Chapter 20: Applications of Robotics – Industrial Robotics

Abstract:

Industrial robotics are used in a wide variety of applications, including welding (arc and spot), material handling, packing/palletizing, machine tending, painting, dispensing, quality inspection, and material removal, improving efficiency, accuracy, and safety in manufacturing processes. 

Here's a more detailed look at some of the key applications:

Manufacturing & Assembly:

• Welding:

  • Arc Welding: Robots excel at arc welding, a common process for joining steel structures and industrial fabrication. 
  • Spot Welding: Spot welding, where intense heat melts metal joints, is another common application, particularly in automotive assembly. 
• Material Handling:

  Robots efficiently move parts and materials within a factory, improving the overall efficiency of a production process. 
• Packing and Palletizing:

  Robots automate the packing of products into cases and palletizing operations, ensuring efficient and safe handling of goods. 
• Machine Tending:

  Robots load and unload manufacturing machinery, freeing up human workers for other tasks and potentially enabling "lights out" operation. 
• Painting:

  Industrial robots are used for painting, a task that can be both tedious and hazardous for humans. 
• Dispensing:

  Robots precisely dispense materials like glue, paint, or spray onto surfaces, ensuring accurate and repeatable processes. 
• Quality Inspection:

  Robots can inspect items for defects, measure against specific parameters, or test products to ensure quality standards are met. 
• Material Removal:

  Robots perform tasks like machining, cutting, deburring, sanding, and polishing, which are often dull, dirty, and dangerous for human workers. 

Beyond Manufacturing:

• Agriculture:

  Robots are increasingly used in agriculture for tasks like harvesting and planting. 
• Healthcare:

  Robotics are being used in healthcare for tasks like assisting in surgery, delivering medication, and reducing hospital-acquired infections. 
• Inspection:

  Robots equipped with sensors and cameras can perform inspections in various industries, including energy, transportation, and manufacturing. 
• Order Picking:

  Robots are used in warehouses to efficiently pick and pack orders, improving warehouse efficiency and turnaround times. 

20.1 Introduction

Industrial robotics has revolutionized manufacturing by improving efficiency, precision, and safety. Robots are extensively used in tasks such as assembly, welding, painting, and material handling, reducing human intervention in hazardous and repetitive processes.

This chapter explores various applications of industrial robotics, discussing robot types, programming approaches, benefits, and real-world implementations in different industries.

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20.2 Industrial Robotics: An Overview

Industrial robots are automated machines designed for manufacturing tasks, classified based on:

1. Degrees of Freedom:

   • 2-DOF to 6-DOF robots for flexibility in movement.

2. Actuation Method:

   • Electric, hydraulic, or pneumatic robots based on power sources.

3. Control Systems:

   • Pre-programmed, adaptive, or AI-driven control mechanisms.

4. End Effectors:

   • Grippers, welding torches, spray nozzles, suction cups, etc., based on task requirements.

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20.3 Applications of Industrial Robotics

20.3.1 Assembly Robots

Function: Automated robots perform high-speed assembly operations with precision.

Key Technologies:

• SCARA Robots (Selective Compliance Articulated Robot Arm) for small-part assembly.
• Delta Robots for high-speed pick-and-place tasks.
• Collaborative Robots (Cobots) working alongside humans in flexible production lines.

Advantages:

• High accuracy in assembling small components (e.g., electronics).
• Reduced cycle time in production.
• Consistent quality with minimal defects.

Real-World Example:

• Automotive Industry: Robots assemble engines, gearboxes, and dashboards.
• Electronics Industry: Robots place microchips on circuit boards (e.g., PCB assembly).

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20.3.2 Welding Robots

Function: Robotic arms automate arc welding, spot welding, and laser welding with high precision.

Key Technologies:

• Articulated Robots with 6-axis movement for complex welding paths.
• Vision-Guided Welding Robots for adjusting in real time.
• AI-Based Welding Systems that optimize parameters dynamically.

Advantages:

• High consistency with minimal weld defects.
• Increased safety in handling high temperatures and fumes.
• Faster production with minimal downtime.

Real-World Example:

• Automotive Manufacturing: Robots perform spot welding in car body assembly lines.
• Shipbuilding: Robotic welders work on steel panel welding for ship structures.

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20.3.3 Painting Robots

Function: Robots automate spray painting to ensure uniform coatings.

Key Technologies:

• Cartesian Robots for controlled linear movement.
• Electrostatic Spray Painting for even distribution.
• AI-Based Flow Control for optimal paint usage.

Advantages:

• Consistent finish without human errors like over-spraying.
• Minimal paint wastage, reducing costs.
• Safer environment, preventing exposure to toxic fumes.

Real-World Example:

• Automotive Industry: Robots paint car exteriors with high precision.
• Aerospace Industry: Robots coat aircraft surfaces with protective layers.

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20.3.4 Material Handling Robots

Function: Robots transport, lift, and sort materials efficiently in warehouses and factories.

Key Technologies:

• Autonomous Mobile Robots (AMRs) for flexible warehouse logistics.
• Robotic Arms with AI Vision for pick-and-place tasks.
• Automated Guided Vehicles (AGVs) for pallet transportation.

Advantages:

• Increased efficiency in material flow.
• Reduced labor costs for repetitive handling.
• Improved safety in handling heavy loads.

Real-World Example:

• E-commerce Warehouses: Amazon uses Kiva robots for order fulfillment.
• Automotive Manufacturing: Robots transport components across assembly lines.

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20.4 Programming for Industrial Robots

20.4.1 Programming a Pick-and-Place Robot (Python – ROS & OpenCV)

This example shows a simple robot arm picking and placing objects using ROS (Robot Operating System).

import rospy
from moveit_commander import RobotCommander, PlanningSceneInterface, MoveGroupCommander

rospy.init_node('pick_and_place')

robot = RobotCommander()
scene = PlanningSceneInterface()
group = MoveGroupCommander("arm")

pose_target = group.get_current_pose().pose
pose_target.position.x = 0.5  # Move to pick position
group.set_pose_target(pose_target)
group.go(wait=True)

pose_target.position.x = 1.0  # Move to place position
group.set_pose_target(pose_target)
group.go(wait=True)

This script moves a robotic arm between predefined pick-and-place positions.

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20.5 Benefits of Industrial Robotics

20.5.1 Increased Productivity

• Robots work 24/7 without fatigue, ensuring faster production.

20.5.2 Enhanced Safety

• Robots handle hazardous tasks, reducing workplace injuries.

20.5.3 Cost Reduction

• Lower operational costs due to automation of repetitive tasks.

20.5.4 Consistent Quality

• Minimizes defects in production, ensuring high standards.

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20.6 Challenges in Industrial Robotics

20.6.1 High Initial Investment

• Expensive setup and maintenance costs.

20.6.2 Need for Skilled Workforce

• Requires specialized training for robot operation and programming.

20.6.3 Integration Complexity

• Compatibility issues with existing manufacturing systems.

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20.7 Future Trends in Industrial Robotics

20.7.1 AI-Driven Robotics

• Machine learning will enhance robots' decision-making.

20.7.2 Collaborative Robots (Cobots)

• Safe human-robot interaction in factories.

20.7.3 Cloud Robotics

• Robots connected via cloud for shared learning.

20.7.4 3D Vision Systems

• Improved object recognition for better automation.

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20.8 Summary

This chapter explored industrial robotics applications in assembly, welding, painting, and material handling. Advanced robotics enhances productivity, safety, and precision, transforming industries like automotive, electronics, aerospace, and logistics. Future advancements in AI, cloud computing, and collaborative robots will further drive industrial automation.