Industrial Robot Proposal - Revision history

YK at 15:35, 22 September 2011

2011-09-22T15:35:52Z

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	sourcing. 1 day for soldering and assembling electronics as well as		sourcing. 1 day for soldering and assembling electronics as well as
	connecting the hydraulic circuit. 2 days for fabrication and assembly		connecting the hydraulic circuit. 2 days for fabrication and assembly
	of structural components. ~~Additional time~~ for software file		of structural components. 3 weeks for software file development and
	development and testing. Ensuring the functionality of 1 axis		testing. Ensuring the functionality of 1 axis control, hydraulics,
	control, hydraulics, and structure is optimal preparation for		and structure is optimal preparation for manufacturing the remaining
	manufacturing the remaining 5 axes.		5 axes.
	</P>		</P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm">General time allocation for the full
			prototype as follows: 4 weeks for sourcing. 5 days for soldering and
			assembling electronics as well as connecting the hydraulic circuit.
			20 days for fabrication and assembly of structural components. 5 days
			for 6-axis testing.</P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
	<P STYLE="margin-bottom: 0cm">The partial prototype contains a		<P STYLE="margin-bottom: 0cm">The partial prototype contains a
	fraction of the components in the following diagrams:</P>		fraction of the components in the following diagrams:</P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><IMG SRC="http://opensourceecology.org/w/images/9/96/IndustrialRobotControlSystem.jpg" NAME="graphics1" ALIGN=BOTTOM WIDTH=661 HEIGHT=378 BORDER=0></P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
	<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotControlSystem.jpg">Control		<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotControlSystem.jpg">Control
	System Diagram</A></P>		System Diagram</A></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><IMG SRC="http://opensourceecology.org/w/images/thumb/d/d0/IndustrialRobotHydraulicCircuit.jpg/800px-IndustrialRobotHydraulicCircuit.jpg" NAME="graphics2" ALIGN=BOTTOM WIDTH=664 HEIGHT=459 BORDER=0></P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
	<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotHydraulicCircuit.jpg">Hydraulic		<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotHydraulicCircuit.jpg">Hydraulic
	System Diagram</A></P>		System Diagram</A></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><IMG SRC="http://opensourceecology.org/w/images/2/2c/Irstructuralsystem.jpg" NAME="graphics3" ALIGN=BOTTOM WIDTH=441 HEIGHT=478 BORDER=0></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:Irstructuralsystem.jpg">Structural
			System Diagram</A></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><IMG SRC="http://opensourceecology.org/w/images/9/93/Irhydmotorencodermounting.jpg" NAME="graphics4" ALIGN=BOTTOM WIDTH=519 HEIGHT=478 BORDER=0></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><A HREF="http://opensourceecology.org/wiki/File:Irhydmotorencodermounting.jpg">Mounting
			Diagram for Hydraulic Motor and Encoder onto Structural System</A></P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
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			</P>
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	</P>		</P>
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	Diagram</B> –		Diagram</B> –
	</P>		</P>
			<P STYLE="margin-bottom: 0cm"><BR>
			</P>
			<P STYLE="margin-bottom: 0cm"><IMG SRC="http://opensourceecology.org/w/images/thumb/d/d5/Industrialrobotoverview.jpg/787px-Industrialrobotoverview.jpg" NAME="graphics5" ALIGN=BOTTOM WIDTH=653 HEIGHT=477 BORDER=0></P>
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	</P>		</P>
	<P STYLE="margin-bottom: 0cm"><B>Timeline</B> – 1 month plan: 3		<P STYLE="margin-bottom: 0cm"><B>Timeline</B> – 1 month plan for
	days for completion of tangible ~~partial prototype~~ given access to		partial prototype: 3 days for completion of tangible manufacturing
	required resources as aforementioned in “Deliverables”. ~~Rest~~ of		given access to required resources as aforementioned in
	the month for finalizing software files, testing, and uploading		“Deliverables”. 3 weeks (rest of the month) for finalizing
	documentation.</P>		software files, testing, and uploading documentation.</P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
	<P STYLE="margin-bottom: 0cm"><B>~~Project Plan~~</B> –		<P STYLE="margin-bottom: 0cm">1 month plan for full prototype: 25
			days for completion of tangible manufacturing given access to
			required resourced as aforementioned in “Deliverables”. 5 days
			for finalizing 6-axis testing and uploading documentation.</P>
			<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
			<P STYLE="margin-bottom: 0cm"><B>Project Plan</B> – For partial
			prototype:</P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
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	</P>		</P>
	<P STYLE="margin-bottom: 0cm">*Slewing Bearing: Use higher precision		<P STYLE="margin-bottom: 0cm">*Slewing Bearing: Use external gear
	~~geared slewing~~ bearing.</P>		slewing bearing with zero backlash worm or higher-precision slewing
			bearing with internal gear</P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>
	</P>		</P>
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	</P>		</P>
	<P STYLE="margin-bottom: 0cm">*Mechanical Stiffness at Axes of		<P STYLE="margin-bottom: 0cm">*Mechanical Stiffness at Axes of
	Rotation: Use back-end flow control orientation, ~~auto-correcting~~		Rotation: Use back-end flow control orientation, autocorrecting
	movement software configuration, or ~~improved hydraulic motors~~		movement software configuration, or
	</P>		</P>
	<P STYLE="margin-bottom: 0cm"><BR>		<P STYLE="margin-bottom: 0cm"><BR>

