design and manufacturing of 7 degrees of freedom mounted …psrcentre.org/images/extraimages/17...

Abstract— This paper details of design and implementation of an

intelligent manipulator for industrial applications. The manipulator has seven degrees of freedom and can be used for pick and placed or for welding and painting application depending on the gripper which is left to the end user to select based on his demand. The key features of the manipulator include an intuitive user interface and extra degrees of freedom compared to available systems in the market. The flexible design utilizes off-shelf components for ease of maintenance and repairs. The robot is low-cost, intuitive operation and ease to maintain promote its widespread appeal, thereby advanced industrial applications.

Keywords— Manipulator ,Industrial, Design, Manufacturing.

I. INTRODUCTION NDUSTRIAL Manipulators are designed to meet every possible handling requirement and are ideal for applications

which involve lifting and locating, painting, welding … etc. The flexibility of the industrial manipulator's design will allow operators to control and maneuver the load in all directions.

Loads may be rotated and manipulated manually or powered via a actuator. On the other hand, manipulators in industry has many more applications. All sorts of items that are too heavy, too bulky, too hot or too something for workers to safely and comfortably pick up and move. Countless workplace injuries happen needlessly as a result of employees wrestling with their work. Manipulators and robots are here to help and this will appear in improving productivity and protecting workers by designing and building industrial manipulator systems. Robotic manipulators are widely used to help in dangerous, monotonous, and tedious jobs. Most of the existing robotic manipulators are designed and build in a manner to maximize stiffness in an attempt to minimize the vibration of the end-effectors to achieve a good position accuracy. This high stiffness is achieved by using heavy material and a bulky design [1]. Hence, the existing heavy

Dr. Meteb Altaf is with the National Center for Robotics and Intelligent Systems, King Abdulaziz City for Science and Technology, Riyadh, Saudi Arabia (phone:+96614883555; fax:+96614813211; e-mail: maltaf@ kacst.edu.sa).

Dr. Eball Ahmad is with the National Center for Robotics and Intelligent Systems, King Abdulaziz City for Science and Technology, riy Riyadh, Saudi Arabia (phone:+96614883555; fax:+96614813211; e-mail: eahmad@ kacst.edu.sa).

rigid manipulators are shown to be inefficient in terms of power consumption or speed with respect to the operating payload [2]. Also, the operation of high precision robots is severely limited by their dynamic deflection, which persists for a period of time after a move is completed. These conflicting requirements. In order to improve industrial productivity, it is required to reduce the weight of the arms and/or to increase their speed of operation. For these purposes it is very desirable to build flexible robotic manipulators. Compared to the conventional heavy and bulky robots, flexible link manipulators have the potential advantage of lower cost, larger work volume, higher operational speed, greater payload-to-manipulator-weight ratio, smaller actuators, less energy consumption, better maneuverability, better transportability and safer operation due to reduced inertia [6,7]. But the greatest disadvantage of these manipulators is the vibration problem due to low stiffness. [8-10].

II. MISSION AND MOTION LIMITATIONS Layout of the inspection procedure is done in AutoCAD to

check procedure, design and for links parameters design. Consider the structure requirements and the layout, we can

get the maximum and the minimum value of L3 as 750mm -1150mm. As shown in figure 1 and 2, the initial requirements of the manipulator links are determined in accordance with our simulation results.

. Fig. 1 Initial condition

Design and Manufacturing of 7 Degrees of Freedom Mounted Manipulator for

Industrial Application Dr. Meteb Altaf, and Dr. Eball Ahmad

I

2nd International Conference on Mechanical, Electronics and Mechatronics Engineering (ICMEME'2013) June 17-18, 2013 London (UK)

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Fig. 2 Parameters of links

Figure 3, shows all links and joints parameters of the manipulator from which our manufacturing process will start.

Fig. 3 Link and joint specifications

III. DESIGN OPTIMIZATION The purpose of optimization technique for design is to

optimize stress condition, decrease displacement, increase safety factor and decrease mass. The criterion of optimization design is:

• Maximum displacement < 0.001L; • L:distance between point to constraint center • Minimum safety factor>1.5 • Decrease mass • Links parameters

TABLE I FINAL LINKS PARAMETER

Joint Motion Range Motion Type Driving Type

J1 ±170° Rotation Servo Motor + reducer



P1 350-1550mm Translation Servo Motor + reducer


P2 750-1150mm Translation Servo Motor + reducer

J5 ±100° Rotation Servo Motor + reducer+



• V- joints parameters

TABLE II. FINAL JOINTS PARAMETERS

Joint Max. velocity Max. Acceleration

Peak Torque N*m

Rated Torque N*m

Load inertia N*m

J1 11.25 deg/s 56.25 deg/s2 227.5 48.3 185.45

J2 11.25 deg/s 2.25 deg/s2 1275.4 334.6 203.2

J3 11.25 deg/s 5.625 deg/s2 640.8 177.5 116.9

P1 94.2 mm/s 942 mm/s2 7.7 7.3 0.01

J4 11.25 deg/s 11.25deg/s2 115.5 43.3 17.8

P2 180 mm/s 1800 mm/s2 2.7 2.5 0.004

J5 1125 deg/s 4500 deg/s2 34.4 21.7 0.61

J6 1125 deg/s 4500 deg/s2 34.3 21.6 0.59

J7 1125 deg/s 7500 deg/s2 0.67 0.57 0.11

IV. CONCEPTUAL DESIGN After finding the manipulator specifications and

requirements number of software, such as: Adams, Matlab, Solidworks were used to simulate the final product. Our Mechanical, Electrical and computer engineers were deeply involved in design and simulation stages. The results are shown in Figures 4 to 10.

