Material depositing robot arm for arc welding: Structure & driving mechanism

This thesis presents the research work on the design and modeling of a 3-DoF robot arm as part of the 6-DoF arc welding robot called Robotums RA-01 developed at Centre of Materials & Minerals, Universiti Malaysia Sabah. A 3-DoF robot arm has been designed with the ability to interface with a for...

Full description

Saved in:

Bibliographic Details
Main Author:	Choong, Wai Heng
Format:	Thesis
Language:	English
Published:	2008
Subjects:	TJ Mechanical engineering and machinery
Online Access:	https://eprints.ums.edu.my/id/eprint/6428/1/mt0000000157.pdf
Tags:	Add Tag No Tags, Be the first to tag this record!

id	my-ums-ep.6428
record_format	uketd_dc
institution	Universiti Malaysia Sabah
collection	UMS Institutional Repository
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Choong, Wai Heng Material depositing robot arm for arc welding: Structure & driving mechanism
description	This thesis presents the research work on the design and modeling of a 3-DoF robot arm as part of the 6-DoF arc welding robot called Robotums RA-01 developed at Centre of Materials & Minerals, Universiti Malaysia Sabah. A 3-DoF robot arm has been designed with the ability to interface with a forearm mechanism developed by Chua (2007) to form a complete 6-DoF arc-welding robot with a maximum reachable distance of 1,300mm and a handling payload of 6kg at the wrist center. As well as designing of the robot-arm mechanics and structure, and the driving system design fundamentals. The robot kinematics model has been developed to serve as the fundamental mechanics of the robot-arm system. Modified Denavit-Hartenberg frame assignment is introduced to resolve the complexity of the skeleton structure frame assignment with a final reference coordinate frame been fixed, which leads to the forward and inverse kinematics model formulation. Each joint of the designed robot arm is given a degree of freedom by attaching a joint driving system using servomotors and harmonics drive partnership. The joint driving systems are designed based on the criteria to meet acceleration and manipulation of the robot arm structures and inertia masses achieving the 6kg payload at the wrist center point. Prediction of harmonic drive safety functional life span of the shortest period of 8 years is achieved at 1st joint driving system before failure is anticipated. The robot arm 3-D virtual prototype linkage structures are designed through SolidWorks to meet the design requirement of a maximum deflection value of 0.257mm and an equivalent stiffness of 295717.5 N/mm for 6kg payload acting at the wrist center has also been achieved. The main linkage structures design involved the theoretical model, and the iteration or numerical via CAD with CAE verification has been introduced. For analyzing the theoretical dynamic behavior of the robot arm, a dynamic model of the arm has been developed based on the Lagrange approach. An ideal theoretical dynamic model, neglects on the frictional force terms are simulated in the development of inverse dynamic solutions of the joint torques. A close-to real life dynamic simulation or 3-D motion numerical analysis has also been performed through CosmosMotion CAE application tool for comparison and verification of the results with the theoretical model. The linear trajectory simulation of the GMAW robot-arm wrist center Cartesian position error range of 0.00mm to 0.35mm is achieved at 400 mm/min for standard gas metal welding operation, which permitted tolerance variation position between the arc and joint gap not to exceed more than +0.5 mm. Therefore, the designed GMAW robot-arm has successfully met the requirement of gas metal arc welding operation.
