Automation and Robotics (May-2013, R09) JNTU-Anantapur QP.

1
Code No: 9A03702/R09
B.Tech. IV Year I Semester Supplementary Examinations
May - 2013
R09
Solutions
AUTOMATION AND ROBOTICS
( Mechanical Engineering )
Time: 3 Hours Max. Marks: 70
Answer any FIVE Questions
All Questions carry equal marks
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1. List out and discuss about the basic elements of an automated system. (Unit-I, Topic No. 1.1)

2. List out the various types of flow lines. Discuss flow line with and without buffer storage. (Unit-II, Topic No. 2.2)

3. What are the considerations to be made in assembly line design? (Unit-III, Topic No. 3.1)

4. Explain various configurations of robot with neat sketches. (Unit-IV, Topic No. 4.1)

5. Explain in detail about DH representation of robot with a suitable example. (Unit-V, Topic No. 5.1)

6. Discuss the following methods of robot programming,

(i) Lead through teaching
(ii) Walk through teaching
(iii) Off-line programming. (Unit-VI, Topic No. 6.3)

7. (a) Classify different sensors and actuators used in robotics. (Unit-VII, Topic No. 7.1.1)
(b) Discuss the working of following actuators,
(i) Pneumatic actuators
(ii) Hydraulic actuators. (Unit-VII, Topic No. 7.1)

8. (a) What are the desirable features of a robot for successful machine tool load/unload applications?
(Unit-VIII, Topic No. 8.1)
(b) Describe the applications of a robot in press working operation. (Unit-VIII, Topic No. 8.1)

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SOLUTIONS TO MAY-2013, R09, QP

Q1. List out and discuss about the basic elements 4. Line Efficiency
of an automated system. The efficiency of line operation depends upon uptime
Answer : May-13, (R09), Q1 proportion E. If the value of E goes down, the idle time of
workers will be increased, which reduces the efficiency. All
For answer refer Unit-I, Q3. the workers will be idle if certain line goes down. It is the
Q2. List out the various types of flow lines. management, which is responsible to maintain the value of
Discuss flow line with and without buffer E close to 100%. To attain this, skilled and well-trained
storage. workers are to be employed to quickfix the breakdown when
occurs. All the incoming components should be ready for
Answer : May-13, (R09), Q2
any breakdown of line (i.e., shortage of parts should not
Types of Flow Lines occur).
For answer refer Unit-II, Q9. 5. Sub-dividing Work Element
Flow Line with and without Buffer Storage The smallest task that cannot be sub-divided further
is termed as minimum rational work. It is required to divide
For answer refer Unit-II, Q12. the task so that overall efficiency is better as well as the life
Q3. What are the considerations to be made in of the machine is enhanced. In some cases, as drilling of
assembly line design? hole cannot be sub-divided, the process has to be done in a
single station. If drilling is of bottleneck condition then it
Answer : May-13, (R09), Q3
must be divided into two processes performed at two adjacent
The various possible ways that are to be considered stations, which will improve efficiency of bottleneck
by the designer for improving the operation of assembly situations and tool life of drill bits.
line are as follows, 6. Sharing Work Elements Between Two Adjacent
1. Changing work head speeds at automatic Stations
stations If a work element at one station is at narrow end
2. Parallel stations operations and the adjacent station possesses more idle
time, then the work element can be shared between the two
3. Method analysis stations by alternating their cycle of operation.
4. Line efficiency 7. Utility Workers
5. Sub-dividing work element Utility workers are employed to reduce the blocking
at stations which are temporarily overloaded.
6. Sharing work elements between two adjacent
stations 8. Preassembly for Components
7. Utility workers The total amount of work done on a usual assembly
line can be reduced by manufacturing certain subassemblies
8. Preassembly for components off-line. This can be achieved either by another assembly
9. Storage buffers between stations cell plant or by purchasing the assembly from a vendor
specialized in the required process.
10. Zoning and other constraints.
Preassembly of components is performed for the
1. Changing Work Head Speeds at Automatic Stations following reasons,
For answer refer Unit-III, Q14(i). (i) Process which is difficult to execute on a usual
assembly line can be executed on another assembly
2. Parallel Stations
cell plant.
For answer refer Unit-III, Q14(ii).
(ii) Adjustments or fitting of components on the same
3. Method Analysis assembly line takes a longer time.
For answer refer Unit-III, Q14(iii). (iii) To achieve high quality of work.