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Industrial Robot Prototype

by <A HREF="http://opensourceecology.org/wiki/Yoonseo_Kang">Yoonseo
Kang</A>

September 21, 2011
msn149@hotmail.com

Abstract: – The industrial
robot partial prototype consists of the fabrication, assembly, and
testing of 1 axis for future integration into a fully operational
6-axis robotic arm that is teachable by jogging in either cartesian
or joint space, and controllable with g-code. The industrial robot
serves as a universal “user” machine that can be utilized for the
automation of a wide variety of processes including welding,
pick-and-placing, torching, and more; given the industrial robot's
high reach, payload, speed, and duty cycle, robotic automation allows
a significantly high rate of production with relatively minimal
operator involvement. More broadly, automation lies at the core of
productivity and economic freedom. With regard to distributive
enterprise, robotic processes can be shared among communities through
digital files, the use of which are more simple and less
time-consuming than applying equivalent manual processes. For the
GVCS, the industrial robot is the means with which a small group of
individuals can achieve enormous productive potential; for
civilization, the arm-like universal automation machine at the core
of flexible fabrication infrastructure. Economic analysis suggests
that the industrial robot's output is at least twice the rate of
manual performance for most desired tasks, mainly attributable to the
machine's high duty cycle. The expected deployment timeline for the
industrial robot partial prototype is under 1 month given complete
access to the required resources; for the full prototype integration,
similar timing as sourcing and infrastructure permit.
 

Deliverables – General time
allocation for the partial prototype as follows: 4 weeks for
sourcing. 1 day for soldering and assembling electronics as well as
connecting the hydraulic circuit. 2 days for fabrication and assembly
of structural components. Additional time for software file
development and testing. Ensuring the functionality of 1 axis
control, hydraulics, and structure is optimal preparation for
manufacturing the remaining 5 axes.

 

The partial prototype contains a
fraction of the components in the following diagrams:
 

<A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotControlSystem.jpg">Control
System Diagram</A>
 

<A HREF="http://opensourceecology.org/wiki/File:IndustrialRobotHydraulicCircuit.jpg">Hydraulic
System Diagram</A>
 

<OL>
<LI>Diagrams – Above
<LI>Industry Analysis – Current
costs of some commercially available industrial robots are shown
<A HREF="http://www.trendrobotics.com/products.php?list=C1">here</A>.
In comparison, attributable to the hydraulic drive, open-source
control system, and simplified structure, the cost for the OSE
industrial robot is approximated to be significantly lower (as will
be specified in the cost analysis) while performance expected to
match commercial standards. Significant modularity allows
interchangeability of components (for instance, the encoder) for
even higher resolution; open source fabrication of major components
such as the hydraulic motor and slewing bearings will drastically
reduce total cost in the near future.
<LI>Scaling calculations – To scale
up reach, the structural system need only be enlarged. To scale up
torque, the slewing bearing size can be increased, multiple motors
can be geared to a single slewing bearing, and/or a planetary
gearbox can be attached to the face of the hydraulic motor. To
increase encoder resolution, an encoder with greater cycles per
revolution can be utilized. To increase operating bandwidth, faster
electronics can be incorporated overall into the control system
(such as using the 5i20 card instead of 7i43, and/or using daughter
cards for step/dir generation). The aforementioned modularity allows
easy changes to overall characteristics.
</OL>
 

