlash.
5. Electric motors are not intrinsically safe.
They cannot, therefore, be used in for explosive atmospheres.
Electro-mechanical actuators: Electromechanical actuators are electrical motors that convert
electrical energy into mechanical motion. Motors are the principal means of converting electrical
energy into mechanical energy in industry. Broadly, they are classified into DC motors, AC
motors, and stepper motors.
Electro-magnetic actuators: An electromagnetic actuator is a device that provides working
motion due to an internal electromagnetic field. The solenoid is the most common electromagnetic
actuator. A solenoid consists of a static, hollow-centered wire coil and a movable ferrous metal
plunger. When the wire coil is energized, a magnetic field establishes that provides the force to
push or pull the metal plunger.
Hydraulic and Pneumatic Actuators: A proper selection of actuators and their drive systems for
a particular application is of utmost importance in the design of mechatronic systems.
Hydraulic Actuators:  Hydraulic actuators transform the hydraulic energy stored in a reservoir
into mechanical energy by means of suitable pumps.
 Hydraulic actuators are also fluid power device for industrial robots which utilize high-pressure
fluid such as oil to transmit forces to the point of application desired. Advantages of hydraulic
actuators:
1. It has the advantage of generating extremely large force from a very compact actuator.
2. It can also provide precise control at low speeds
3. robust.
4. self-lubricating.
5. Due to the presence of an accumulator that acts as a storage device the system can meet
sudden demand in power.
6. No mechanical linkages are required.
 7. High efficiency and high power to size ratio.
Disadvantages of hydraulic actuators:
1. The hydraulic system is required for a large infrastructure is high-pressure pump, tank,
distribution lines.
2. Leakage can occur causing a loss in performance.
3. High maintenance.
4. Not suitable for a clean environment.
Pneumatic actuators:  Pneumatic actuators utilize pneumatic energy provided by a compressor
and transforms it into mechanical energy by means of a piston or turbines.
 Pressurized air is used to transmit and control power.
 Pneumatic actuators are devices that cause things to move by taking advantage of potential
energy.
Advantages of Pneumatic Actuators: The advantages of Pneumatic actuators are as follows,
1. Control is simple.
2. When the source of compressed air are readily available, as they often are in engineering
related facilities, pneumatic actuators may be a good choice.
3. It is the cheapest form of all actuators
4. Pneumatic actuators have very quick action and response time, thus allowing for fast work
cycles.
5. No mechanical transmission is usually required.
Disadvantages of Pneumatic Actuators:  More noise and vibration.
 Since air is compressible, pneumatic cylinders are not typically used for applications requiring
accurate motion between two well-defined endpoints.
 Pneumatics are not suitable for heavy loads.
 If mechanical stops are used, resetting the system can be slow.
b) i) Illustrate the differences between i |) PAC and PLC. 5 Marks
ii) Arduino and other micro controllers. 5 Marks
 Sl.No Arduino Micro Controller

1 Arduino is not a micro controller, It is just a micro controller that can be 8

but a system based on an AVR bit,16-bit or 32-bit
(micro controller of ATMEL
family)
2 It has its own IDE (s/w and h/w To program the micro controller, an external programmer board i
libraries) to program this board. required to program the chip.
(open source)
3 It has almost every essential part Breadboard, DC power supply, wires etc are
(ports) needed to start a project required to do any experimentation project
on the board itself
4 It Has 32KB of flash memory It has less RAM (128 bytes), some micro
and 2KB of SRAM.EEROM is controllers do not have EEPROM.
there to store long term
information
5 Operating voltage 6V to 20V via Operating voltage +5V. It requires an
Vin pin.It has power supply jack external power supply
which has inbuilt 5-v and 3-V
regulators
6 Applications: home automation Applications: remote controls, power tools,
system, IoT etc auto engine control systems, toys and more
SECTION IV
7 a) What are the different types of grippers used in industrial applications and what
criteria should engineers consider when selecting grippers to maximize productivity in
manufacturing processes. 10Marks
The grippers are mainly used in a robot for grasping or holding an object.
