Industrial Robot Mechanical Design

Toolchain for Toolpaths

CAD (FreeCAD) > export (stl, dxf, svg) > CAM (PyCAM) > export (gcode) > Machine Controller (EMC2) > export (logic signals) > Machine (CNC milling, various) > export (work)

In FreeCAD, a 3d mesh drawing can be exported as an stl file; alternatively, a 2d drawing can be exported as a dxf or svg file. Any of these files can then be imported in PyCAM, in which toolpaths can be generated for those drawings. These toolpaths can then be exported from PyCAM as a gcode file. EMC2 can then import the gcode file and simulate the toolpath, plus send logic signals to an external electronic controller that moves a machine to correspond to the toolpath. This toolchain allows digital fabrication to be utilized for the construction of the industrial robot.

Mechanical Concept

Hydraulic Motor

Wikipedia on Hydraulic Motors

Damen Technical Agencies on Types of Hydraulic Motors

Hydraulic motors move the industrial robot at each of its 6 joints.

Possibility is epicyclic (gerotor) motors

• Joint 1 (Base Rotation) Motor: after gear reduction, required to have torque of upwards of X

• Joint 2 (Base Tilt) Motor: after gear reduction, required to have torque of upwards of X

• Joint 3 (Elbow Tilt) Motor: after gear reduction, required to have torque of upwards of X

• Joint 4 (Wrist Rotation) Motor: after gear reduction, required to have torque of upwards of X

• Joint 5 (Wrist Tilt) Motor: after gear reduction, required to have torque of upwards of X

• Joint 6 (Endeffector Rotation) Motor: after gear reduction, required to have torque of upwards of X

• where L is the load force (mass of the load multiplied by the gravitational acceleration)
• where D is the perpendicular distance from the joint shaft to the application point of the load force
• assuming 100% efficiency during gear reduction

Stepper Motor

Solarbotics on Stepper Motors

Wikipedia on Stepper Motors

Stepper motors can be electronically operated and can turn the handle on needle valves; in relation, the function of the stepper motor is to allow the electronic control of needle valves.

A stepper motor can be mounted onto a bracket then connected to the needle valve adjusting handle through a shaft coupling connection. The overall design must allow for the shaft, coupling, or handle to move parallel to the shaft because the needle valve moves slightly up or down when turning in its threads.

In total, 6 stepper motors are required to adjust the 6 needle valves.

Stepper Motor and Needle Valve Mounting Bracket

Green is stepper motor, mounted directly onto the angle piece. Yellow is the stepper motor shaft, connected directly to the pink hub. The pink hub is bolted to the orange hub, completing the shaft coupling. The orange hub is connected directly to the needle valve shaft. The blue needle valve is held between 2 plates. The 2 plates are held in place by 3 bolts that connect to the main angle piece.

Gearbox

Presentation Slides on Gearbox Design

The gearbox is used to make a torque-speed tradeoff with the hydraulic motors. In this case, the speed of the hydraulic motors must be reduced and the torque increased.

By virtue of using hydraulic drive, the motor shaft speeds are low enough that we might be able to use a compact spur gearbox at each joint instead of a more complicated configuration such as harmonic drive.

The gearbox must accomodate a shaft encoder.

The gearbox must have an output shaft that is keyed and fastened to a hub; the hub will be bolted to the next frame piece in the design.

The gearbox must withstand the various kinetic forces that exist when the industrial robot is stationary or moving.

Kinematic Parameters

Wikipedia on Denavit-Hartenberg Parameters (video included)

Formal Lecture Notes on Denavit-Hartenberg

• To be updated

• The Denavit-Hartenberg parameters define the position relationships between 2 motors of the industrial robot. More specifically, the robot has 6 motors, hence one parameter would be between motor 1 and 2; another between motor 2 and 3, 3 and 4, 4 and 5, and 5 and 6.

• The Denavit-Hartenberg parameters are as follows, for joint(i): depth(i), normal length(i), z angle (i), x angle (i).

