Fundamentals of Automation and Robotics
1.1 Automation and Robots, Industrial Automation using Robots, Introduction of
Programmable Logic Controllers (PLC) and Supervisory Control and Data Acquisition
(SCADA)
1.2 Robot Classification, Robot Specification, Joints, Coordinates, Coordinate frames,
Workspace, Notations
1.3 Robot language, Classification of Robot languages, Computer control and Robot
software, Variable Assembly Language system and language
📘 Fundamentals of Automation and Robotics
🔹 1. What is Automation?
Automation means using machines, computers, or control systems to perform tasks without human
intervention.
👉 Simple line for exam:
Automation is the technology of performing tasks automatically with minimal human involvement.
✅ Examples:
● Automatic washing machine
● Traffic signal system
● Industrial assembly lines
🔹 2. Types of Automation
1. Fixed Automation (Hard Automation)
● Used for mass production
● Same task repeated
● High speed, low flexibility
👉 Example: Car manufacturing line
2. Programmable Automation
● Machines can be reprogrammed
● Used for batch production
👉 Example: CNC machines
3. Flexible Automation
● Highly adaptable
● Can handle different products easily
👉 Example: Modern robotic systems in factories
🔹 3. What is Robotics?
Robotics is the branch of engineering that deals with the design, construction, and operation of
robots.
👉 Exam definition:
Robotics is the science and technology of robots, including their design, manufacture, and
application.
🔹 4. What is a Robot?
A robot is a programmable machine that can perform tasks automatically.
👉 Simple definition:
A robot is a reprogrammable, multifunctional device used to perform tasks automatically.
🔹 5. Components of a Robot
1. Manipulator (Arm)
● Main body of robot
● Moves and performs tasks
2. End Effector
● Tool attached to robot
👉 Examples: gripper, welding tool
3. Sensors
● Collect information from environment
👉 Examples: temperature, pressure sensors
4. Controller
● Brain of robot (computer system)
5. Actuators
● Convert energy into motion
👉 Motors, hydraulic systems
🔹 6. Types of Robots
1. Industrial Robots
● Used in factories
👉 Welding, assembly
2. Service Robots
● Help humans
👉 Cleaning robots
3. Mobile Robots
● Can move
👉 Delivery robots
4. Humanoid Robots
● Human-like robots
🔹 7. Advantages of Automation & Robotics
● High accuracy
● Increased productivity
● Reduced human effort
● Works 24/7
● Improves safety
🔹 8. Disadvantages
● High initial cost
● Job loss (unemployment)
● Maintenance required
● Needs skilled operators
🔹 9. Applications
● Manufacturing industries
● Healthcare (surgical robots)
● Space exploration
● Agriculture
● Defense
📘 Industrial Automation using Robots
🔹 1. What is Industrial Automation using Robots?
It means using robots in industries to perform tasks like manufacturing, assembly, inspection, etc.
automatically.
👉 Exam definition:
Industrial automation using robots is the use of programmable robotic systems to perform
industrial tasks with minimal human intervention.
🔹 2. Why Robots are used in Industries?
● Perform repetitive tasks
● Work in dangerous environments
● Provide high accuracy
● Increase production speed
🔹 3. Common Industrial Robot Applications
1. Material Handling
2. Welding
3. Assembly
4. Painting
5. Inspection & Quality Control
🔹 4. Types of Industrial Robots
1. Cartesian Robot
● Moves in straight lines (X, Y, Z)
2. Cylindrical Robot
● Rotary + linear motion
3. Spherical Robot
● Works in spherical space
4. Articulated Robot
● Most common (like human arm)
5. SCARA Robot
● Used for fast assembly tasks
🔹 5. Advantages of Using Robots in Industry
● High precision and accuracy
● Continuous operation (24/7)
● Increased productivity
● Reduced human error
● Improved safety
🔹 6. Disadvantages
● High installation cost
● Maintenance cost
● Requires skilled workers
● Job displacement
🔹 7. Industrial Automation System Elements
● Sensors → collect data
● Controller (PLC/Computer) → decision making
● Actuators → perform actions
● Robot → executes task
📘 Introduction to Programmable Logic Controllers (PLC)
🔹 1. What is PLC?
A Programmable Logic Controller (PLC) is a digital computer used to control machines and industrial
processes automatically.
👉 Exam definition:
PLC is an industrial digital controller used to automate electromechanical processes using
programmed instructions.
🔹 2. Why PLC is used?
