Industrial Robot/Manufacturing Instructions: Difference between revisions

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Line 57: Line 57:


*[2] Main tubes
*[2] Main tubes
**Mark cut lines with scriber and try-square
**Mark cut lines with scriber and try-square
**Cut with torch cutter
**Cut with torch cutter
**Mark drill points with scriber, try-square, and center punch
**Mark drill points with scriber, try-square, and center punch
**Drill with cordless drill or drill press
**Drill with cordless drill or drill press
**Smooth with file
**Smooth with file


*[2] Support tubes
*[2] Support tubes
**Mark cut lines with scriber and try-square
**Mark cut lines with scriber and try-square
**Cut with torch cutter
**Cut with torch cutter
**Mark drill points with scriber, try-square, and center punch
**Mark drill points with scriber, try-square, and center punch
**Drill with cordless drill or drill press
**Drill with cordless drill or drill press
**Smooth with file
**Smooth with file


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


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


====Fasteners====
====Fasteners====
Line 119: Line 97:


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


*[8] Bolts
*[8] Bolts
Line 135: Line 110:
**Drill 9 holes
**Drill 9 holes
**Weld to tube
**Weld to tube
[[Media:ForearmPlate.jpg]]
**[[Media:ForearmPlate.jpg]]


*Tube
*Tube
Line 142: Line 117:
**Drill 9 holes
**Drill 9 holes
**Weld to tube
**Weld to tube
[[Media:ForearmBar.jpg]]
**[[Media:ForearmBar.jpg]]


*[8] Bolts
*[8] Bolts
Line 159: Line 134:
**Torch holes with torch cutter
**Torch holes with torch cutter
**Smooth with a file
**Smooth with a file
[[Media:BaseAngle.jpg]]
**[[Media:BaseAngle.jpg]]


*[2] Input Plate
*[2] Input Plate
Line 170: Line 145:
**Torch holes with torch cutter
**Torch holes with torch cutter
**Smooth with a file
**Smooth with a file
[[Media:IRGearbox12InputPlate.jpg]]
**[[Media:IRGearbox12InputPlate.jpg]]


*[4] Side Plate
*[4] Side Plate
Line 178: Line 153:
**Drill holes with 1/2" bit and cordless drill
**Drill holes with 1/2" bit and cordless drill
**Smooth with a file
**Smooth with a file
[[Media:IRGearbox12SidePlate.jpg]]
**[[Media:IRGearbox12SidePlate.jpg]]


*[2] Cover Plates
*[2] Cover Plates
Line 186: Line 161:
**Drill holes with 1/2" bit and cordless drill
**Drill holes with 1/2" bit and cordless drill
**Smooth with a file
**Smooth with a file
[[Media:IRGearbox12CoverPlate.jpg]]
**[[Media:IRGearbox12CoverPlate.jpg]]


*[4] Outer Race Plate
*[4] Outer Race Plate
Line 196: Line 171:
**Torch with torch cutter
**Torch with torch cutter
**Smooth with a file
**Smooth with a file
[[Media:IRGearbox12OuterRacePlate.jpg]]
**[[Media:IRGearbox12OuterRacePlate.jpg]]


*[2] Round Bar
*[2] Round Bar
Line 204: Line 179:
**Drill with 1/2" bit and cordless drill
**Drill with 1/2" bit and cordless drill
**Tap with 1/2" - 13 taper/intermediate/plug taps and tap wrench
**Tap with 1/2" - 13 taper/intermediate/plug taps and tap wrench
[[Media:IRGearbox12OutputShaft.jpg]]
**[[Media:IRGearbox12OutputShaft.jpg]]


*[4] Inner Race
*[4] Inner Race
Line 215: Line 190:
**Torch with torch cutter
**Torch with torch cutter
**Smooth with file
**Smooth with file
[[Media:IRGearbox12InnerRace.jpg]]
**[[Media:IRGearbox12InnerRace.jpg]]


*[2] Output Hub
*[2] Output Hub
Line 226: Line 201:
**Torch with torch cutter
**Torch with torch cutter
**Smooth with file
**Smooth with file
[[Media:IRGearbox12OutputHub.jpg]]
**[[Media:IRGearbox12OutputHub.jpg]]


*[2] Support Hub
*[2] Support Hub
Line 237: Line 212:
**Torch with torch cutter
**Torch with torch cutter
**Smooth with file
**Smooth with file
[[Media:IRGearbox12SupportHub.jpg]]
**[[Media:IRGearbox12SupportHub.jpg]]


*[1] Loose Ball Bearings
*[1] Loose Ball Bearings
Line 266: Line 241:


*As shown below
*As shown below
[[Media:ForearmAngle.jpg]]
**[[Media:ForearmAngle.jpg]]


*As shown below
*As shown below
[[Media:WristAngle.jpg]]
**[[Media:WristAngle.jpg]]


*Input Plate
*Input Plate
[[Media:IRGearbox3456InputPlate.jpg]]
**[[Media:IRGearbox3456InputPlate.jpg]]
*Note: Location of mounting holes for hydraulic motor unknown
**Note: Location of mounting holes for hydraulic motor unknown


*Side Plate
*Side Plate
[[Media:IRGearbox3456SidePlate.jpg]]
**[[Media:IRGearbox3456SidePlate.jpg]]


*Cover Plates
*Cover Plates
[[Media:IRGearbox3456CoverPlate.jpg]]
**[[Media:IRGearbox3456CoverPlate.jpg]]