format	Thesis
qualification_level	Master's degree
author	Choong, Wai Heng
author_facet	Choong, Wai Heng
author_sort	Choong, Wai Heng
title	Material depositing robot arm for arc welding: Structure & driving mechanism
title_short	Material depositing robot arm for arc welding: Structure & driving mechanism
title_full	Material depositing robot arm for arc welding: Structure & driving mechanism
title_fullStr	Material depositing robot arm for arc welding: Structure & driving mechanism
title_full_unstemmed	Material depositing robot arm for arc welding: Structure & driving mechanism
title_sort	material depositing robot arm for arc welding: structure & driving mechanism
granting_institution	Universiti Malaysia Sabah
granting_department	School of Engineering and Information Technology
publishDate	2008
url	https://eprints.ums.edu.my/id/eprint/6428/1/mt0000000157.pdf
_version_	1747836325339332608
spelling	my-ums-ep.64282017-10-11T03:04:00Z Material depositing robot arm for arc welding: Structure & driving mechanism 2008 Choong, Wai Heng TJ Mechanical engineering and machinery This thesis presents the research work on the design and modeling of a 3-DoF robot arm as part of the 6-DoF arc welding robot called Robotums RA-01 developed at Centre of Materials & Minerals, Universiti Malaysia Sabah. A 3-DoF robot arm has been designed with the ability to interface with a forearm mechanism developed by Chua (2007) to form a complete 6-DoF arc-welding robot with a maximum reachable distance of 1,300mm and a handling payload of 6kg at the wrist center. As well as designing of the robot-arm mechanics and structure, and the driving system design fundamentals. The robot kinematics model has been developed to serve as the fundamental mechanics of the robot-arm system. Modified Denavit-Hartenberg frame assignment is introduced to resolve the complexity of the skeleton structure frame assignment with a final reference coordinate frame been fixed, which leads to the forward and inverse kinematics model formulation. Each joint of the designed robot arm is given a degree of freedom by attaching a joint driving system using servomotors and harmonics drive partnership. The joint driving systems are designed based on the criteria to meet acceleration and manipulation of the robot arm structures and inertia masses achieving the 6kg payload at the wrist center point. Prediction of harmonic drive safety functional life span of the shortest period of 8 years is achieved at 1st joint driving system before failure is anticipated. The robot arm 3-D virtual prototype linkage structures are designed through SolidWorks to meet the design requirement of a maximum deflection value of 0.257mm and an equivalent stiffness of 295717.5 N/mm for 6kg payload acting at the wrist center has also been achieved. The main linkage structures design involved the theoretical model, and the iteration or numerical via CAD with CAE verification has been introduced. For analyzing the theoretical dynamic behavior of the robot arm, a dynamic model of the arm has been developed based on the Lagrange approach. An ideal theoretical dynamic model, neglects on the frictional force terms are simulated in the development of inverse dynamic solutions of the joint torques. A close-to real life dynamic simulation or 3-D motion numerical analysis has also been performed through CosmosMotion CAE application tool for comparison and verification of the results with the theoretical model. The linear trajectory simulation of the GMAW robot-arm wrist center Cartesian position error range of 0.00mm to 0.35mm is achieved at 400 mm/min for standard gas metal welding operation, which permitted tolerance variation position between the arc and joint gap not to exceed more than +0.5 mm. Therefore, the designed GMAW robot-arm has successfully met the requirement of gas metal arc welding operation. 