They are classified as:
1) Vacuum Grippers– Vacuum grippers depend on atmospheric pressure and a vacuum to lift,
move, or hold objects. This vacuum is created by miniature electromechanical pumps or
compressed air-driven pumps. The vacuum flow must be uninterrupted so that the Cabot can
safely hold the object it has picked up. These are four and ten times more powerful than
electromechanical grippers Applications: packaging and palletizing.
2) Pneumatic Grippers– Pneumatic grippers use pistons and compressed air to operate fingers
(jaws). This type of gripper will be mostly found in a 2-finger or 3-finger configuration. They can
be used for an many applications. Application: It can be used in tricky multi operation tending
task inside CNC machines (placing parts in CNC machine, dipping the CNC finished part in
rinsing solution, pass it through an air jet before finally placing the washed and dried part on a
rack for shipping)
3) Hydraulic Grippers – Hydraulic fluids power these hydraulic grippers. Hydraulic grippers
give more gripping power than pneumatic grippers, making them suitable for heavy duty
applications Application: For heavy applications that require higher levels of gripping power.
However, this type of gripper will require extensive maintenance and might be unsuitable for
medical applications.
4) Electric Grippers – Electric grippers are a popular choice for many cobot applications
including machine tending and pick & place. Although they do not offer the same strength as their
hydraulic counterparts, electronic grippers can improve high-speed applications that require
moderate or light gripping force.
5) Magnetic grippers: Magnetic grippers can be configured by permanent magnets or
electromagnets. Permanent magnets, don’t need of an external supply for grasping but
electromagnets, have a controller unit and a DC power which can grasp magnetic objects.
Criteria for selection of the right robot gripper:
There are several factors to keep in mind when choosing a gripper, but the most important is to be
led by the specific application you have in mind.
Some of them are:
• Will the gripper be handling a single item or a mix?
• What types of items –foodstuffs, electrical components, for example.
• Part to be handled: - The weight, size, and shape needs to be considered.
• Power and signal transmission: Pneumatic, electric, mechanical or hydraulic needs to be
considered.
• The feedback data from the gripper is required or not is to be considered.
• Gripper force- Weight of between fingers needs to be considered.
• Positioning: Length of the fingers and tolerance of the part size needs to be considered.
• Operating Environment: We need to check whether gripper be opera humidity, or dirt
environment.
b) Explain types of Robots used in different Industries for specific operational
Challenges or tasks. 10Marks
Types of Robot :
1) Cartesian Or Rectangular Configuration
2) Cylindrical Configuration
3) Spherical Configuration
4) Articulated (Revolute) Configuration
5) SCARA configuration
1)Cartesion Or Rectangular Configuration
• All arm joints are linear
• Movement along all 3 axes can occur simultaneously
• Work envelop (covering design) is rectangular
Advantages: Simple in control and good accuracy
Disadvantages: This is limited for certain movements only
Applications: For assembly, Surface finishing, Inspection etc.
1) Cylindrical Configuration
• This Robot have good rigidity and are good for jobs requiring straight line moves.
• It has 2 linear joints and 1 rotary joint.
• Work envelope is cylindrical.
Advantages: Larger work envelop than Cartesian configuration
Disadvantages: More sophisticated control system required than Cartesian
Applications: Suitable for Pick and Place operations.
2) Spherical Configuration
• It has 1 linear joint and 2 rotary joints.

• The work envelope is Spherical

• It has more movements compare to Cartesian and Cylindrical robots
 Advantages: Simple is Design and larger work envelope
Disadvantages: More sophisticated control system compare to Cartesian and Cylindrical robots
Applications: Forging, Material transfer etc.
4)Articulated or Joint arm or Revolute configuration
• It has 3 rotary joints.
• A wrist is attached to the end of the 4 arm to provide additional joint.