*Outer Race Plate
*Outer Race Plate
[[Media:IRGearbox3456OuterRacePlate.jpg]]
**[[Media:IRGearbox3456OuterRacePlate.jpg]]


*Output Hub
*Output Hub
[[Media:IRGearbox3456OutputHub.jpg]]
**[[Media:IRGearbox3456OutputHub.jpg]]


*Output Shaft
*Output Shaft
[[Media:IRGearbox3456OutputShaft.jpg]]
**[[Media:IRGearbox3456OutputShaft.jpg]]
**Keyed
**Keyed


*Inner Race
*Inner Race
[[Media:IRGearbox3456InnerRace.jpg]]
**[[Media:IRGearbox3456InnerRace.jpg]]


===Gearbox 5,6===
===Gearbox 5,6===
Line 299: Line 274:


*As shown below
*As shown below
[[Media:WristAngle.jpg]]
**[[Media:WristAngle.jpg]]


*Input Plate
*Input Plate
[[Media:IRGearbox3456InputPlate.jpg]]
**[[Media:IRGearbox3456InputPlate.jpg]]
*Note: Location of mounting holes for hydraulic motor unknown
**Note: Location of mounting holes for hydraulic motor unknown


*Side Plate
*Side Plate
[[Media:IRGearbox3456SidePlate.jpg]]
**[[Media:IRGearbox3456SidePlate.jpg]]


*Cover Plates
*Cover Plates
[[Media:IRGearbox3456CoverPlate.jpg]]
**[[Media:IRGearbox3456CoverPlate.jpg]]


*Outer Race Plate
*Outer Race Plate
[[Media:IRGearbox3456OuterRacePlate.jpg]]
**[[Media:IRGearbox3456OuterRacePlate.jpg]]


*Output Hub
*Output Hub
[[Media:IRGearbox3456OutputHub.jpg]]
**[[Media:IRGearbox3456OutputHub.jpg]]


*Output Shaft
*Output Shaft
[[Media:IRGearbox3456OutputShaft.jpg]]
**[[Media:IRGearbox3456OutputShaft.jpg]]
**Keyed
**Keyed


*Inner Race
*Inner Race
[[Media:IRGearbox3456InnerRace.jpg]]
**[[Media:IRGearbox3456InnerRace.jpg]]


===Encoder Mount===
===Encoder Mount===
Line 331: Line 306:
**Mark drill holes with scriber, try-square, and rule
**Mark drill holes with scriber, try-square, and rule
**Drill holes with 1/2" bit, 1/4" bit, and cordless drill
**Drill holes with 1/2" bit, 1/4" bit, and cordless drill
 
**[[Media:IREncoderMountAngleA.jpg]]
[[Media:IREncoderMountAngleA.jpg]]


*Encoder Mount Main Angle
*Encoder Mount Main Angle
Line 339: Line 313:
**Mark drill holes with scriber, try-square, and rule
**Mark drill holes with scriber, try-square, and rule
**Drill holes with 1/4" bit, 0.15" bit, and cordless drill
**Drill holes with 1/4" bit, 0.15" bit, and cordless drill
 
**[[Media:IREncoderMountAngleB.jpg]]
[[Media:IREncoderMountAngleB.jpg]]


*Encoder Mount Coupling
*Encoder Mount Coupling
Line 349: Line 322:
**Mark set hole with box square
**Mark set hole with box square
**Drill holes with 1/2" bit, 1/4" bit, and cordless drill
**Drill holes with 1/2" bit, 1/4" bit, and cordless drill
 
**[[Media:IREncoderMountCoupling.jpg]]
[[Media:IREncoderMountCoupling.jpg]]


=Stepper Mount=
=Stepper Mount=

Revision as of 12:44, 18 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

Taps and Dies

  • 1/2"-13 Taps
  • Tap Wrench

Drilling

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

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 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
  • [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] 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

Fasteners

  • [12] Bar Bolts
  • [4] Ground Bolts
  • [4] Plate Bolts

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

  • [2] Hydraulic Motor
  • [1] Angle
    • Mark hole centers with a scriber, rule, try-square, nipple punch (for torch holes), and center punch (for drill holes)
    • Mark torch holes with a divider
    • Drill holes with 1/2" bit and cordless drill
    • Torch holes with torch cutter
    • Smooth with a file
    • Media:BaseAngle.jpg
  • [2] Input Plate
    • Note: Location of motor mounting holes TBD
    • Mark cuts with scriber and try-square
    • Cut with torch cutter
    • Mark hole centers with a scriber, rule, try-square, nipple punch (for torch holes), and center punch (for drill holes)
    • Mark torch holes with a divider
    • Drill holes with 1/2" bit and cordless drill
    • Torch holes with torch cutter
    • Smooth with a file
    • Media:IRGearbox12InputPlate.jpg
  • [4] Side Plate
    • 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:IRGearbox12SidePlate.jpg
  • [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
  • [1] Loose Ball Bearings
  • [12] Side Plate Bolts
  • [12] Side Plate Nuts
  • [4] Cover Plate Bolts
  • [4] Cover Plate Nuts
  • [4] O-ring Seal
  • [4] Output Shaft Bolts
  • [4] Lube Bolts
  • [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 cuts with scriber and try-square
    • Cut with torch cutter
    • Mark drill holes with scriber, try-square, and rule
    • Drill holes with 1/2" bit, 1/4" bit, and cordless drill
    • Media:IREncoderMountAngleA.jpg
  • 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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