Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

Finite Element Analysis and Design

Optimisation of Welding robot base using ANSYS
Dr. Fahad Alhajri1; Hadyan Ali Alajmi2
1
Specialist Trainer (A), the Public Authority for Applied Education and Training, Ain Shams University, Egypt
2
Specialist Trainer (B) in Public Authority for Applied Education and Training, the University of Arab Academy for Science,
Technology and Transport

Abstract:- The study on Finite Element Analysis and A welding robot may require minimal human
Design Optimization of a welding robot base using intervention, which means inaccuracies and variations in the
ANSYS explores the crucial role of welding robots in dimensions of the workpiece, thermal distortions and
enhancing industrial productivity and quality. It Imperfect edge problems might happen [2]. The base of the
addresses the challenges of structural integrity, welding robot is one of its most important parts, so it must be
operational efficiency, and durability under harsh designed to have a large capacity to withstand high
conditions. The research focuses on optimizing the robot production [1].
base design to withstand high production demands, using
ANSYS for detailed modelling and simulation. It reviews The welding robot consisted -in general – of three
previous studies highlighting the importance of sliders to position it in any direction, when the welding
vibrational characteristics and structural dynamics in process begins, these sliders remain constant. [4], all
robot design. The methodology involves creating a moveable pieces accelerate very slowly because of the
geometric model, defining material properties, meshing, extremely smooth alignment before welding. This means that
and applying boundary conditions and loading scenarios. the mechanism's design can employ static approaches to
The results indicate that the optimized design account for the smallest loading increment caused by
significantly improves stress distribution, reduces dynamic forces. The robot's common operating state—that is,
deformation, and enhances the dynamic response, making the slider positioning—does not result in increased dynamic
the robot base more robust and reliable. The study loading [4].
concludes with recommendations for broader
applications in robotic systems to improve safety and Therefore, the significance of this paper is
productivity in industrial settings. comprehensive and has multiple aspects in the field of
industrial automation. This study highlights the fundamental
Keywords:- Finite Element Analysis, Welding Robot, ANSYS challenge of improving the robustness of welding robots in
Software, Productivity and Quality, Structural Integrity, particular, and improving the effectiveness and reliability of
Operational Efficiency, Durability. robots.

I. INTRODUCTION Since welding robots have a vital and widespread role in

the operations of various industries [4]. This improvement is
A robot is a mechanical machine created by humans to crucial because these robots majorly contribute to the
perform programmed tasks to make life easier and speed up efficiency of production lines across different sectors. This
work completion. The importance of robots has emerged in research aims to make welding robots more resilient to faults
industry, as they have been utilized to increase production and and better overall performance. This is to ensure that the
quality. The robot is characterized by reliability because it is robots are able to carry out all their tasks with sufficient
a machine, meaning it is accurate and fast, so it is utilized in accuracy and reduce the possibility of breakdown, to make
welding [1]. A welding robot is one of the best solutions in these robots more powerful and reliable. This research
harsh environments where temperatures and fumes are very contributes significantly to the advancement of technology in
high, as manual welding is ineffective in these conditions. [2] industrial automation, enhancing overall productivity and
production quality in various industries.
The welding stage is carried out using the robot in two
ways: the first is the welding stage, and the second is the Addressing structural integrity and extending the life of
analysis stage. In the first, the robot must track and maintain the robot: Continuous operation of welding robots leads to
the direction of the tangent and the second requires an corrosion, which may cause failure or damage to one of the
operator to evaluate the piece [2]. Factories today are moving robot parts. This research aims to analyse some of these
to increase the number of welding robots in production lines failures of the robot rule. This includes determining the type
[2], and this requires continuous improvement and and loading conditions under which these failures occur. This
development of this robot, to reduce the problems and risks is crucial, with the aim of preventing downtime and extending
incurred due to its malfunction, the automobile and shipping the service life of these robots.
industries are examples of applications of welding robot.