• The work envelope is of irregular shape
Advantages: Larger work envelope compare to Cartesian, Cylindrical and Spherical robots
Disadvantages: More sophisticated control system compared to Cartesian, Cylindrical and
Spherical robots.
Applications: Used for complicated kind of work like welding, drilling etc.
5) SCARA (Selective Compliance Articulated Robot Arm) Configuration:
• The SCARA configuration or a Spherical configuration version of the jointed arm robot.
Whose shoulders and elbow joints rotate about vertical axis along horizontal axis.
Advantages: Larger work envelope and has versatile configuration etc.
Disadvantages: It requires sophisticated control compared to other robots
Applications: Suitable for automatic assembly, Painting, welding etc
8 a) Explain the different programming methods employed in robotics to analyze their
effectiveness and suitability for various tasks. 10 Marks
Programming the Robot There are various methods which Robot can be programmed to perform
a given task
1)Manual method • This method is not really programming in the conventional sense of the
world. It is more like setting up a machine rather than programming.
• It is the procedure used for the simple robots and involves setting mechanical stops, switches
and control unit.
• This is used for pick and place operations.
2)Walk through Method • In this method the programmer manually moves the robot arm and
hand through the motion sequence of the work cycle. • Each movement is recorded into memory
for frequent playback during production.
• The speed with which the movements are performed can usually be controlled independently.
• The main concern is to get the position sequence correct. • The walk-through method would be
appropriate for spray painting and arc welding robot.
3)Lead through/ Teach through method • The lead through method make use of a teach pendant
to power drive the robot through its motion sequence.
• The teach pendant is usually a small hand device with switches and dials to control the robots’
physical movements.
• Each motion is recorded into memory for future play back during the work cycle.
• The control method is very popular among robot programming method because of its ease and
convenience.
4)Off-line programming • This method involves the preparation of the robot program offline, in
a manner like numerical control programming.
• Offline robot programming is typically accomplished on a computer terminal.
• After the program has been prepared, it is entered into the robot memory for use during the work
cycle.
• The advantage of offline robot programming is that production type of the robot is not lost to
delay and teaching a new task.
• Programming offline done when the work still in reduction. This means higher utilization of the
robot and the equipment with which it operates.
5)Textual Programming • This method uses an English like language to establish logic and
sequence of the work cycle.
• A computer terminal is used to input the program instructions into the controller but a teach
pendant is also used define the locations of the various points in the work space.
• The robot programming language names the points as symbols, in the program and these
symbols are subsequently defined by showing the robot for their locations
b) How can an Arduino-based obstacle detection robot be designed and implemented?
Write block diagrams to illustrate the design process. 10 Marks
Designing and implementing an Arduino-based obstacle detection robot involves several key
components and steps. Block diagrams to illustrate the design process:

1. Hardware Components:
 Arduino microcontroller (e.g., Arduino Uno or Arduino Nano)
 Ultrasonic distance sensor (e.g., HC-SR04)
 Motor driver (e.g., L298N) or motor control shield
 DC motors (usually two for differential drive)
 Wheels and chassis for the robot
 Power source (e.g., batteries)
 Optional: additional sensors for line following, edge detection, etc
3. Design and Implementation Steps:
Step 1: Hardware Setup:
 Connect the Arduino to the motor driver/control shield and the ultrasonic distance sensor.
 Connect the motor driver to the DC motors that control the movement of the robot.
 Assemble the chassis, wheels, and other mechanical components of the robot.
Step 2: Sensor Integration:
 Write Arduino code to interface with the ultrasonic distance sensor.
 Use appropriate libraries or write custom code to read distance measurements from the
sensor.
Step 3: Motor Control:
 Write Arduino code to control the movement of the DC motors.
 Implement functions to drive the motors forward, backward, turn left, and turn right based
on sensor readings.
Step 4: Obstacle Detection Algorithm:
 Develop an algorithm to detect obstacles based on the readings from the ultrasonic
distance sensor.
