Thesis Project
Thesis Project
INTRODUCTION
In today's business industry, industrial automation is a critical factor in the growth and success of
many companies. Automation involves using technology to replace human labor with machines,
not only for performing physical tasks but also for decision-making. One of the significant
benefits of automation is that robots can operate with greater efficiency than humans, resulting in
higher productivity and precision. Robotic manipulators, also known as robotic arms, are the
machines that replace human arms. They are composed of a set of rigid bodies connected by
mechanical joints that form a kinematic chain, allowing for a certain degree of articulation.
There are many possible configurations for the kinematic chain, each representing a different
type of manipulator, including cartesian, cylindrical, spherical, SCARA, and anthropomorphic.
The manipulator is equipped with a mechanical wrist that allows for the attachment of terminal
devices, which are used to manipulate objects or perform operations on workpieces. Terminal
devices can be divided into two categories: robotics tools and robotic grippers.
Robotics tools are designed for specific functions such as soldering, spray painting, milling, and
drilling, while robotic grippers are used to grasp objects and allow movement, processing, or
assembly operations. There are four types of robotic grippers: electrical/servo, pneumatic,
suction cups, and magnetic, each with their own advantages and disadvantages regarding cost
and efficiency.
1.1 Background
Robotic arms are machines that are programmed to execute a specific task or job quickly,
efficiently, and extremely accurately. Generally, motor-driven, they’re most often used for the
rapid, consistent performance of heavy and/or highly repetitive procedures over extended periods
of time, and are especially valued in the industrial production, manufacturing, machining and
assembly sectors.
A typical industrial robot arm includes a series of joints, articulations and manipulators that work
together to closely resemble the motion and functionality of a human arm (at least from a purely
mechanical perspective). A programmable robotic arm can be a complete machine in and of
itself, or it can function as an individual robot part of a larger and more complex piece of
equipment.
A great many smaller robotic arms used in countless industries and workplace applications today
are benchtop-mounted and controlled electronically. Larger versions might be floor-mounted, but
either way they tend to be constructed from sturdy and durable metal (often steel or cast iron),
and most will feature between 4-6 articulating joints. Again, from a mechanical perspective, the
key joints on a robotic arm are designed to closely resemble the main parts of its human
equivalent - including the shoulder, elbow, forearm and wrist.
1.2 Problem statement (motivation)
The reason for selecting this project was twofold: firstly, during our intern program, one of us
applied to AMHARA METAL WORKS INDUSTRY and observed that the company faces
difficulties in component assembly and disassembly for maintenance and services due to reasons
such as inadequate availability of components, lack of skilled workers, and outdated
technological equipment. The project focuses on the staking process of the transformer core,
which is currently done manually using simple equipment like a flat head screwdriver. This
process is time-consuming and requires at least two technicians. Automated or semi-automated
robotic machines could perform this task, but they are not used due to their cost and availability.
The use of manual labor in this process is costly and time-consuming, and it is repeated for each
transformer that comes in for maintenance. The objective of this project is to reduce that time
and manpower required at least by half for this process. Secondly, to create a system that is
highly flexible, accurate, and efficient, while also being easy to program and operate. This
involves balancing trade-offs between factors such as speed, precision, payload capacity, and
cost, as well as addressing issues such as safety and reliability.
Moreover, it has practical applications in the current industry and it provides valuable experience
for a novice engineer. This project necessitated expertise in design, mechanics, electronics, and
programming within the field. Ultimately, the goal is to create a robot that can perform a wide
range of tasks in a variety of industries, and help to improve productivity and efficiency in
manufacturing and other fields.
1.3 Objective
1.3.1 General objective
Design and develop a SCARA robotic arm that perform precise and repeatable movement.
Fig
SCARA robots, which were first used on industrial assembly lines in 1981, continue to provide
the finest value for money when it comes to high-speed assembly. The SCARA robot-based
Japanese flexible assembly technology sparked a global boom in the production of small
electronics, resulting in goods that fueled the economy and altered the course of history.
1 0 0 D1 q1
2 0 A1 0 q2
3 0 A2 0 0
4 0 0 0 0
DH TABLE
Let
• A1 = 240mm
• A2 = 153mm
• D1 = 400mm
• q1 = 450
• q2 = 300
209.332^2 +317.35^2−240^2−153^2
q2 = cos-1 ( )
2∗240∗153
43,819.8+100,711.022−57,600−23,409
q2 = cos-1 ( )
2∗36,720
63521.822
q2 = cos-1( )
73440
q2 = cos-1(0.864)
q2 = 300
using q2 to find q1
317.35 153∗sin 30
q1 = tan-1 209.332 – tan-1
240+153∗𝑐𝑜𝑠30
76.5
q1 = tan-1 (1.516) - tan-1 372.501
q1 = 56.589- 11.605
q1 = 450
These parts have their own function in the function of the robot as well as the assembly process.
In this sub-topic we are going to discuss some of the major components like base of the robot, the
couplers, the Arduino uno, CNC shield, power supply and many more.
1. Base
One of the most crucial components of the robotic arm is its base. Because it serves as the
foundation for the robotic arm, it is affected by the weight of all the other components, as well as
the payload. The robotic arm base is equipped with a steeper motor that works with the rotating
shaft.
