Chapter 2

The Basic Robot System

• Industrial Robots Components
• Basic Robot Terms
• Robot Classification :
- by Arm Geometry
- by Control System

Prepared by : ADLI BIN BAHARI

Revision: 4
Industrial Robot Components
The system requires 6. Data
storage
6 components: device
• robot arm
• controller
• power source
• end-of-arm tooling 5.
Teaching 2.
• teaching device device Controller
• data storage device

3. Power 4. End-of-
1. Robot
source arm
arm
tooling

Typical industrial robot system

1. The Robot Arm
• example:Elbow
jointed-spherical robot arm (figure
2.3) extension

Shoulder
swivel
Yaw
Arm sweep
Roll

Pitch

Tool
mounting
plate
Figure 2.3 Jointed-spherical robot arm
The Robot Arm - Drive Mechanism

• the robot arm is mechanical system; each joint

must have a drive mechanism:

– hydraulic (compressed fluid)

– pneumatic (compressed air)
– electric (electrical signal)
Hydraulic robot arm system
More ………
Hydraulic robot arm system
 2. The Controller
• definition:
a special purpose computer to control the
robot arm, interface with the teaching
devices and other computers, and do other
communication functions

• the controller is the most complex

component of the robot system

• controller designs are numerous

throughout industry
Robot controller block diagram
System power
converter
Servo drive
interface To all controller
sections
Robot controller Solid state
computer memory
To all controller
sections
Production sensors

Production equipment
System coding
Teaching devices
Input/output
Cassette tape storage section
Feedback sensors
Hard copy printer
Other computer
hardware
The Controller - Components
• The robot controller computer and the solid state memory: together,
provide the microprocessor “heart” of the controller

• input/output section:
provides the communication interface between hardware and the
computer

• servo drive interface:

passes drive signals to the actuators (motors) on the robot arm

• system power converter:

connects factory power to level required and protects against power
surge

• system cooling component - computer generates heat

3. Power Source
• all robots have a primary power source - electricity

• electrical power, in turn, may power hydraulic and/or pneumatic

systems unique to the robot design

• example:

a Cincinnati Milicron T3-566 robot - the primary power source

electrical; drives both hydraulics (in the arm), and pneumatics (in
the end-of-arm tooling)
Cincinnati Milicron T3 robot
4. Tooling
• definition:

it enables the robot to produce work; it is mounted to the arm

tool plate (or Tool Attachment Point, TAP)
• correct term: end-of-arm tooling

• also called: end effector

Tooling (Gripper) Weld Tool
5. Teaching Devices
• definition: used to program an industrial robot

• teaching devices include:

– Visual terminals - it permits a visual display and program development or

editing on the keyboard

– teach pendants - it is a remote computer with all the same programming

abilities, usually used to move the robot arm to desired positions during
programming

– controller front panels - it has controls for required power, program execution
and teach mode choice, and in some cases, system fault monitoring
6. Data Storage Device

• definition:

a device to store computer programs, and in most

cases, location variables in joint coordinate and its
transformation in world coordinate

• examples of storage devices:

– floppy disks a:\
– hard disks c:\
Basic Robot Terms

1. Degree of Freedom
• definition:

the number of joint axes capable of motion in the robot arm, each equals
one degree of freedom

• also referred to as:

– number of axes
– axes of motion

• degrees of freedom are rarely less than 3 or greater than 6

2. Position Axes
• arm sweep, shoulder swivel and elbow extension are examples of position
axes in the arm
• robot systems usually have at least 3 position axes in the arm
 Position Axes - Example
• an additional axis is “linear movement”, or “base traverse” where the robot
Figure 2.10 Robot on traverse base
moves along a track

seat_high.wmv
3. Orientation Axes - Definition

• pitch, yaw and roll are the orientation axes

• orientation plus position axes equals degrees

of freedom
 Orientation Axes - Example
• compare to the human wrist
A - human (3 degree freedom)
B - robot (3 degree freedom)
C - robot (3 degree freedom; alternative design)

A. Human wrist B. Robot wrist C. Robot wrist

Practical 1 : Jog the Robot in Joint Axis
Let see demonstration of ABB robot on:
• Degree of freedom
( 6 joint axes)
• Position Axes
• Orientation Axes
4. Work Envelope
• definition:
the maximum and minimum reach of the end effector

• some robot work envelopes can reach from 2 inches

to 65 feet
• manufacturer’s specify the work envelope by:

– horizontal and vertical planes (function and stroke)

– degrees of rotation
Work Envelope - Example
• robot compared to a human

Human Robot
ABB IRB1410
Work Envelope
5. Tool Center Point (TCP)
• definition:

also called “end point”; the exact point of work on the effector
Tool Center Point (TCP) - Example
• example: the TCP is the tip of the welding gun

Figure 2.9 Robot tool center point (TCP)

Yaw

Tool
Center
Point

Pitch

Roll
6. Accuracy

• definition:

a measure of how well the robot controller, arm and TCP

respond to commands from a remote terminal

• note: often confused with “repeatability”, the next term

covered

• all claims for “accuracy” should be verified by the user

7. Repeatability
• definition:
one of the most important specifications, repeatability is the measure
of the variation that occurs during repeated returns to a point required
during a taught program

• the point required is a manually taught point (using a teaching device)

• repeatability is calculated for the “worse case” situation

• example: repeatability for large, hydraulic robots:

± 1.25 mm or ± 0.0150 inches

• repeatability is always specified by a vendor

8. Payload
• definition:
maximum lifting capacity of the robot arm under operating
conditions

• note: payload includes the weight of the tooling and the part to
be lifted

• example: T3-776

load 250 mm (10 inches) from tool plate - 60 kg (150 lb.)