 Determine thresholds for obstacle detection and define actions for the robot to take when
obstacles are detected (e.g., stop, turn, reverse).
Step 5: Integration and Testing:
 Integrate the sensor readings and motor control functions into a cohesive Arduino sketch.
 Test the robot in a controlled environment to ensure that it accurately detects obstacles and
responds appropriately.
Step 6: Refinement and Optimization:
 Refine the obstacle detection algorithm and motor control logic based on testing results.
 Optimize the code for efficiency and reliability, considering factors such as power
consumption and responsiveness.
Step 7: Expansion and Customization (Optional):
 Explore additional sensors or features to enhance the capabilities of the robot, such as line
following, edge detection, or wireless communication.
 Customize the design to meet specific application requirements or preferences.
SECTION V
9 a) Distinguish between AMR from AGV. 5 Marks
AMR AGV
1 AMR is an acronym of AGV is an acronym of Automated
Autonomous Mobile Robot. Guided Vehicle.
 2 They do not require any tracks for They require wired or marked tracks for
navigation. navigation.
3 They move freely around obstacles. They get stopped when come in contact
with obstacles.
4 They travel around people more They travel only in dedicated areas due
and highly safe. to safety measures.
5 Expansion of path is easily possible Expansion of path is difficult in AGVs
in AMRs. due to infrastructural changes.
6 AMR have no or little need of AGV are highly dependent on depots for
depots. movement.
7 They are highly flexible and agile. They are less flexible and are not agile.
8 AMRs need simple software AGVs need complex changes in software
changes for their missions. and hardware too.
9 It is less expensive than AGVs. It is comparatively more expensive than
AMRs.
10 Example – Self-driving forklifts Example – Automated guided carts etc.
etc.

ii) Explain the significance of 'degree of freedom' with respect to a robot movement.
5Marks
Degree of freedom is significant in robot movement:
1. Flexibility in Movement: The degree of freedom determines the flexibility of a robot in
navigating its environment and performing tasks. A higher number of DOFs allows a robot to
move more freely and perform a wider range of motions.
2. Manipulation and Dexterity: In robotic manipulation tasks, such as grasping objects or
manipulating tools, the degree of freedom directly impacts the robot's dexterity and ability to
perform complex motions. Robots with more DOFs can achieve more intricate and precise
movements.
3. Workspace Coverage: The number of DOFs influences the workspace coverage of a
robot, which refers to the volume of space that the robot can reach and operate within. A higher
DOF typically results in a larger workspace coverage, enabling the robot to access more areas and
perform a greater variety of tasks.
4. Task Adaptability: Robots with multiple degrees of freedom are more adaptable to
different tasks and environments. They can adjust their configurations and motions to
accommodate variations in task requirements or workspace constraints.
5. Redundancy and Fault Tolerance: Having redundancy in degrees of freedom can
improve a robot's fault tolerance and ability to recover from failures. Redundant DOFs allow the
robot to adjust its motion path in case of obstacles or malfunctions, potentially avoiding collisions
or completing tasks with degraded performance.
6. Control Complexity: While higher DOFs offer greater flexibility, they also increase the
complexity of robot control. Controlling a robot with numerous degrees of freedom requires
sophisticated algorithms and strategies to coordinate motion, ensure stability, and achieve desired
task outcomes.
7. Energy Efficiency: Optimizing the degree of freedom in robot design can lead to more
energy-efficient operation. By minimizing unnecessary DOFs or utilizing passive compliance
mechanisms, robots can conserve energy and improve overall efficiency.
b) Analyse the Robot path planning for AGV. 10 Marks
Automated guidance vehicles are actually mobile robots that are electrically powered and
run on their own. They are guided by a computerized system that determines their movement
with software applications.
