This document provides an introduction to industrial robots and their applications in architectural manufacturing. It defines industrial robots as automatically controlled, reprogrammable manipulators that can be programmed in three or more axes. Examples of typical industrial robot applications discussed include welding, laser cutting, painting, palletizing, and machine tending. The document also explores emerging applications of robots and drones in architectural construction through masonry stacking and flight assembled architecture.

1. Introduction to Industrial
Robotic Automation for
Architectural
Manufacturing
General Introduction to Automation
Instructor Brian Ringley

2. What is an “Industrial Robot”
An industrial robot, commonly referred to as an industrial robotic arm, can be
identified by the following common characteristics:
• Automatically controlled
• Reprogrammable
• Multipurpose manipulator
• Programmable in three or more axes

3. Automatically Controlled
Industrial robots are automated, meaning
that they operate by themselves with little or
no direct human control. This is achieved
through a robotic controller, a computing
device that calculates robotic movement by
reading code and sending motion
instructions to the motors of the robot.
Note: Each axis of motion is controlled by
one motor. For example, a six axis robot has
six motors, one at each articulated joint.
The IRC5, ABB’s fifth generation robot
controller. The IRC5 unit is modular and
can control up to 36 synchronized axes.

4. Wait, Did You Say 36 Axes?
“Kara” video game concept trailer from
Heavy Rain

5. Seriously, 36 Axes?
A behind the scenes look at how
robotics are utilized at the Tesla Motors
factory by WIRED Magazine.
Some robotic operations pictured are
synchronously controlled, while others
operate independently but are times to
work together. This timing is set up and
monitored via a PLC or “Programmable
Logic Controller.” A PLC engineer often
has a background in electrical and/or
mechanical engineering.
Can you tell which is which?

6. Okay, Now You’re Just Showing Off
Demonstration of ABB IRC5 controller
“Multi-Move” technology with Fanta

7. Reprogrammable
Industrial robot controllers encode motion
information to the joint motors by reading
machine code.
Note: Industrial robot programming code is
different than the common G code used in
CNC programming, and is typically
proprietary. For example, we use the ABB
RAPID language with ABB controllers.

8. Text-Based Programming (RAPID)
RAPID code can be edited in most text
editors and mark-ups can be imported
into apps like Notepad++. However, it is
easiest to program within the
RobotStudio environment.
The RAPID editor is similar to the
RhinoScript editor, with conveniences
like instant semantics checks, argument
pick lists, and syntax coloring.

9. Graphical Programming (RobotStudio)
Screen shot from RobotStudio.
It would be very tedious to use
text-based programming for an
entire robot program so, just
as we do with CNC
programming, we use a
graphical editor that allows us
to manipulate and simulate a
CAD model.
The difference here is that we
can synchronize the code very
quickly without the need to
specify a post-processor, as
we are using ABB
programming software for ABB
robot controllers.

10. Parametric Programming (HAL)
HAL is an example of an industrial robotic programming plugin for Grasshopper which allows users to simulate their
robots and generate RAPID code in near real time. The advantage is that the code output is directly tied to a parametric
model, allowing the user to bypass tedious importing and re-importing of CAD geometry into RobotStudio.
Image from hal.thibaultschwartz.com

11. Multipurpose Manipulator
Industrial robots are different from task-specific fabrication equipment such as
3D printers, laser cutters, and CNC mills in that they are intentionally unspecific
and, as a result, can be used for an almost endless range of applications. The
arm is fitted with what are called “end effectors” or “end-of-arm tooling” which
are specific to whichever application the robot is intended to perform. Common
industrial robot applications include (but are certainly not limited to):
• Welding
• Laser Cutting
• Painting
• Palletizing
• Machine Tending

12. Robotic Welding
Robotic arms can weld along curves using
MIG or TIG welding end effectors, or they
can weld at points using spot welding end
effectors. Spot welding end effectors can
be open/closed and on/off, whereas
MIG/TIG welders are only on/off.
Note: Unlike CNC end mills, these tools
can’t be directly touched off, but rather
have an offset distance from the target not
unlike a laser cutting head’s focal length.
ABB robotic arm with spot
welding end effector

13. Robotic Laser Cutting
Laser tubes, where wattage generates the laser beam, and the ensuing optics
assembly have to be in a straight line for a robotic arm, versus configured with
mirror turns as in a typical laser cutter.

14. Robotic Painting (ASM)
Robotic painting arms use
ASM, or Automated Spray
Method, to rapidly and evenly
coat cars and airplane
components with paint. These
robots are covered in draped
cloth which allows the robot its
full range of motion while
protecting the arm from paint.

15. Robotic Palletizing
Robotic palletizing is used to
quickly and accurately stack
objects onto pallets. These
robots are known for long
reach, high payload, and fast
speed and typically require
only three axes.