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Automation and Robotics (May-2013, R09) JNTU-Anantapur
9. Storage Buffers Between Stations
A location in production line where work units are
temporarily stored is called a storage buffer.
Storing buffers between stations is included for the
following factors,
(i) Gathering of different products from different stages
when production rates between two stages of the
line fluctuate.
(ii) For smooth production between stations having
large task time variations.
(iii) For a continuous operation of the production line
when other sections are temporarily down for service
or repair.
(iv) To improve the performance of the line operation by
increasing the line efficiency.
10. Zoning and other Constraints
Zoning constraints limit the grouping of work
elements and their distribution to work stations. Zoning
constraints may be positive or negative,
(i) A positive zoning constraint is the grouping of
elements together at same work station.
Example: Spray painting elements are grouped
together as they require special enclosures.
(ii) A negative zoning constraint is the separation of
work elements located near each other such that they
do not interfere with each other
Example: A work element with delicate adjustments
is located away from an assembly operation with loud
sudden noises and hammering vibrations.
A position constraint is another limitation for the
distribution of work to stations. It is executed in the assembly
of large components such as in trucks and automobiles.
Since the task becomes difficult for the workers to
operate on both sides of the work, therefore operators are
positioned on either sides of an assembly line for easy
handling of work.
Q4. Explain various configurations of robot with
neat sketches.
Answer : May-13, (R09), Q4
For answer refer Unit-IV, Q2.
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Q5. Explain in detail about DH representation of
robot with a suitable example.
Answer : May-13, (R09), Q5
For answer refer Unit-V, Q2 and Q4.
Q6. Discuss the following methods of robot
programming.
(i) Lead through teaching
(ii) Walk through teaching
(iii) Off-line programming.
Answer : May-13, (R09), Q6
(i) Lead Through Teaching
For answer refer Unit-VI, Q16, Topic: Lead Through
Methods.
(a) Powered Lead Through
Powered lead through is the common programming
method for playback robots with point to point
control. In this method various joint motors having
toggle switches or contact buttons controlling the
movement of the manipulator joints are controlled by
a hand held control box.
The toggle switches are used by the programmer for
driving the robot arm to the desired positions in se-
quential order. These positions are recorded into the
memory.
During the next play back, the robot moves by the
sequence of positions with its own power.
(b) Manual Lead Through
Manual lead through method is suitable for a continu-
ous path programming where the continuous path is
an irregular motion pattern such as in spray painting.
In this method, the programmer physically grasps
the tools attached to the arm and manually moves it
through the motion sequence. This arm movement is
recorded into the memory. The robot arm possesses
large mass and it is physically difficult to move,
therefore the actual robot is replaced by a special
programming device for the teach procedure. The
programming device has the same geometry as the
robot. The programming device has a provision for a
trigger handle or other control switch which are
activated when the motions are to be recorded into
memory by the operator. The motions are recorded in
a sequence of closely spaced points. Through the
same sequence of points, the path during the playback
is recreated by controlling the actual robot arm.
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(ii) Walk Through Teaching
In walk through teaching, the operator has a physical contact with the robot arm. The operator controls and walks
the robots arm in desired positions within the robots working area. The robots controller scans and stores the co-ordinate
values on a fixed-time interval basis. The co-ordinate values and other functional data are replayed in the automatic mode.
Replaying may be done in various speeds than that used in walk-through.
This method uses triggers on manual handles to move the robot. When the trigger is lowered or held down, the
controller memorizes the position. As the program is played, the controller generates the movement between the points. The
walk through teaching requires the operator to be within the working area along with the robots controller energized in the
position sensors. In this method, the operator is in an unsafe position as the safe guarding devices are deactivated.

Operator

Figure: Walk Through Teaching

(iii) Off-line Programming
In off-line programming, the computers are positioned away from the robot area.
A simulation software is used to generate data. The data is then sent to the robots controller where it converts the
data into instructions. This software also contains a modelling data which helps in the selection of the best robot configuration
for certain applications.
The main advantages of off-line programming is that the production is not interrupted while creating a primary or
modified program.

Production area

Off-line programming area

Figure: Off-line Programming

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Automation and Robotics (May-2013, R09) JNTU-Anantapur QP.5
Q7. (a) Classify different sensors and actuators used in robotics.
Answer : May-13, (R09), Q7(a)
Sensors
For answer refer Unit-VII, Q20.
Actuators
For answer refer Unit-VII, Q1, Topic: Types of Actuators.
(b) Discuss the working of following actuators,
(i) Pneumatic actuators
(ii) Hydraulic actuators.
Answer : May-13, (R09), Q7(b)
(i) Pneumatic Actuators
Pneumatic actuator is a power device, used to drive the robot arms by means of compressed air as working fluid. This
type of actuator is applied to gripper for opening and closing motions of jaws. Pneumatic actuator operates in the range of
0.1 0.12 klb/in2.
The schematic diagram of pneumatic actuator control unit is shown in figure (1),

Pressure gauge

Actuator Tank

Pressure Secondary Dryer

Control Compressor
regulator filter
valve

Primary
filter

Air

Figure (1): Pneumatic Actuator Control Unit

Air is passed through primary filter to clog the dust particles present in air. This filtered air enters into compressor,
where the pressure of air increases. The high pressured air is stored into the tank and it is made to pass through dryer, which
reduces the moisture content of filtered air. From the dryer, high pressure air enters into actuator through secondary filter,
pressure regulator and control value.
Where,
(i) Secondary filter is used to minimize the impurities of air.
(ii) Pressure regulator is provided with a gauge to measure and control the flow of working fluid.
(iii) Control valve is used to control the direction of fluid flow.
Compressor plays a significant role in the control unit of pneumatic actuator because the reciprocating motion of the
piston compresses the air inside the cylinder. Pneumatic actuator utilizes the compressed air for actuating the linear joint of
robot arms. Cylinder type pneumatic actuator is shown in figure (2),
Working fluid
Cylinder
port

Piston rod

Piston
Figure (2): Cylinder Type Actuator
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The empirical relations which help in deciding the type of actuator are,
1. Actuator velocity in terms of input power,

f
V=
A
Where,
V = Velocity of fluid
f = Flow rate of fluid.
2. Force in terms of input power,

p
F=
A
Where,
p = Fluid pressure
A = Area of piston.
The above empirical relations can be used to predict the payload carried by the robot at a given speed.
(ii) Hydraulic Actuators
For answer refer Unit-VII, Q2.
Q8. (a) What are the desirable features of a robot for successful machine tool load/unload
applications?
Answer : May-13, (R09), Q8(a)
For answer refer Unit-VIII, Q3.
(b) Describe the applications of a robot in press working operation.
Answer : May-13, (R09), Q8(b)
For answer refer Unit-VIII, Q10.

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