AGVs are powered by a battery or electric motor that enables the complete operation of
warehouse loading, manufacturing, and other operations. AGV guidance or navigation system -
Every industry has its own requirements and uses for AGV and it is therefore important to
consider the navigation or guidance system needed before AGV is implemented in the
warehouse. The requirement dictates the functions and routes the AGV.
There are a wide variety of navigation systems that are used to guide these robots. The
navigation system will be determined by the path and is classified in:
• A fixed path
• free-ranging the way an AGV calculates its current position (It has to know where it is and
where to go) is classified as:
• Absolute: Vehicle knows its position at all times for example laser systems
• Relative: The vehicle does not always know its location, a calculation from the previous
position determines its position for example radiometric systems
Magnetic tape - This is a fixed relative system where the AGV is fitted with a magnetic reader in
the front that detects magnetic field fluctuation. Tape embedded on the ground creates a
magnetic field to guide the path. The magnetic reader, wheel turning, scanners are all
connected to a control unit that guides the vehicle into performing complex manoeuvre. RFID
cards are used in conjunction with the magnetic strip and are read at the same time. This
enables the vehicle to:
• Execute stops
• Changes of trajectory
• Take different paths, make stops
• Charge battery.
Optical vision This system is a fixed relative system that is an optical vision-based. With
cameras and sensors, the AGV acquires information about its environment and makes decisions.
There are various types of optical systems, such as:
• QR code recognition: Codes and reference points are arranged on the ground in advance with
great precision. The AGV recognizes them and knows where it is and how far to move and the
right detection or path to get to the next reference.
• Ground guidance: The AGVs path is painted on the ground in a contrasting colour to the
ground. It is similar to the magnetic strip scenario.
 • 3D cameras: This system provides the AGV with images of its surrounding environment in real-
time. It adds values like distance intensity and confidence thresholds, allowing detection of
landmarks and recognizing obstacles and relating it to a pre-loaded map.
• Laser systems: These systems operate freely and are absolute. AGVs with laser navigation are
also called Laser Guided Vehicles (LGVs). These vehicles are fitted with a device that emits
thousands of light beams per second. These light beams bounce off reflectors (catadioptric) that
are captured by a receiver. The system calculates the time that the beam takes to go and come in
order to navigate distance. By being able to detect up to 3 reflectors the vehicle can calculate its
position in a triangle and then compare it to a map stored in its memory. This is a very accurate
and reliable system that lends to great flexibility and when changes are made to the management
software, it does not affect the production environment. This allows the AGV to follow multiple
paths.
• Slam system: This is a free and absolute system and the name is derived from the acronym
“Simultaneous Localization and Mapping.” This navigation technique is quite natural as it allows
the AGV to build a map of the environment and navigate through at the same time. This system
can also use a laser to detect the environment but with SLAM it is not necessary to install
reflectors. The navigation system has a preloaded map with a series of reference points. The secret
is that SLAM uses complex algorithms.
10. a) Give the advantages of ROS over other programming methods. 10Marks
1. ROS is general: The same base code and knowledge can be applied to many kinds of robots:
robotic arms, drones, mobile bases, once you’ve learned about how communication is done
between all the nodes of the program, you can setup new parts of an application very easily. In the
future, if you need to switch to a totally different robotics projects, you won’t be lost.
2. ROS packages for everything You need to compute a trajectory for your robot? There is a
package for that. Use your joystick to control the robot? There is also a package for that. Or you
want to map out a room with a drone? There are many packages to do that. Well, if you search a
little bit, you will find many, many ROS packages for almost any robotic application.
3. ROS is language-agnostic You can easily communicate between a Python node and a C++
node. It means a lot of re usability and possibilities of co working. Many libraries also allow you
to use other languages (because ROS has mainly targeted C++ and Python).
4. ROS has great simulation tools You cannot always get your robot running for real, so you
need simulation tools. ROS has many great tools, such as Rviz and Gazebo. With Gazebo you can
even add some physical constraints to the environment, so when you run the simulation and the
real robot, the outcome is pretty much the same. Imagine mapping a room in 3D with a drone
directly on your computer, that could save you a huge amount of time. The simulation tools also
allow you to see and use other robots that you do not possess, for educational purposes or to test
in a specific environment.