Manipulator's construction materials. The objective was to use a material that was affordable and
accessible but also light, strong, and long-lasting enough to satisfy the project's needs for the
linkages of the manipulator prototype. The prototype might have been made from a variety of
materials, including steel, aluminum, polylactic acid (PLA), and Acrylonitrile Butadiene Styrene
(ABS). Then ABS "Table 1" was chosen because it was more durable and heat resistant than PLA.
In comparison to aluminum and steel, manufacturing was also simpler, making it a good material
for the manipulator. ABS has the disadvantage of being less rigid than other materials, which is a
disadvantage.
Table 1. Materials Properties of Acrylonitrile Butadiene Styrene
property Value
Density 1040 kg/m3
Tensile 41.4 MPa
Elongation 0.15-100%
2. Couplers
The couplers used in this robotic arm system are used to facilitate the joining of links and
joining the base with the z-axis component of the robotic arm.
3. Robotic links
▪ Arm 1
▪ Arm 2
▪ Arm 1 cover
▪ Arm 2 cover
They use the same type of material as the base of robotic arm which is Acrylonitrile
Butadiene Styrene(ABS).
4. Bearing:
A bearing is a component of a machine that limits relative motion to only that motion that
is intended and lessens friction between moving elements. The bearing's design may, for
instance, permit free rotation around a fixed axis or free linear movement of the moving
part. It may also serve to prohibit motion by managing the vectors of normal forces acting
on the moving parts.
▪ Ball bearing
• Thrust ball bearing: SKF thrust ball bearings are manufactured as single direction
or double direction thrust ball bearings. They are designed to accommodate axial
loads only and must not be subjected to any radial load.
• Radial ball bearing: In order to reduce friction, radial ball bearings transport loads
radially around their axis. They are a subclass of ball bearings that work by
sandwiching two grooved rings with lubricated steel balls. Conrad bearings or
deep-groove bearings are common names for them.
▪ M4 * 60mm bolt
▪ M4 * 50mm bolt
▪ M8 washer
▪ M8 locknut
▪ M4 lock nut
6. Plastic tube
A plastic tube is a hollow, cylindrical cylinder composed of plastic. It is frequently utilized for a
variety of purposes, such as fluid transmission, transportation, and packaging. Depending on the
particular need, plastic tubes are available in a variety of diameters, forms, and materials.
7. Belt and pulley
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most
often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track
relative movement.
A gear wheel is a toothed wheel that connects to another toothed mechanism to modify the
transmission of motion's speed or direction.
They are utilized for the transmission of force, changing of torque (turning force), direction, and
speed.
8. Smooth rod
A smooth rod is a metal rod usually used on the axis for components such as the X-carriage
or print bed of a RepRap to slide on. The most commonly used diameter is 8 mm, but 10
mm and 12 mm are seen in more rigid designs as well.
9. Threaded rod
A threaded rod, commonly referred to as a stud, is a long rod that has threaded ends and may even
have thread running the entire length of the rod. They are made to be used under pressure.
Threaded rod is frequently used to make a link between two materials, such as concrete and another
object or two objects made of metal or wood.
3.3 Electrical Systems (control system)
3.3.1 Microcontroller
A microcontroller is a computer. All computers share a number of characteristics, whether we're
talking about a small microcontroller, a massive mainframe computer, or a personal desktop
computer:
• Programmes are executed by the central processor unit (CPU) in every computer. If you
are viewing this article while sat at a desktop computer, a programme that implements the
Web browser that is displaying this page is presently executing on that device's CPU.
• The programme is loaded by the CPU from somewhere. The browser programme is loaded
from the hard drive on your desktop computer.
• The computer contains input and output devices so it can communicate with people, as well
as RAM (random-access memory) where it can store "variables."
• The monitor and printer are output devices on a desktop computer, whereas the keyboard
and mouse are input devices. An I/O device, such as a hard drive, manages both input and
output.
You are currently using a desktop computer, which is a "general purpose computer" that can
execute any of countless programmes. It is true that microcontrollers are "special purpose
computers." Microcontrollers excel at just one thing. Microcontrollers are characterised by a
variety of additional traits. A computer can be referred to as a "microcontroller" if it possesses
the majority of these features:
• In order to control the functions or actions of another device (often a consumer good),
microcontrollers are "embedded" into that device. Consequently, "embedded controller" is
another name for a microcontroller.
• Microcontrollers only perform one function and execute a single programme. The
programme is typically not changed and is kept in read-only memory (ROM).
• Microcontrollers are frequently low-power electronics. A desktop computer may use up to
50 watts of electricity and is often hooked into a wall socket. 50 milliwatts may be used by
a microcontroller that runs on batteries.
• •A microcontroller has an exclusive input device and typically, though not always, contains
a tiny LED or LCD display for output. A microcontroller not only sends signals to various
parts of the device it is managing, but also receives input from the device it is controlling.
As an illustration, the microcontroller in a television receives input from the remote control
and outputs it on the screen. The controller regulates the sound system, the channel selector,
and a few picture tube electrical settings like tint and brightness. A car's engine controller
receives data from sensors like oxygen and knock sensors and uses that data to regulate
factors like fuel mix and spark plug timing. A microwave oven controller operates a relay
that turns the microwave generator on and off while accepting input from a keypad and
displaying output on an LCD display.
• A microcontroller is often small and low cost. The components are chosen to minimize size
and to be as inexpensive as possible.