IJISRT24SEP877 www.ijisrt.com 3424

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

Improve the design of the robot base: The welding robot Complementing Liao's work, Chung et al. [6] also
base plays an important role in its work. The robot's base is applied ANSYS-10.0 software, in designing and analysing
the essential load-bearing component. It therefore has a vital procedures of the heavy-duty industrial robots. The studied
role in the overall stability and function of the robot. This robots’ weight reaches several hundreds of kilograms. Their
study involves the design and analysis of new robotic parts research involved static and dynamic analysis for heavy-duty
using ANSYS, with a focus on improving their efficiency and applications. They also included several comparisons of
durability compared to older designs. This leads to an experimental and Finite Element Method (FEM) results.
increase in the lifespan of robots in general, and thus Researchers highlighted the significance of elastic rigid body
contributes to improving industrial profitability. dynamics to estimate the robustness of robot parts during
robots’ operational motion. Which is a critical aspect in the
Use of advanced simulation and analysis tools: The design of industrial robots. The results of their research
research takes advantage of the capabilities of the ANSYS determined the frequency of the interaction forces, which
finite element analysis (FEA) program. This allows detailed reached 6.67 Hz, and the natural frequency was equal to 18
and accurate modelling and simulation of the robot base, Hz.
providing insights into stress distribution, deformation,
natural frequencies and more complex and necessary details. In 2015, Varma et al. [7] made a significant contribution
This analysis is necessary to validate the design and ensure it to this field by designing a welding robot gun and conducting
meets the required performance standards. an analysis using ANSYS benchmark version 15.0. Their
research was centred on creating a support structure for the
Effective contribution to the field of robotic design: The welding robot gun, specifically intended for use in light
results of this research have broad implications for the design vehicle door frames. The researchers paid special attention to
of robotic systems in many industrial applications. By the functionality of the welding subsystem, given its
optimizing the size and enhancing the dynamic and static extensive range of applications. They engineered the welding
performance of the welding robot base, the research provides subsystem to include a support structure that could facilitate
valuable insights and methodologies that can be applied to rapid and robust movements, a crucial attribute for operating
other. effectively in the dynamic welding environments. The study
discussed earlier, which involved modelling the robot's base
The key goal of this research is to enhance structural and assessing its vibration behaviour, further underscores the
integrity, improve operational efficiency and extend the importance of reliable design and analysis tools such as
operational life of welding robot bases. This will be done by ANSYS. This modelling approach presented in the previous
applying FEA and using design optimization techniques study can be potentially adapted for the design of support
using ANSYS software. This study seeks to address the structures like the one considered by Varma et al. for their
challenges resulting from continuous operation of welding welding robot gun, ensuring robust and efficient performance
robots, in addition to dynamic loading conditions. Therefore, in various applications.
developing a robot base will make it more robust, and
perfectly designed to withstand the various pressures and In their 2021 study, Niresh et al. [8] aimed to ensure the
loads that robots face during their operation. effective mounting of robots under numerous loading
conditions. Authers highlight the importance of avoiding
II. LITERATURE REVIEW overdesign and under-design of the robot's base frame. The
proper design avoid several issues like robot’s vibrations,
In this literature review section on the topic of FEA and failures, and decreased robot manufacturing costs. Niresh et
optimization of welding robot base design using ANSYS. al. employed ANSYS software to create a three-dimensional
Current research will be critically studied and examined, and model of the robot platform. They applied relevant boundary
the latest developments in this field will be analysed. This for conditions. They also analysed von-Mises stress and
establishing a scientific basis for the current study. This deformation of robot’s bridge riser. They compared these
section delves into various studies that have contributed results with the initial design, to determine new design safety
significantly to our understanding of structural dynamics and aspect. The study optimized the base design in structural
optimization of welding robot rules. aspect. They created a CAD model that was validated using
ANSYS. Ultimately researchers showed the superiority of
In 2010, Liao [5] provide an exploration in welding their new optimized design. This research offers valuable
robots optimisation field. Liao focused on investigation the insights for optimizing robot mounting base designs using
natural frequencies and mode shapes of the welding robot FEA and design optimization.
base. He utilised ANSYS benchmark version 10.0. In his
paper Liao investigated the dynamic analysis of the welding Yadav et al. [1] conducted a related study focused on
robot and its base in particular. This paper’s findings revealed analysing robot bases. Robot bases are basic support
that the upper and tail edges of the base are prone to larger structures. They provide stability to industrial robots. In this
vibrations, which is leading to potential fatigue and damage, research, Yadav et al. employed ANSYS 15.0 software, in
with a notable maximum amplitude observed at the 7th aim to perform a FEA of the robot's base. As a primary step,
natural frequency (39.249 Hz). This study underscores the researchers created a pre-defined 3D model of the base. Then,
importance of considering vibrational characteristics in the they employed pre-defined boundary conditions (as robot's
design of robot bases to prevent structural fatigue. weight and the applied forces). The analysis included