2008 Thesis https://eprints.ums.edu.my/id/eprint/6428/ https://eprints.ums.edu.my/id/eprint/6428/1/mt0000000157.pdf text en public masters Universiti Malaysia Sabah School of Engineering and Information Technology Appleton, E., & Williams, DJ. 1987. Industrial Robot Applications. New York: John Willey & Sons. Ashby, M.F. 1999. Materials Selection in Mechanical Design. (2nd edition). Oxford: Butterworth-Heinemann. Aspragathos, N.A. & Dimitros, J.K. 1998. A Comparative Study of Three Methods for Robot Kinematics. Systems/ Man and Cybernetics - Part B: Cybernetics. 28(2): 135-145. Balafoutis, C.A. 1994. A Survey of Efficient Computational Methods for Manipulator Inverse Dynamic. Journal of Intelligent and Robotic Systems 9:45-71. Banka, N. & Lin, YJ. 2003. Mechanical Design for Assembly of a 4-DoF Robotic Arm Utilizing a Top-Down Concept. Robotica. 21: 567-573. Bolmsjo, G., Olsson, M. & Cederberg, P. 2002. Robotic Arc Welding - Trends and Developments for Higher Autonomy. Industrial Robot: An International Journal. 29(2): 98-104. Brown, A. 2002. Protecting Against Extreme Welding Hazards. Occupational Hazards. July. New York: Penton Media Inc. Cary, H.B., 1995. Arc Welding Automation. New York: Marcel Dekker, Inc. Cary, H.B. & Helzer, S.c. 2005. Modern Welding Technology. Singapore: Pearson Prentice Hall. Charpa, S.C. & Canale, R.P. 2002. Numerical Methods for Engineers. (4th edition). New York: McGraw Hill. Choi, H.5. & Oh, J. 2005. A New Revolute Robot Manipulator Adapting The Closed Chain Mechanism. Journal of Robotic Systems. 22(2):99-105. Chua, B.L., Choong, W.H., Yoong, H.P. & Yeo, K.B. 2004. Kinematics Models for 3- Axes Articulated Manipulator Control. Proceeding of ft International Conference on Product Design & Development, Unversiti Malaysia Sabah. pp:133-138. Chua, B.L. 2007. Design of Spherical Wrist and Trajectory Solution for Robotic Arc Welding Application. School of Engineering and Information Technology. Kota Kinabalu: Universiti Malaysia Sabah Clark, S. & Lin, YJ. 2007. Cad Tools Integration for Robot Kinematics Design Assurance With Case Studies On Puma Robots. Industrial Robot: An International Journal. 18(3):240-248. Coy, JJ., Townsend, D.P. & Zaretsky, D.V. 1985. Gearing. NASA Reference Publication. 1152. Cleveland: NASA Lewis Research Center. Daerden, F. & Lefeber, D. 2002. Pneumatic Artificial Muscles: Actuators for Robotics and Automation. European Journal of Mechanical and Environmental Engineering. 47: 11-21. Derby, S. 1983. The Deflection and Compensation of General Purpose Robot Arm. Mechanism and Machine Theory. 18(6):445-450. Duysinx, P. & Geradin, M. 2004. An Introduction to Robotics: Mechanical Aspects. Belgium: university of Liege. Ersu, E. & Nungesser, D. 1984. A Numerical Solution of the General Kinematic Problem. Proceedings IEEE International Conference on Robotics and Automation. 1:162-168. Fanuc. 2003. Arc Mate i8-02 Catalogue. Japan: Fanuc Ltd. Gordon, L. 2005. Real Cells Go Virtual. Welding Megazine - May. New York: Penton Media Inc. Groover, M.P., Weiss, M., Nagel, N.R., & Odrey, N.G. 1986. Industrial Robotics: Technology, Programming, and Application. USA: McGraw-Hill. Habibi, S.R., Richards, RJ. & Goldenberg, A.A. 1994. Hydraulic actuator analysis for industrial robot multivariable control. Proceedings of the American Control Conference. 1:1003-1007. Harmonic Drive. 2006a. CSD and SHD Series: Cup Type Component Sets and Housed Units. USA: Harmonic Drive Inc. Harmonic Drive. 2006b. SHF and SHG Series: Cup Type component Sets and Housed Units. USA: Harmonic Drive Inc. Harrison, H.R., & Nettleton, T. 1997. Advanced Engineering Dynamics. New York: John Wiley & Sons, Inc. Helzer, S.C. & Cary, H.B. 2005. Modern Welding Technology. Singapore: Pearson Prentice Hall. Hibbeler R.C. 1997. Engineering Mechanics: Statics and Dynamics. New Jersey: Prentice Hall, Inc. Horn, B.K.P. 1987. New Notation for Serial Kinematic Chains. Huang, SJ. & Wang, T.Y. 1993. Structural Dynamics Analysis of Spatial Robots With Finite Element Approach. Computer & Structures. 