5. You can control multiple robots with ROS ROS can work with multiple ROS masters. It
means that you can have many independent robots, each with its own ROS system, and all robots
can communicate between each other.
6. ROS is light: The core base of ROS doesn’t take much space and resources. You can quickly
install the core packages and get started in a few minutes. Plus, you can also use ROS on
embedded computers, such as Raspberry Pi 3 boards. Thus, you can easily start a new project
without much trouble.
7. More and more compatible ROS products: When you build a robot, you don’t necessarily
want to reinvent or recreate every part of it. You might want to focus on some development points,
and integrate the rest from other manufacturers. The good news here is you can find many
robotics products – such as grippers, controller boards, that already have a ROS package. So, in
addition to the physical tool, the software that goes with it is directly compatible with your ROS
system.
8. ROS is an open-source project: with a permissive license One of the greatest strengths of
ROS is that it’s open source. Most of the core packages are released under a BSD license. A BSD
license allows you to modify and use the code for commercial purposes, without having to release
your code with an open-source license. This can be a good point when a company decides to
integrate an open-source software.
b) Illustrate the role of Artificial Intelligence in Robotics and the advantages. 10 Marks
Role of AI technology used in Robotics
1) Computer Vision • Robots can also see, and this is possible by one of the popular
Artificial Intelligence technologies named Computer vision. Computer Vision plays a crucial role
in all industries like health, entertainment, medical, military, mining, etc.
• Computer Vision is an important domain of Artificial Intelligence that helps in extracting
meaningful information from images, videos and visual inputs and acts accordingly.

2) Natural Language Processing • NLP (Natural Languages Processing) can be used to give
voice commands to AI robots. It creates a strong human-robot interaction.
• NLP is a specific area of Artificial Intelligence that enables the communication between humans
and robots.
• Through the NLP technique, the robot can understand and reproduce human language.
• Some robots are equipped with NLP so that we cannot differentiate between humans and
robots.
• Similarly, in the health care sector, robots powered by Natural Language Processing may help
physicians to observe the decease details and automatically fill in HER
• Besides recognizing human language, it can learn common uses, such as learn the accent, and
predict how humans speak.
3) Edge Computing • Edge computing in robots is defined as a service provider of robot
integration, testing, design and simulation.
• Edge computing in robotics provides better data management, lower connectivity cost, better
security practices, more reliable and uninterrupted connection. 4) Complex Event Process
• Complex event processing (CEP) is a concept that helps us to understand the processing of
multiple events in real time.
• An event is described as a Change of State, and one or more events combine to define a
Complex event.
• The complex event process is most widely used term in various industries such as healthcare,
finance, security, marketing, etc. It is primarily used in credit card fraud detection and in stock
marketing field.
Advantages of integrating Artificial Intelligence into robotics:
• The major advantages of artificially intelligent robots are social care. They can guide people,
especially come to aid for older people, with chat bot like social skills and advanced processors.
• Robotics also helps in Agricultural industry with the help of developing AI based robots.
These robots reduce the farmer's workload.
• In Military industry, Military bots can spy through speech and vision detectors, along with
saving lives by replacing infantry
• Robotics also employed in volcanoes, deep oceans, extremely cold places, or even in space
where normally humans can't survive.
• Robotics is also used in medical and healthcare industry as it can also perform complex
surgeries that have a higher risk of a mistake by human and added Intelligence.

CERTIFICAT
This is to certify that the above model answers is prepared by me which are within the
syllabus prescribed by DTE, and have given relevant solutions whose reference is taken
from genuine websites / Industry / Real time exposure.

MAMATHA M M
Sr. LECTURER ,E&C DEPT,
S.J(GOVERNMENT) POLYTECHNI.
BANGALORE