16. Robotic Grippers
The end effectors used for palletizing and stacking operations are fairly wide
ranging, and include servo grippers, pneumatic grippers, vacuum holders, and
more.

17. Robotic Machine Tending
Robots can be integrated
into assembly line or other
manufacturing processes.
For example, a robotic arm
may be used to retrieve
finished parts from a CNC
machining center and reload
the machine with fresh
stock.

18. Programmable in 3 or More Axes
An industrial robotic arm requires 3 axes (or “degrees of freedom”) because 2
axes are required to reach any point in a plane and the third is required to
reach any point in space. Think of the 3 axes as yaw, pitch, and roll rather than
X, Y, and Z as in a CNC mill.

19. Typical 6 Axis Arm
A typical 6 axis arm (as well as our
own IRB 140 arm) have 6 axes that
work in tandem (interpolate and
configure) to reach targets. Ranges
of motion for the axes are:
• Axis 1 (base twisting) 360d
• Axis 2 (base bowing) 200d
• Axis 3 (forearm flapping) 280d
• Axis 4 (forearm twisting) 400d*
• Axis 5 (wrist flapping) 240d
• Axis 6 (wrist twisting) 800d*
*unlimited but set to default value

20. Robot Reach
Reach is more of an art than a
science and is based on joint
interpolation as well as joint
configuration (deciding between
multiple possible joint positions to
reach a target). The image to the left
is a typical reach diagram for the
ABB IRB 140. The 810mm front
reach is almost 32in.
Reach is also dependent on how the
robot is mounted.

21. Robot Mounting
Robots can be bolted to steel tables
or other rigid bases but are often wall
or ceiling-mounted to enhance reach
relative to the intended robotic
application.
If the object the robot is mounted to
can also be moved via the robotic
controller, such as gantry or rail-
mounting, this is considered an
additional axis or additional axes
depending on the configuration.

22. External Axes
As mentioned, axes in a robotic system can be limited to a single robotic arm,
can be a summation of multiple robotic arms synchronized through a single
robotic controller, and can also include external axes (also synchronized
through the same controller). Typical external axis configurations include:
• Gantry
• Rails
• External Workpiece Positioners
• Robotic Arm as End Effector for Other Robotic Arm

23. Robot on Gantry
Example of robotic machine tending with
ABB 5 axis robot on linear gantry

24. Robot on Rails (or “Tracks”)
Tracks are useful for
allowing robots to work
on larger workpieces
than fit into the robot’s
initial reach, for longer
range machine tending,
and for the ability to
perform different
research or different
tasks at various
locations.

25. External Workpiece Positioners
Coordinated motion between two IRB
1600ID arc welding robotic arms and an
IRBP R (rotary) type positioner.

26. Robot as End Effector of Another Robot
Robots can actually be
mounted to other robots to
increase reach and
articulation at the workpiece.
This is a Fronius welding
effector on an IRB 140 (6
axis) which is in turn mounted
to an IRB 660 (3 axis). A
chassis (not pictured) is being
welded on an R type
positioner (1 axis). This 10
axis welding system is the
IRB 800.

27. Robots in Architecture
Robots are increasingly becoming a focus of architectural research and
architectural production. Certain fabrication labs (Stuttgart ICD, ETH Zurich,
Carnegie Mellon, Michigan, Sci-Arc Robot House, and UCLA) have emerged
as premier facilities for architectural robotic arm research and pedagogy.
The Association for Robots in Architecture has emerged to help create a
community around these efforts, and hosts a conference on the subject once
every two years titled “Rob|Arch.”

28. Robotic Masonry Stacking
“Pike Loop” was a project by
architects and ETH Zurich
researchers Gramazio &
Kohler which transported a
robot to a location within a
trailer where it proceeded to
stack a 72’ long brick
structure.

29. Robotic Masonry Stacking
Autonomous stacking has not
been limited to robotic arms -
the same researchers
Gramazio & Kohler are now
looking into the autonomous
construction of masonry walls
by drone assembly. This
project is titled “Flight
Assembled Architecture.”

30. Wait… Drones Can Do That?
Also at ETH Zurich (a pretty
cool place, right?)
researchers are exploiting
the ability to program drones
to learn their positions and to
maintain balance with and
against physics-based
interactions. As opposed to
axes drone motion is
controlled through its rotors.

31. Okay Drones Are Awesome
Oh my gosh this video is
sweet.
Note: Notice the mention of
roll, pitch, and yaw as we
discussed with robotic arm
motion.

32. The Future of Drones
Imagine a world where we
interact with these devices in
our daily life.
How will this affect
manufacturing? How will this
affect architecture and urban
space? How will this affect
our social behavior?