Industrial Robot/Manufacturing Instructions: Difference between revisions

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===Encoder Mount===
===Encoder Mount===


*Encoder Mount Support Angle
====Encoder Mount Support Angle====
**Mark cuts with scriber and try-square
*Mark cut lines with scriber and combination square
**Cut with torch cutter
 
**Mark drill holes with scriber, try-square, and rule
*Cut to appropriate dimensions with torch cutter
**Drill holes with 1/2" bit, 1/4" bit, and cordless drill
 
**[[Media:IREncoderMountAngleA.jpg]]
*Mark drill holes with scriber, try-square, and rule
 
*Drill holes with 1/2" bit, 1/4" bit, and cordless drill
 
*Remove burrs with file
 
*[[Media:IREncoderMountAngleA.jpg]]


*Encoder Mount Main Angle
====Encoder Mount Main Angle====
**Mark cuts with scriber and try-square
**Mark cuts with scriber and try-square
**Cut with torch cutter
**Cut with torch cutter
Line 338: Line 344:
**[[Media:IREncoderMountAngleB.jpg]]
**[[Media:IREncoderMountAngleB.jpg]]


*Encoder Mount Coupling
====Encoder Mount Coupling====
**Mark cuts with scriber and box-square
**Mark cuts with scriber and box-square
**Cut with torch cutter
**Cut with torch cutter

Revision as of 00:06, 20 August 2011


Industrial Robot
   Home  |  Research & Development  |  Bill of Materials  |  Manufacturing Instructions  |  User's Manual  |  User Reviews    Industrial Robot.png


Tooling and Infrastructure

Measuring and Marking

  • Scriber
  • Try-square
  • Box-square
  • Metal Rule
  • Combination Set
  • Center Punch
  • Nipple Punch

Taps and Dies

  • 1/2" - 13 Taps
  • 9/16" - 18 Taps
  • Tap Wrench

Port Cutting

  • SAE6 Port Contour Cutter

Drilling

  • Cordless Drill
  • 1/2" drill bit
  • 3/8" drill bit
  • 1/4" drill bit
  • 5/32" drill bit
  • 1/8" drill bit

Soldering

  • Soldering Iron and Stand
  • Solder

Torching

  • Oxy-acetylene Torch

Turning

  • Lathe
  • Cutting tools - turning, grooving

Hand Tools

  • Adjustable pliers
  • File

Open Section Fabrication and Assembly

Cadrobotnew.png

Structure

Foundation

[2] Main tubes

  • Mark cut lines with scriber, tape measure, and try-square
  • Cut to dimensions with a torch cutter
  • Mark 1/2" dia. hole centers with scriber, tape measure, try-square, and center punch
  • Drill 1/2" dia. holes with 1/2" bit and cordless drill
  • Remove burrs around the holes with a file

[2] Support tubes

    • Mark cut lines with scriber and try-square
    • Cut with torch cutter
    • Mark drill points with scriber, try-square, and center punch
    • Drill with cordless drill or drill press
    • Smooth with file

[4] Raising Bars

    • Mark cut lines with scriber and try-square
    • Cut with torch cutter
    • Mark drill points with scriber, try-square, and center punch
    • Drill with cordless drill or drill press
    • Smooth with file
    • (new image TBD)
    • Media:Pillar.jpg

[1] Base Plate

    • Mark drill points with scriber, try-square, and center punch
    • Drill with cordless drill or drill press
    • Smooth with file
    • (new image TBD)
    • Media:IROverplate.jpg

Main Arm

  • [1] Bar
    • Mark with scriber, try-square, divider, center punch
    • Drill with drill press or cordless drill
    • Media:MainArm.jpg
  • [8] Bolts
  • [8] Bolts

Forearm

  • Tube
  • [8] Bolts
  • [8] Bolts


Gearbox 1,2

[1] Angle

  • Mark the 1/2" dia. hole centers with a scriber, rule, try-square, and center punch
  • Mark the larger dia. hole centers with a scriber, try-square, and nipple punch; then their circumferences with a divider
  • Cut the larger dia. holes with a torch cutter
  • Drill the 1/2" dia. holes with a 1/2" bit and cordless drill
  • Remove burrs around the holes with a file

[2] Input Plate

  • Mark cut lines with scriber, rule, and try-square
  • Cut plates with appropriate dimensions with torch cutter
  • Mark the 1/2" dia. holes with a scriber, rule, try-square, and center punch
  • Mark the 2" and 3.5" dia. hole centers with a scriber, rule, try-square, and nipple punch
  • Mark the 2" and 3.5" dia. hole circumferences with a divider
  • Cut the 2" and 3.5" dia. holes with a torch cutter
  • Drill the 1/2" dia. holes with a 1/2" bit and cordless drill
  • Remove burrs around the holes with a file
  • Note: Location of motor mounting holes TBD

[4] Side Plate

  • Mark cut lines with a scriber, rule, and try-square
  • Cut to appropriate dimensions with torch cutter
  • Mark 1/2" dia. hole centers with a scriber, try-square, and center punch
  • Drill the 1/2" dia. holes with a 1/2" bit and cordless drill
  • Remove burrs with a file