46(4):703-716. Hyundai Robotics. 2007. H006 Robotic Arm/ Manipulator. (on-line) http:www.hyundairobotics.com Accessed on 15th March 2007. JARA (Japan Robot Association), 2007. January - December 2006 Results. (on-line) http://www.jara.jp/e/dI(2006.pdf Accessed on 20th September 2007. JETRO (Japan External Trade Organization). 2006. Trends in The Japanese Robotics Industry. Japan Economic- March. (on-line) http://www.jetro.go.jp/en/market/trend/industrial(pdf/jem0602-2e.pdf Accessed on 20th March 2007. Joseph, H. & Huston, R.L. 2002. Dynamics of Mechanical Systems. New York: CRC Press. Kawasaki Robotics. 2006. F-Series Catalogue. USSA: Kawasaki Robotics (USA) Inc. Kelly, S.G. 2000. Fundamentals of Mechanical Vibrations. Singapore: McGraw- Hill. Kennedy, C.W. & Desai, J.P. 2003. Estimation and Modeling of The Harmonic Drive Transmission In The Mitsubishi PA-l0 Robot Arm. Intelligent Robots and Systems. 4:3331-3336. KHK Co. Ltd., 2007. KHK Stock Gears 2007: All Product Guide and Technical Data. Japan: KHK Co. Ltd. Kissell, T.E. 2006. Industrial Electronics. (2nd edition). New Jersey: Prentice Hall. Kurfess, T.R. (ed.). 2000. Robotics and Automation Handbook. New York: CRC Press. Kuvin, B. F., 2006. Robotic Welding - Helps Stamper Grow in Automotive. MetalForming â€“ April. Ohio: Precision Metalforming Association. Landry, J. 2001. New Rules for Sizing Servos. Machine Design. July: 68. Cleveland: Penton Press. Lenarcic, J., Nemec, B., Stanic, U. & Oblak, P. 1988. Design of Robot Manipulators Based on Kinematic Analysis. Robotics & Computer-Integrated Manufacturing. 4(1/2):203-209. Litvin, F.L. 1997. Development of Gear Technology and Theory of Gearing. NASA Reference Publication. Cleveland: NASA Lewis Research Center. Man, Z. 2004. Robotics for Computer Engineering Students. Singapore: Prentice Hall. Markus, L. 1994. Application of The General Elimination Method In Robot Kinematics. Journal of Intelligent and Robotic Systems. 11:109-116. Mavroidis, c., Lee, E. & Alam, M. 200l. Geometric Design Problem Of Spatial Denavit And Hartenberg Parameters. 123(1): 58-67. A New Polynomial Solution to The R-R Robot Manipulators Using The Journal of Mechanical Design. Mitsubishi Electric. 2005. Servo Amplifiers and Servo Motors: MELSERVOjMR2-J2- SUPER. (7th edition). Ratingen: Mitsubishi Electric Europe Inc. Morecki, A. & Knapczyk, J. (ed.). 1999. Basic of Robotics: Theory and Components of Manipulators and Robots. New York: Springer-Verlag Wien. Motoman. 2006. Motoman September News Release. (on-line) http://www.motoman.com/news/releases/2006/DA20robot-b.pdf Accessed on 20th September 2006. Motoman. 2007. Robot Series Brochure. Ohio: Motoman Corporate. Mott, R.L. 1999. Machine Elements in Mechanical Design. New Jersey: Prentice Hall, Inc. Mur, J.M., Teculescu, D., Pham, Q.T., Gaertner, M., Massin, N., Meyer-Bish, c., Moulin, J.J., Diebold, F., Piece, F., Meurou-Poncelet, B. & Muller, J. 1985. Lung Function and Clinical Findings In a Cross-Sectional Study of Arc Welders. International Archivers of Occupational and Environment Health. 55: 1-17. Nielsen, J. and Roth, B. 1999. On The Kinematic Analysis of Robotic Mechanisms. The International Journal of Robotics Research. 18(12): 1147-1160. Niku, S.B. 2001. Introduction to Robotics: Analysis/ Systems, & Application. New Jersey: Prentice Hall. Norish, J., 1992. Advanced Welding Processes. London: lOP Publishing Ltd. Norton, R.L. 1999. Design of Machinery: An Introduction of the Synthesis and Analysis of Mechanisms of Machines. Singapore: McGraw-Hill. Ohm, D.Y. 2006. Selection of Servo Motors and Drives. (on-line) http://www.drivetechinc.com/articles/pm96sizrev2.pdf Accessed on 25th September 2006. OICA, 2007. World Motor Vehicle Production by Country 2005-2006. International Organization of Motor Vehicle Manufacturers (OICA). (on-line) http://oica. netjwp-contentjuploadsj2007/06/worldprod_country-revised .pdf Accessed on 17th November 2006. Otten, E. 2003. Inverse and Forward Dynamics: Models of Multi-body Systems. Philosophical Transactions of the Royal Society B: Biological Sciences. 