• • Joint(1): Depth(1)=0.2m , Normal Length(1)=0.2m , Z Angle(1)=90deg , X Angle(1)=*

• • Joint(2): Depth(2)=0.0m , Normal Length(2)=1.0m , Z Angle(2)=00deg , X Angle(2)=*

• • Joint(3): Depth(3)=0.0m , Normal Length(3)=0.1m , Z Angle(3)=90deg , X Angle(3)=*

• • Joint(4): Depth(4)=0.0m , Normal Length(4)=0.0m , Z Angle(4)=90deg , X Angle(4)=*

• • Joint(5): Depth(5)=0.2m , Normal Length(5)=0.0m , Z Angle(5)=90deg , X Angle(5)=*

• • where * is the joint variable

Mass

Given density of A36 steel as 0.28 pounds per cubic inch, or 7750 kilograms per cubic metre, and using numbers from the current design:

• Foundation Underplate: 15.75 pounds, or 7.144 kilograms

• Foundation Pillar: 11.2 pounds, or 5.08 kilograms

• Foundation Pillar Angle: 1.68 pounds, or 0.76 kilograms

• Foundation Overplate: 8.47 pounds, or 3.84 kilograms

• Base Angle: 33.6 pounds, or 15.2 kilograms

• Main Arm: 120.96 pounds, or 54.98 kilograms

• Forearm Angle: 33.6 pounds, or 15.2 kilograms

• Forearm Hub: 8.96 pounds, or 4.1 kilograms

• Forearm: 43.5 pounds, or 19.8 kilograms

• Wrist Angle: 16.8 pounds, or 7.6 kilograms

• Endeffector Angle: 16.8 pounds, or 7.6 kilograms

• Hydraulic Motor 1: est 10 pounds, or 4.5 kilograms

• Hydraulic Motor 2: est 10 pounds, or 4.5 kilograms

• Hydraulic Motor 3: est 10 pounds, or 4.5 kilograms

• Hydraulic Motor 4: est 10 pounds, or 4.5 kilograms

• Hydraulic Motor 5: est 10 pounds, or 4.5 kilograms

• Hydraulic Motor 6: est 10 pounds, or 4.5 kilograms

• Gearbox 1: est 30 pounds, or 13.6 kilograms

• Gearbox 2: est 30 pounds, or 13.6 kilograms

• Gearbox 3: est 30 pounds, or 13.6 kilograms

• Gearbox 4: est 30 pounds, or 13.6 kilograms

• Gearbox 5: est 30 pounds, or 13.6 kilograms

• Gearbox 6: est 30 pounds, or 13.6 kilograms

• Sum of components including and after main arm: 332.48 pounds, or 151.13 kilograms

Force Analysis

• Format

Force is expressed in newtons (N)

Maximum absolute displacement is expressed in millimeters (mm)

Dimensions are expressed in inches (“)

• A36 Steel Specifications

Poisson Ratio = 0.285

Young's Modulus = 200GPa

• Some results strange - retesting to be done, remainder of force analysis to be posted, new analysis for different robot components to be completed

• 36” length by 6” height by 1” width A36 steel bar

• • [Vertical Force + Vertical Gravity] [Wall and force at opposite ends of length]

500N > 39 mm

1000N > 39 mm

1500N > 39 mm

2000N > 40 mm

2500N > 40 mm

• • [Horizontal Force + Horizontal Gravity] [Wall and force at opposite ends of length]

500N > 330 mm

1000N > 330 mm

1500N > 330 mm

2000N > 330 mm

2500N > 330 mm

• 18” length by 6” height by 1” width A36 steel bar

• • [Vertical Force + Gravity] [Wall and force at opposite ends of length]

500N > 1.9 mm

1000N > 1.9 mm

1500N > 2 mm

2000N > 2 mm

2500N > 2 mm

• • [Horizontal Force + Horizontal Gravity] [Wall and force at opposite ends of length]

500N > 16 mm

1000N > 17 mm

1500N > 17 mm

2000N > 17 mm

2500N > 17 mm

• 8” width A and B by 8” length by 1” thickness A36 steel angle

• • [Vertical Force (Load face faces downward) + Vertical Gravity] [Wall and force at opposite outward larger faces]

500N > 0.92mm

1000N > 0.92 mm

1500N > 0.1 mm

2000N > 0.11 mm

2500N > 0.12 mm

• • [Horizontal Force (Load face faces horizontally) + Horizontal Gravity] [Wall and force at opposite outward larger faces]

500N > 0.097 mm

1000N > 0.11 mm

1500N > 0.12 mm

2000N > 0.13 mm

2500N > 0.14 mm

Design Resources

FANUC Maintenance Manual