Fig. 4 Solid Model of Joint2


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Figure 5 Solid Model of Joint3

Fig. 6 Solid Model of Prismatic

Fig. 7 Solid Model of Prismatic2

Fig. 8 Solid Model of Prismatic3

Fig. 9 Solid Model of Robot

Receiver

Motion Controller

RS232

DC ServoDriver

Absolute Encoder

DC Motor

DC ServoDriver

Absolute Encoder

DC Motor

Battery

Remote Controller(10 Channels)

9 Axis

Fig. 10 the manipulator control system

V. KINEMATICS ANALYSIS Forward kinematics analysis is to consider certain

discover the position of the end effect based on the arms motion, while the inverse kinematics is to see how the joints need to move so that the end effect can reach certain position .


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VI. FORWARD KINEMATICS ANALYSIS There is a base(world) coordinate, we describe motion

relative to the base coordinate. As shown in figure 18, the base frame in the base of the robot and it is a fixed coordinate. The first moving frame is called “frame joint1”, which rotate about Z axis. The “frame joint1” and the base frame are in the same place but one rotate about Z axis and the other is a fixed coordinate.

Fig. 11 Coordinate system of EOD robot

VII. THE FINAL PRODUCT: The final product is shown in figure 21 with all the links are

functioning and the control system is connected separately without effecting the manipulator motion. The pick and place gripper was working as planned and other grippers can be connected to the system like the pick and place gripper or the welding.

Fig. 12 Industrial Manipulator Robot

VIII. CONCLUSION In this work, a manipulator design was coupled with an

easy to use graphic user interface and control system to provide industry with advanced capabilities. The visual and

sensor feedback from the robot aids the operator to do the required industrial application from far distance. When compared to the cost of commercially available robots, even if the cost is doubled in the finalization of the design, a significant cost reduction can be seen, greatly increasing the accessibility of the robot. Though the completed robot is only a prototype, there are several key features that, with further development, will increase the efficiency and abilities of bomb disposal units.

ACKNOWLEDGMENT We would like to Thank and Acknowledge King Abdulaziz

City for Science and Technology represented by The National Center for Robotics and Intelligent Systems. Also, Our great thanks will be conveyed specially to the Center Director Dr. Mohammed Khorsheed for his support and directions. Special thanks to the Engineers and technicians of the center for their participation in the design and implementation faces. We would like to thank also Googoltech Company in China and University of Hong Kong for Science and Technology for their training and support to our engineers.

REFERENCES [1] R.G.K.M. Aarts, J.B. Jonker," Dynamic simulation of planar flexible

link manipulators using adaptive modal integration", Multibody System Dynamics, 7 (2002), pp. 31–50

[2] S. Ahmad "Constrained motion force/position control of flexible joint robots" IEEE Transactions on Systems, Man and Cybernetics, 23 (2) (1993), pp. 374–381

[3] V.I. Gouliaev, T.V. Zavrazhina "Dynamics of a flexible multi-link cosmic robot-manipulator" Journal of Sound and Vibration, 243 (4) (2001), pp. 641–657

[4] DeLuca, B. Siciliano "Explicit dynamic modeling of a planar two-link flexible manipulator" Proceedings of the IEEE Conference on Decision and Control, 2 (1990), pp. 528–530

[5] T.R. Parks, H.A. Pak " Effect of payload on the dynamics of a flexible manipulator modeling for control" ASME J Dynamic Systems, Measurement, and Control, 113 (1991), pp. 409–418

[6] M.H. Shaheed, M.O. Tokhi "Dynamic modeling of a single-link flexible manipulator: parametric and non-parametric approaches" Robotica, 20 (2002), pp. 93–109

[7] 20mm Recoilless MK111." EOD Tools, Waterjet Disrupters and Forced Entry Tools. 2006. Web. http://www.proparms.com

[8] News and Other Resources.‖ Technology News, Analysis, Comments and Product Reviews for IT Professionals. CBS Interactive, 2011. Web. 25 Apr. 2011.

[9] Ames, Ben. "Makers of Ground Robots Ask for Better Sensors and Communication." Military & Aerospace Electronics. 1 July 2004. Web. 21 Apr. 2011.

[10] "Astronomy: Tips for Meade's Autostar, LXD-75 and LX200." Astronomy & Photography by Thomas Knoblauch. Web. 21 Apr. 2011.http://www.starshine.ch/astro/autostar/


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