● Replace manual control systems
● Reduce wiring complexity
● Increase reliability
● Easy to program and modify
👉 Example: Controlling conveyor belts, traffic lights, elevators
🔹 3. Basic PLC Structure
Components:
1. Input Module
● Takes signals from sensors, switches
👉 Example: temperature sensor, push button
2. CPU (Central Processing Unit)
● Brain of PLC
● Executes program
● Makes decisions
3. Output Module
● Sends signals to devices
👉 Example: motors, lights, alarms
4. Power Supply
● Provides electrical power to PLC
5. Programming Device
● Used to write program (ladder logic)
🔹 4. Working of PLC (Simple Steps)
1. Input devices send signals
2. PLC reads input
3. Program executes in CPU
4. Output is generated
5. Devices perform action
👉 This cycle repeats continuously (scan cycle)
🔹 5. PLC Scan Cycle
● Input Scan
● Program Execution
● Output Scan
👉 Important line:
PLC works in a continuous loop called scan cycle.
🔹 6. Advantages of PLC
● High reliability
● Easy troubleshooting
● Flexible programming
● Less wiring
● Fast operation
🔹 7. Disadvantages
● Initial cost is high
● Needs programming knowledge
● Not suitable for very small tasks
🔹 8. Applications of PLC
● Industrial automation
● Traffic light control
● Elevator systems
● Packaging industries
● Power plants
📘 Robot Classification
Robots are classified based on structure, application, and movement.
✅ Based on Structure (Most Important)
1. Cartesian Robot:
● Moves in X, Y, Z directions
● High accuracy
2. Cylindrical Robot:
● Rotary base + linear motion
● Used in assembly
3. Spherical (Polar) Robot:
● Works in spherical space
● Flexible movement
4. Articulated Robot
● Like human arm
● Most widely used
5. SCARA Robot
● Fast and precise
● Used in electronics
🔹Drive Technology (Robot Drives)
The drive system provides motion to the robot.
1. Electric Drive
● Uses motors
● Most common
● Clean & accurate
👉 Example: Servo motors
2. Hydraulic Drive
● Uses fluid pressure
● High power & force
👉 Used in heavy load robots
3. Pneumatic Drive
● Uses compressed air
● Fast but less precise
👉 Used in pick-and-place
🔹Work Envelope (Work Space)
Work envelope is the area/volume in which a robot can operate.
👉 Exam definition:
It is the 3D space within which the robot’s end effector can move.
Types of Work Envelope
1. Rectangular
● Used in Cartesian robots
2. Cylindrical
● Used in cylindrical robots
3. Spherical
● Used in polar robots
4. Irregular
● Used in articulated robots
🔹 4. Motion Control Methods
Controls how the robot moves.
1. Point-to-Point (PTP) Control
● Moves from one point to another
● Path not important
👉 Example: Pick and place
2. Continuous Path (CP) Control
● Path is important
● Smooth motion
👉 Example: Welding, painting
3. Servo Control
● Uses feedback system
● High accuracy
4. Non-Servo Control
● No feedback
● Less accurate
📘 Robot Joints
🔹 1. What are Joints?
Joints are the connections between robot links that allow movement or motion.
👉 Exam definition:
A joint is a mechanical connection between two links that allows relative motion.
🔹 2. Purpose of Joints
● Provide movement to robot
● Decide robot flexibility
● Help in positioning the end effector
🔹 3. Types of Robot Joints (Very Important)
1. Revolute Joint :
● Rotational motion
● Moves around an axis
👉 Example: Human elbow
2. Prismatic Joint (P)
● Linear motion
● Moves in straight line
👉 Example: Sliding drawer
3. Cylindrical Joint
● Multi-directional movement
● Like ball-and-socket
👉 Example: Human shoulder
🔹 4. Degrees of Freedom (DOF)
● Number of independent movements a robot can make
● Each joint = 1 DOF
👉 Example:
● 6 joints → 6 DOF
👉 Important line:
More DOF = More flexibility
🔹 5. Joint Notation (Important)
● R → Revolute
● P → Prismatic
👉 Example:
● R-R-R robot → 3 rotational joints
📘 Coordinates & Coordinate Frames (Robotics)
🔹 1. What are Coordinates?
Coordinates are used to define the position of a point in space.
👉 Exam definition:
Coordinates are numerical values that specify the position of a point in space with respect to a
reference system.
🔹 2. Types of Coordinate Systems
1. Cartesian Coordinate System (Most Important)
● Uses X, Y, Z axes
● Position written as → (x, y, z)
● Most commonly used in robotics
2. Cylindrical Coordinate System
● Uses (r, θ, z)
● Combines rotation + height
3. Spherical Coordinate System
● Uses (r, θ, φ)
● Represents position in spherical form
🔹 3. What is a Coordinate Frame?
A coordinate frame is a reference system with axes used to describe position and orientation.
👉 Exam definition:
A coordinate frame is a set of axes (X, Y, Z) used as a reference to measure position and
orientation.
🔹 4. Types of Coordinate Frames
1. World Frame (Base Frame)
● Fixed reference frame
● Attached to robot base
2. Tool Frame (End Effector Frame)
● Attached to end effector
● Moves with robot
3. Joint Frame
● Attached to each joint
● Used in motion analysis
🔹 5. Importance in Robotics
● Helps in positioning robot accurately
● Used in robot programming
● Essential for motion planning