[2] Cover Plates

    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark holes with scriber, try-square, rule, and center punch
    • Drill holes with 1/2" bit and cordless drill
    • Smooth with a file
    • Media:IRGearbox12CoverPlate.jpg

[4] Outer Race Plate

    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark drill holes with scriber, try-square, rule, and center punch
    • Mark torch hole with scriber, rule, nipple punch, and divider
    • Drill with 1/2" bit and cordless drill
    • Torch with torch cutter
    • Smooth with a file
    • Media:IRGearbox12OuterRacePlate.jpg

[2] Round Bar

    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Mark drill holes with scriber, combination set, and center punch
    • Drill with 1/2" bit and cordless drill
    • Tap with 1/2" - 13 taper/intermediate/plug taps and tap wrench
    • Media:IRGearbox12OutputShaft.jpg

[4] Inner Race

    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Mark with scriber and divider
    • Turn with lathe
    • Groove with lathe
    • Mark hole with scriber, combination set, nipple punch, and divider
    • Torch with torch cutter
    • Smooth with file
    • Media:IRGearbox12InnerRace.jpg

[2] Output Hub

    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Mark with scriber and divider
    • Turn with lathe
    • Groove with lathe
    • Mark hole with scriber, combination set, nipple punch, and divider
    • Torch with torch cutter
    • Smooth with file
    • Media:IRGearbox12OutputHub.jpg

[2] Support Hub

    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Mark with scriber and divider
    • Turn with lathe
    • Groove with lathe
    • Mark hole with scriber, combination set, nipple punch, and divider
    • Torch with torch cutter
    • Smooth with file
    • Media:IRGearbox12SupportHub.jpg
  • [2] Input Gear
  • [2] Output Gear
  • [2] Key

Gearbox 3,4

Forearm Angle

Gearbox 5,6

  • Wrist Angle

Encoder Mount

Encoder Mount Support Angle

  • Mark cut lines with scriber and combination square
  • Cut to appropriate dimensions with torch cutter
  • Mark drill holes with scriber, try-square, and rule
  • Drill holes with 1/2" bit, 1/4" bit, and cordless drill
  • Remove burrs with file

Encoder Mount Main Angle

    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark drill holes with scriber, try-square, and rule
    • Drill holes with 1/4" bit, 0.15" bit, and cordless drill
    • Media:IREncoderMountAngleB.jpg

Encoder Mount Coupling

    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Turn with lathe and cutting tool
    • Mark thru- and mount holes with scriber, try-square, combination set, and center punch
    • Mark set hole with box square
    • Drill holes with 1/2" bit, 1/4" bit, and cordless drill
    • Media:IREncoderMountCoupling.jpg

Stepper Mount

  • Stepper Motor Mount Angle
    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark holes with scriber, rule, try-square, and center punch
    • Drill holes with 1" bit, 1/4" bit, 1/8" bit, and cordless drill

Media:StepperMotorMountAngle.jpg

  • Stepper Motor Mount Plate
    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark holes with scriber, rule, try-square, and center punch
    • Drill holes with 1/4" bit and cordless drill

Media:StepperMotorMountPlate.jpg

  • Shaft Bar
    • Mark cuts with scriber and box-square
    • Cut with torch cutter
    • Mark thru hole with scriber, combination set, and center punch
    • Drill holes with 1/2" bit, 1/4" bit, 5/32" bit, and cordless drill
    • Tap holes with 10-24 taper/intermediate/plug taps and tap wrench

Media:ShaftBar.jpg

Assemble Components

Assemble Gearboxes

Media:AssembleGearbox.png

Assemble Industrial Robot

  • As shown below

Media:cadrobotnew.png

Assemble Stepper Motor Mount

  • As shown below, repeat for a total of 6 mounts

Media:Stepneedlemount.jpg

Connect Components

Hydraulic Connections

  • 2 Axes Hydraulic Circuit
    • Correction: Relief valve inline between pump and input tee set

Media:HydraulicCircuit2.jpg

  • Hydraulic Circuit

Media:HydraulicCircuit.jpg

Electronic Connections

  • As shown below

Media:ElectronicConnections.jpg

Programming

  • Programming the Microcontroller
    • Download Arduino IDE Arduino IDE Download
    • Connect Arduino microcontroller to computer through USB port
    • Execute Arduino IDE
    • Copy and paste microcontroller code from the source file [here]
    • Sketch > Verify/Compile
    • Upload
  • Python Jogger
    • Get python code [here]
    • Execute python jogger program
    • Get instructions [here]

Testing

Homing

  • Connect the microcontroller to the computer via USB
  • Execute python jogger program
  • Turn on the pump
  • Press H on the keyboard
  • If the python jogger prints failure text, turn off the pump and troubleshoot

Record Sequence Test

  • Connect the microcontroller to the computer via USB
  • Execute python jogger program
  • Turn on the pump
  • Home all axes
  • Follow python jogger instructions [here] to record a waypoint and save the .ini file

Perform Sequence Test

  • Connect the microcontroller to the computer via USB
  • Execute python jogger program
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