IJISRT24SEP877 www.ijisrt.com 3425

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

evaluation of stresses, total deformation, and natural

frequency. Model analysis revealed that the natural frequency
of the pedestal ranged from 69.536 Hz to 446.36 Hz. This
research demonstrated the effectiveness of the ANSYS
program in predicting the vibration behaviour of robot bases.
This confirm ANSYS software reliability as analysis tool.
The modelling approach presented in this study holds promise
for improving substrate designs in practical applications.

These previous works collectively highlight the

evolving nature of FEA and design optimization in the realm
of robotic welding systems. By understanding and addressing
the challenges posed by structural dynamics and loading
conditions, these studies have significantly contributed to the
development of more robust, efficient, and reliable welding
robots. This literature review serves as a platform to Fig 1: The Geometry of the Welding Robot for the Original
understand the depth and scope of research in this field, Base Structure
setting the stage for the current study's contribution to the
ongoing development of welding robot technology. B. Specification of Material Properties
Constructed from Q235 steel, the base structure's
Poruba et al.'s study [4] focuses on the force analysis and material is designated for its favourable mechanical
optimization of emergency stop mechanisms in welding properties suitable for rigorous operational demands. The
robots, which is extremely crucial for safety and performance. material properties defined for the analysis contain an elastic
Dynamic simulations were employed to track stress modulus (E) of 2.1 MPa, which dictates the stiffness of the
trajectories. Researchers identified peak stress values caused material under stress. Furthermore, a Poisson's ratio (μ) of 0.3
by dynamic loading. The study led to design improvements is applied, reflecting the material’s ability to resist
by reinforcing the lower horizontal rail with more stiffening deformation in directions perpendicular to the applied force.
plates. This is significantly reducing maximum stress levels The density is set at 7,900 kg/m^3, offering the gravitational
in the construction. However, it's essential to note that under forces calculations within the model.
dynamic loading, stress levels were found to be about 30%
higher than those under static loading. This highlighted the C. Meshing of the Model
need to consider dynamic loading's impact on structural For the FEA, the model was discretized utilising
design. These requirements as the exceeding of material's tetrahedral elements with each element measuring 15 mm.
yield point, which could result in plastic deformation or The generated mesh included a total of 69,472 elements
cracks. This study underscored the importance of optimizing besides 120,816 nodes. This setup achieved a mesh skewness
emergency stop mechanisms. It is also highlighted the value of 0.4, demonstrating a high-quality mesh with
importance of taking account for dynamic loading in elements well-suited for precise simulation results. The
structural design for welding robots. meshing process and its high fidelity are represented in Figure
2:
III. METHODOLOGY

A. Development of Geometric Model for the Original Basic

Structure
The base structure of the welding robot is designed with
a cylindrical shape. To precisely model this structure,
SOLIDWORKS, a 3D modelling software, was employed.
The detailed geometric model created serves as the
foundation for subsequent analyses and was efficiently
imported into ANSYS Workbench, a robust FEA software.
This importation besides initial setup are captured in Figure
1, showcasing the model ready for further analysis.

Fig 2: Modelling of Mesh of the Welding Robot for the

Original Base Structure

IJISRT24SEP877 www.ijisrt.com 3426

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

D. Application of Boundary Conditions and Loading Mounted atop this base is the robot’s main assembly,
Scenarios subjecting the base to a combination of static and dynamic
The base model incorporates twelve bolt holes on its loads. This contains the robot’s own weight and operational
base plate, which facilitate a secure bolted linking to the loads such as inertia generated during movement in addition
ground, ensuring stability during operation. Fixed constraints emergency manoeuvres. Specifically, vertical and horizontal
were applied to the internal cylindrical surfaces of the holes inertia moments and forces are critical during scenarios such
of the bolt on the bottom base plate, effectively eliminating as rotational emergency stops and forward tilting. The precise
all degrees of freedom associated with rotation and distributions of these loads are illustrated in Figures 3 and 4
translation. correspondingly:

Fig 3: (a) Under the Influence of the Inertia Vertical Moment, (b) Under the Influence of Vertical Force

Fig 4:(a) Under the Influence of the Inertia Horizontal Moment (b) Under the Influence of Horizontal Inertial Force

IV. RESULTS AND DISCUSSION characteristics, the base also needs to show robust dynamic
performance, typically characterized by favourable low-order
A. Finite Element Analysis (FEA) Results modal properties of the construction.
As the primary support structure for the body of robot,
the base must be capable of enduring several types of loads The von-Mises stress, the of shape 1st order mode, and
whereas maintaining stable performance. Initially, it is total deformation results for the basic base under several
essential that the base meets the necessary strength loading situations are depicted in Figure 5, Figure 6, Figure
requirements, meaning that the maximum stress experienced 7, and Figure 8. The figures reveal that the highest total
should not exceed the material's allowable stress. deformations and total equivalent stress occur under sheer
Additionally, the base should fulfil the static stiffness criteria inertia moments during scenarios such as forward tilting of
by diminishing overall deformation. Beyond these static the robot body besides emergency stopping. The peak von-

IJISRT24SEP877 www.ijisrt.com 3427

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

Mises stress reaches 105 MPa at a hole of the bolt on the The stress distribution across the robot base differs
bottom plate, whereas the maximum value of deformation is significantly depending on the type of loading condition.
measured at 0.0368 mm at a critical load-bearing area on the Under vertical moments of inertia and forces, the stress is
higher surface. Additionally, the frequency of the base 1st cantered and diminishes outward, representing central
order modal is determined to be 703.95 Hz. With the material concentration. Horizontally, stress is distributed more
yield strength of Q235 steel being 235 MPa in addition the towards the periphery, particularly under moments of inertia,
value of safety factor is 1.2, the FEA displays that the highlighting the base's response to twisting and bending
maximum value of stress that’s experienced by the base is forces.
below the acceptable limit of 195 MPa, thus fulfilling the
required strength criteria.

Fig 5: Complete Von-Mises Stress Distribution Across the Base Subjected to Various Operational Settings,
(a) Subjected to Inertia Vertical Moment (b) Subjected to Vertical Force.

Deformation patterns on the robot base also reflect the horizontal loading spreads deformation towards the edges,
nature of applied loads. Vertical loading conditions result in suggesting the base undergoes flexing and potentially faces
more centralized deformation, mainly under moments, higher stress at these points under rotational dynamics.
suggesting significant bending at the centre. In contrast,

Fig 6: Complete Total Deformation Cloud Diagram of the Base Structure Subjected to Various Operational Settings
(a) Subjected to Vertical Moment of Inertia (b) Subjected to Vertical Force

IJISRT24SEP877 www.ijisrt.com 3428

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

Fig 7: Complete Total Deformation Cloud Diagram of the Base Structure Subjected to Various Operational Settings
(c) Subjected to Horizontal Moment of Inertia (d) Subjected to Horizontal Inertial Force

B. Optimization of the Robot Base Dimensions C. Finite Element Analysis (FEA) Results for the Revised
From the FEA discussed in figures above, the base Base Framework
generally sustains minimal stress across most conditions, with The studied base component underwent the same finite-
significant exceptions under sheer inertia moment loads element procedures, yielding deformation and stress analyses
where stress concentrates around the holes of the bolt of the presented in Figures 9 and 10. The modifications have
bottom plate. To enhance the welding workshop layout, slightly reduced stress and deformation levels; the maximum
facilitate the addition of more robots, as well as boost the stress dropped to 102.36 MPa, and the maximum deformation
automation rate, it's feasible to optimize the original structural decreased to 0.0302 mm. Notably, the 1st order natural-
dimensions. This contains reducing the thickness and external frequency became 1348.4 Hz, suggesting enhanced structural
diameter of the cylinder sidewall and the plate of the bottom dynamics. These changes also adjust the robot base's bolt
base plate, specifically downsizing the bottom plate diameter connection locations, further influencing the overall
to 1,180mm, based on stress distribution and structural structural efficacy under several operational conditions. The
characteristics. analysis of performance, both static and dynamic, ahead of
and after optimization is detailed in below points,
demonstrating the significant improvements achieved
through this optimization process.