9. Speed
• definition:
maximum rate the controller can move the TCP with the
payload to a point

10. Drive Power

• definition:

method used to power the axes

11. Memory Capacity

• definition:

length of the program, and in some cases, the

different programs that can be stored

• example: a paint spraying robot (a continuous path

machine) will have a memory capacity rating which
tells the maximum time permitted for a program
ROBOT CLASSIFICATION
- robot can be classified from several category

• Classification based on Arm configuration

• Classification based on Control System
• Classification based on Level of Technology
• Classification based on Field of Application
• Classification based on Drive System
• Classification based on Design Generation etc

note  for our syllabus we limited our discussion based on

classification by :
1. Arm Geometry
2. Control System
1. Robot Classification by Arm Geometry

• definition:

when a robot is classified by number and

kind of axes and the resultant work envelope

note: arm geometry includes both the tasks of

support of tooling and positioning of tooling
Classification by Arm Geometry - Types
• three basic types of arm geometry
(or three basic work envelopes):

– rectangular

– cylindrical

– spherical

note: industry sometimes includes a fourth category:

• articulated-arm geometry
Classification by Arm Geometry

Spherical

Rectangular

Cylindrical

Principal robot work envelopes and arm geometries

The Rectangular-Arm Geometry - Definition

• definition:

the simplest arm geometry, requiring only

three axes of linear motion to complete the
work envelope VIDEO
Cartesian kinematics

• also referred to as a “Cartesian-coordinate

arm”
 The Rectangular-Arm Geometry - Example
• example: found in pick and place robots; also in Gantry robots

Rectangular gantry robot

 Advantages of Rectangular-Arm Geometry:

• they have the simplest geometry and control

system

• they allow for very large work envelopes

• the Gantry-type utilize overhead space, an

efficiency for often unused space
Disadvantages of the Rectangular-Arm Geometry:

• overhead maintenance is difficult in Gantry

types

• overhead crane access is limited in Gantry

types

• lateral response time is poor (note: the axis A

actuator must drive the entire arm)
 Applications for Rectangular-Arm Robots:

• material handling

• machine tending

• resistance welding

• quality testing

• inspection

• arc welding

• adhesive bonding
Cylindrical-Arm Geometry - Definition
• definition: VIDEO
cylindrical kinematics

where the arm has a rotary base axis and two linear
arm axes

note: the labels R2P, or RPP etc. as shown on are

not used throughout industry as designators
 Cylindrical-Arm Geometry- Example
Common terms of cylindrical arm motion:
• swing - rotation of the base
• reach - distance from the robot center to the farthest point in the envelope
• stroke - extent of the vertical and horizontal travel

Top view Side view

Cylindrical work envelope and robot motion terms

SCARA Configuration 1
SCARA (Selective Compliance Articulated Robot Arm) VIDEO
SCARA kinematics
- a horizontal jointed configuration

• the work envelope of a horizontal jointed arm is cylindrical

• vertical motion in the SCARA robot is done by moving gripper up

and down with a linear actuator at the end of the arm
SCARA Configuration
• compare and contrast typical cylindrical arm geometry with
SCARA:

– SCARA has special vertical gripper action to produce

cylindrical work envelope

– cylindrical arms utilize vertical motion by raising the entire

arm
SCARA Robot Arm 1

SCARA robot arm

SCARA Robot Arm 2

SCARA robot arm

Cylindrical Work Envelope of Horizontal-jointed Arm

Top view Side view

Cylindrical work envelope of horizontal-jointed arm

 Advantages of Cylindrical Arm Geometry:
• horizontal reach is deep at the top and bottom of the envelope

• reduced floor space needs

• rigid structure allows large payloads

• rigid structure permits repeatability

• smaller arm = quicker arm response

Disadvantages of Cylindrical Arm Geometry:

• limited horizontal reach

Applications:
• machine tending

• assembly

• material handling

• pallet loading

• arc welding

• adhesive bonding

• sealing, grinding and deburring

Spherical Arm Geometry - Types

• Polar Spherical Arm Geometry

• Jointed Spherical Arm Geometry

 Spherical (Polar Coordinates) 1

• definition:

utilizes a base rotation, shoulder rotation and linear motion

(2RP or RRP)