Systems Engineering Breakdown
Diagram –

 

<A HREF="http://opensourceecology.org/wiki/File:Industrialrobotoverview.jpg">Overview
Diagram</A>
 

<A HREF="http://opensourceecology.org/wiki/OSE_Specifications">OSE
Specifications</A> Assessment –

 

Open-sourced:
 

PWM Driver
Stepper Driver
Control Software
Supporting Frame
 

Not yet open-sourced:
 

Hydraulic Motor
Hydraulic Filter
Pressure Relief Valve
Stepper Motor
Needle Valve
2/4 Solenoid Valve
Slewing Bearing
Incremental Encoder
Electric Power Supply
Anything IO Card
Computer
 

Design:
 

The software side of the control system
(emc2) is already open-source and built for customization and
modification (even with help programs for custom HAL and INI files in
specialized applications). Furthermore, the operator may choose to
use a wholly different software for the control system, for which the
compatibility is mainly attributable to the versatile “Anything I/O
Card”.

 

The hardware side of the control system
is a simple network of 5 major components including the computer,
anything IO card, stepper driver, pwm driver, and power supply. Any
component can be switched for another of the same function easily
with terminal block connections.

 

The hydraulic system is also a
relatively simple circuit that is easy to modify and assemble.
 

The structural system includes simple
components such as 1-piece foundations and frame connections. The
absence of a dedicated gearbox significantly lowers the complexity of
this system (the gear reduction between the motor shaft pinion and
geared slewing bearing provides sufficient torque due to hydraulic
drive). Even a directly coupled shaft-to-frame connection is
available as an option, as is the use of a planetary gearbox or
multiple motors on one bearing as mentioned in the scaling analysis.
 

Resources – The major
resources required for manufacturing the industrial robot partial and
full prototype include various GVCS tools: Precision CNC
Multimachine, Drill press, Torch Table. Additionally, hand tools
include wrench set, hex key set, tap and die set.
 

Timeline – 1 month plan: 3
days for completion of tangible partial prototype given access to
required resources as aforementioned in “Deliverables”. Rest of
the month for finalizing software files, testing, and uploading
documentation.
 

Project Plan –

 

Electronics: Solder PWM Driver 1.1,
then connect electronics as shown in the electronics diagram but for
1 axis
 

Hydraulics: Connect components as shown
in the hydraulic diagram but for 1 axis. Fabricate and assemble the
stepper mount, then fit it onto the needle valve.
 

Structure: Drill holes in foundation
and shoulder angle, assemble by sandwiching (bolts/nuts) the slewing
bearing between those two components. Fabricate the pinion gear,
mount the hydraulic motor, fabricate the encoder coupling, mount the
encoder, fabricate and assemble cover components.

 

Budget – See <A HREF="http://opensourceecology.org/wiki/Industrial_Robot/Bill_of_Materials">Industrial
Robot Bill of Materials</A>
 

Assessment – Functionality,
proximity to expected characteristics, and potential for future
improvement. These 3 assessment criteria will aid in understanding
the differences between the design and actual prototyping process, as
well as setting the ground for better development in the future.
 

Failure Mode Analysis and Recovery
Plan –

 

Industrial robot function substitutes
and enhancements are discussed here as options.
 

Flow Control: Use higher torque step
motors or proportional valves
 

Structural Angle: Use short
reinforcing angles or thicker metal
 

Slewing Bearing: Use higher precision
geared slewing bearing.
 

Anything IO: Use Mesa 5i20
 

Mechanical Stiffness at Axes of
Rotation: Use back-end flow control orientation, auto-correcting
movement software configuration, or improved hydraulic motors

 

*Intergear Spacing: Use higher
precision gears or spring-loaded double gear design
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