358:1493-1500. Otto, K., & Wood, K. 2001. Product Design: Techniques in Reverse Engineering and New Product Development New Jersey: Prentice Hall. Panasonic G2 Series Catalog, 2006. Panasonic G2 Series Catalog. Panasonic Factory Solutions Company of America. (on-line) http://industrial.panasonic.com/www-data/pdf/ ABD3000j ABD3000CE1. pdf Accessed on 4th July 2006. Park, LW., Kim, J.Y., Lee, J. & Oh, J.H. 2005. Mechanical Design of Humanoid Robot Platform KHR-3. Humanoid Robots, 2005 5th IEEE-RAS International Conference. 321-326. Ridley, P.R. 1994. Robot Kinematics - 1. Graphical Solution of the Inverse Equation of Closure. Mechanism and Machine Theory. 29(7):1043-1052. Robacta. 2000. Robot Torches. USA: Fronius International. Rooks, B., 2005. Welding and More Feature at ABB UK Open Days. Industrial Robot: An International Journal. 32(1): 10-14. Roy, J. & Whitcomb, L.L. 1997. Structural Design Optimization and Comparative Analysis of a New High Performance Robot Arm via Finite Element Analysis. Proceeding for 1997 IEEE International Conference on Robotics and Automations. New Mexico. Saikkonen, M. 1996. The Kinematics and Strength of Biharmonic Gear Drives. Mechanical Series of Acta Polytechnica Scandinavica. 123. Helsenki: Finish Academy of Technology. Sawa, T. & Kume, T. 2004. Motor Drive Technology - History And Visions For The Future. 3gh Annual IEEE Power Electronics Specialists Conference. 1: 2-9. Schilling, RJ. 1990. Fundamentals of Robotics: Analysis and Control. New Jersey: Prentice Hall, Inc. Selig, J.M. 2005. Geometric Fundamentals Of Robotics. New York: Springer, Inc. Shigley, J.E. & Maischke, C.R. 2001. Mechanical Engineering Design. Singapore: McGraw-Hili Book Co. Slatter, R. & Mackrell, G. 1994. Harmonic Drives in Tune with Robots. Industrial Robot; An International Journal. 21(3): 24-28. Slatter, R., & Koenen, H. Lightweight Harmonic Drive Gears for Service Robots. Technical Paper. Germany: Harmonic Drive Ag. Spong, M.W. & Vidyasacar, M. 1989. Robot Dynamics and Control. USA: John Wiley & Sons. Tsai, L.W. 1999. Robot Analysis: The Mechanics of Serial and Parallel Manipulators. USA: John Wiley & Sons, Inc. van Beek, B. & de Jegar, B. 1997. RRR-Robot Design: Basic Outlines, Servo Sizing and Control. Proceedings of the 1997 IEEE International Conference on Control Applications, Hartford, USA. 36-41. Walewander, J. 2001. Two for One. April-Motion System Design. 39-45. Cleveland: Penton Media Inc. Wang, Y., Hang, L. & Yang, T. 2006. Inverse Kinematics Analysis of General 6R Serial Robot Mechanism Based on Groebner Base. Frontiers of Mechanical Engineering in China. 1(1):115-124. Waltmusser. 2007. C Walton Musser's Development of Harmonic Drive Gearing. (on-line) http://www.waltmusser.org/HD.htm Accessed on 2nd May 2006. Wikipedia. 2008. IP Code. (on-line) htlp://www.wikipedia.org'/wikijip_code Accessed on 4th May 2007 Wilson, M., 2002. The Role of Seam Tracking in Robotic Welding and Bonding. Industrial Robot: An International Journal. 29(2): 132-137. Yoong, H.P. 2000. The Design of Computer Interface Card and Computer Base Control System of a 3-axis Robotic Arm. School of Engineering and Information Technology. Kota Kinabalu: Universiti Malaysia Sabah. Zaluck, A. 1986. Beam Bending Compensation. USA: 4606691. Zhang, Y., Gruver, W.A. and Gao, F. 1999. Dynamic simplification of three degree of freedom manipulators with closed chains. Robotics and Autonomous Systems. 28:261-269.

Material depositing robot arm for arc welding: Structure & driving mechanism

Similar Items