• one of the first in industry

• lack of versatility: covers a small segment of a sphere

VIDEO
polar kinematics
Spherical (Polar Coordinates)
• Advantages:

– hours of proven performance

– long horizontal stroke

• Disadvantages:

– requires floor space

– inferior arm flexibility

Spherical (Polar Coordinates)

• Applications:

– machine tending

– material handling

– spot welding

– historical use - unloading of die-casting machines

 Jointed Spherical Arm Geometry 1
• definition:

also called revolute coordinate, where the envelope is

very close to a perfect sphere

• left and right moves produced in the base; shoulder

produces horizontal motion; elbow produces vertical
travel

• most popular robot types; most resembles the

capabilities of the human arm

VIDEO
articulated kinematics
Jointed Spherical Arm Geometry
• Advantages:
– deep horizontal reach
– minimum use of floor space
– high positioning mobility of end effector

• Disadvantages:
– complex controller
– technician demands
– higher cost

• applications:
– general purpose
Work Envelope for Spherical
(Polar) Robot

Top view Side view

Work envelope for spherical (polar) robot

Jointed-spherical Robot (Polar)
Robot

Jointed-spherical robot (polar) robot

2. Robot Classification by Control System

• key differences in open loop and closed loop

has to do with feedback sensors

– open-loop (or non-servo system) relies on 3 to 6

actuators to move the arm through the path (no
feedback)

– feedback sensors are in a closed loop (servo system)

where signals indicate arm position to the controller
 Classification by Control System
• programmed motion path typical of open or closed paths

Program motion path

 Classification by Control System
• open-loop control (non-servo)

• closed-loop control (servo)

• both systems refer to the path of the arm

through the program
 Open-loop Control Overview
• in open-loop, the robot arm must be stopped without
sensors to tell the controller to stop; positions are
kept by:
– actuator stroke

– fixed hard stops

– variable hard stops

– stepper motors
 Actuator Stroke 1
• the stroke maximum/minimum determines the position of the
end effector
Fully retracted

Fully extended

Actuator stroke
 Actuator Stroke 2
• such robots are called “bang-bang” due to the sound of the
actuator fulfilling the stroke

Actuator-stroke robot
 Fixed Hard Stops
• utilize mechanical stops to interfere and stop the stroke where desired
• robots would have fixed stop for each axis; sometimes called a “bang-
bang” or “stop to stop” robot

Retraction
hard stop

Extension
hard stop

Fixed hard stops

 Variable Hard Stops
• the same as fixed hard stop, except the positions may be
changed mechanically

Axis 1 End of
stroke

End of Axis 2
stroke Variable
screw stop

Axis 3

Variable
screw stop

Robot with variable hard stops

 Stepper Motors
• where a DC motor in conjunction with belt and
pulley system, positions end effector, rotated
by DC electric pulses
 Non-servo Operation - Definition
• since no feedback signal is used, non-servo systems require monitoring
by operators for repeatability

• serious problems can occur if the arm position and program do not agree

• optimum operation example:

– two-axis non-servo robot
– actuator controlled
– pneumatic control valves

• other terms for non-servo robots - “pick and place”, “bang-bang”, and
“stop to stop” systems
Non-servo Operation - Example
Example of open-loop robot system

Open-loop robot system

 Advantages of Open-loop Control

• low cost
short strokes with low weight payloads are cheaper

• high repeatability
“bang-bangs” rarely have large ranges of repeatability

• simplicity
easy to program
 Disadvantages of Open-loop Control

• lack of speed control

actuators move at their maximum speed normally; additional
steps must be taken to achieve variable speeds

• changing a stop position requires a mechanical change

exception is use of stepper motors where pulse program can be
changed

• precision requirements in placement

there being no flexibility, end effectors must be installed to
specifications
Applications for Open-loop Controlled Robots

• over 50% present robots are open-loop

• applications: material handling and machine

tending

• examples: material loading, unloading,

movement of raw material to a
production machine, etc.
Closed-loop Control - Definition
• servo system has feedback sensors which measures
mechanical position

Basic servo system

Example of ABB IRB1400 Servo motor
for axis 4,5,6
Servomotors on Rhino robot….

rhino.wmv
Closed-loop Control - Characteristics
• feedback is converted to electrical pulses

• compares actual to desired position and corrects for variance;

desired positions are stored in program memory

• if variation occurs, controllers can change drive power to

actuators to correct positions

• servo systems can be programmed to stop at any point in the

work envelope
Closed-loop Control - Example
• example: closed-loop system for one axis of system
note: feedback loop and comparison of data

Closed-loop robot system

Advantages of Closed-loop Control
• flexible program control
offers different applications

• ease of changing points

requires a program change only

• can do complex tasks

• multiple program storage and execution

only requires memory and decisions
Disadvantages of Closed-loop Control

• larger capital investment

• maintenance at high levels

 Applications of Closed-loop Control
• welding

• coating/sealing

• material handling

• machine tending

• arc/water jet cutting

• inspection

• assembly