Fig 8: Comprehensive Diagram of Base’s Von-Mises Stress Cloud Subjected to Vertical-Inertia Moment
(a) Basic Configuration (b) Revised Configuration

IJISRT24SEP877 www.ijisrt.com 3429

Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP877

Fig 9: Deformation Cloud-Diagram of the Base Subjected to Vertical Inertial Moment Stress
(a) Initial Design (b) Improved Design

The following points present a comparison of the REFERENCES

dimensions and both static and dynamic performance metrics
for the base component before besides afterward optimization [1]. G. Yadav, A. Pirjade, M. Jadhav and V. Patil, “Design
process: analysis and optimization of robot pedesta,”
International Journal of Engineering and Technical
 The size of Bottom Plate: Initially, the bottom plate size Research (IJETR), 2016.
was 1650 mm, which was reduced to 1180 mm in the [2]. P. Kah, M. Shrestha, E. Hiltunen and J. Martikainen,
optimized design. “Robotic arc welding sensors and programming in
 Cylinder Wall Size: The cylinder wall size was reduced industrial applications.,” International Journal of
from 1200 mm to 1012 mm as part of the optimization. Mechanical and Materials Engineering, vol. 10, no. 1,
 Distance from Base Plate Bolt to Centre: This pp. 1-16, 2015.
measurement was reduced from 720 mm in the original [3]. X. Li and J. Liang, “Optimization design and finite
plan to 560 mm in the optimized configuration. element analysis of welding robot base based on
 Maximum von-Mises Stress: The stress decreased slightly ANSYS Workbench,” In Journal of Physics:
from 105 MPa in the original design to 102.36 MPa after Conference Series, vol. 2383, no. 1, p. 012073, 2022.
optimization. [4]. Z. Poruba, J. Podešva, O. František, M. Fusek, R.
 Maximum Total Deformation: There was a reduction in Brázda and M. Sadílek, “Strength analysis and
deformation from 0.0368 mm initially to 0.0302 mm post- optimization of welding robot mechanism in
optimization. emergency stop state,” Perspectives in Science, vol. 7,
 First Order Frequency: This frequency increased pp. 347-352, 2016.
significantly, from 703.95 Hz in the original design to [5]. X. Liao, C. Gong, Y. Lin and W. Wang, “The finite
1348.4 Hz in the optimized plan, indicating improved element modal analysis of the base of welding robot,”
dynamic response characteristics. In 2010 3rd International Conference on Advanced
Computer Theory and Engineering (ICACTE), vol. 2,
V. CONCLUSION pp. 2-123, 2010.
[6]. G. Chung, D. Kim, H. Shin and H. Ko, “Structural
In conclusion, the comprehensive study on the FEA and analysis of 600Kgf heavy duty handling robot,” IEEE,
Design Optimization of a welding robot base utilising pp. 40-45, 2010.
ANSYS has successfully demonstrated how structural [7]. H. Varma and S. G., “Analysis and Optimization of
integrity, operational efficiency, and lifespan of welding Robot Gun Support Structure for Welding of Light
robots can be significantly enhanced. By meticulously Weight Vehicle Door Frame,” ISSN (Print), vol. 3, no.
refining the base structure's dimensions and employing 6, pp. 2321-5747, 2015.
advanced simulation tools, the study not only enhanced the [8]. J. Niresh, M. Subramanian and S. Neelakrishnan,
robot's static and dynamic performance but also contributed “Finite Element Analysis of Bridge Riser for
to a more robust design capable of withstanding rigorous Automobile Application Robots,” in In Proceedings of
industrial demands. This research offers valuable insights that the First International Conference on Combinatorial
could be applied broadly across robotic applications, ensuring and Optimization, ICCAP 2021, Chennai, India, 2021.
that robots continue to perform efficiently and reliably in [9]. P. D. and W. W., “Optimal design of robot base in
demanding environments, thus bolstering safety and welding workshop based on finite element analysis,”
productivity in industrial settings. J. China Water Transpo pp. 117-118, 2019.

IJISRT24SEP877 www.ijisrt.com 3430