Assign2 Workshop

8/2/2019 Assign2 Workshop

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1.0. IntroductionThe need for speed, accuracy and better payload in the packaging industry is enormous, as

industries are shifting to fully automated manufacturing so as to save cost and have better

production effectiveness. The use of robots has greatly enhanced the performance of

manufacturing industries. For some application, a high acceleration, better inertia and payload

are required; as such the serial manipulator may not be suitable. The parallel manipulator is the

solution to such problems.

Manipulators has ordinary been design as serial kinematic chains (Parasurama, S.Liang, and

P.C.J 2010) with simple analysis and wider workspace. It has been desirable to have

manipulators with better payload, low inertia, high stiffness and large acceleration. Parallel

Kinematics Manipulators are attributed with such capabilities.( Andreas Muller 2008). Parallel

Manipulators has its setbacks such as: smaller workspace as well as many singularities within the

workspace. The application of robotics to the, manufacturing industry is what has spur the

rapidly increasing study on robotics. In this project, I intend to design a parallel manipulator that

will be use in the packaging industry. The manipulator is to pick the product to be package and

place it on a wrapper. In real application, the wrapper is on a fast moving conveyor belt, the

manipulator picks and places the product on the wrapper.

2.0. ObjectiveGenerally, the main objective of this project is to Design and Fabricate a 3 DOF parallel

Manipulator structure for packaging industry. Upon the completion of this project, one must be

able to understand how this system works in the real world (that is how to apply the robotics

manipulator to a packaging industry).

In this project, I will be working to design and fabricate the structure of a parallel manipulator.This entails:

Kinematics analysis of the structure of the parallel Kinematic manipulator (PKM): for a

coherent design of the parallel manipulator, a thorough kinematics analysis will be

carried out. This involves both analytical and numerical analysis.



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Modeling of the parallel kinematic structure: For any engineering design, there are

governing principles that guides it. In this modeling phase of the project, we seek to

model the relationship between factors and parameters that affect the design of the PKM.

Parameters here include size, shapes of components, torque, acceleration and orientation

of the links and moving platform. The workspace modeling and the Jacobian of the PKM.

Factors includes cost, weight of components, availability of materials, suitable actuation

method, availability of software, time constraint, machining skills and proficiency level

of the use of tools that will be use in the project such as solidworks, matlab and robotic

simulator, etc.

Fabrication of the parallel Kinematics structure: This involves Fabrication of the

individual components and joining or assembly of the components.

2.1. Sub Objectives1. Cad modeling of the parallel Manipulator (using Solidworks): this part concentrates

mainly on cad modeling of the parallel manipulator.

2. Static structural analysis of the parallel Manipulator; this involves some static stress

structural analysis of some of the major components. Where necessary, fatigue stress

analysis will be carried out.

3. Control and Programming of the parallel Manipulator: this involves design of the control

system for the project. Tools like Matlab and other control base software suitable for theapplication will be use.



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3.0. Methodology [20 marks]

PROJECT

METHODOLOGY-Identification of the physical system and components of the manipulator.And Jacobians for the 3 Dof parallel manipulator. Suitable microcontrollerand actuation.

RESEARCH

The Equipments/instruments required for the experiment include:spanners, screw drivers, gauge, lathe machine, soldering iron, weighingbalance, measurin ta e, eneral machinin tools, weldin machine

Data to be collected: material properties, packaging information, datasheet of motors, weight of links, speed /rating of motors, acceleration,

Velocity of the manipulator, orientation .

Experiments:

Test to measure speed of the manipulatorTest to determine orientation of the manipulator

EXPERIMENTAND DATACOLLECTION

Modelingand

NumericalSolution

CAD DESIGN: Solidworks is use to model the structure

KINEMATICS ANALYSIS: SolidWorks motion Simulation is use toanalyze the kinematics of the cad model.

Robotics Simulation: Simulation using Robot studio/ any other

AnalyticalSolutions

Fabrication

Mathematical modeling of the 3 DOFParallel manipulator

Machining Processes: Cutting, milling, punching, drilling etc

Joining Processes: Welding, screw, joint design etc

Control System Design

Final Testing

Control system design using PD, PI or PID. Microcontroller Programming.PCB design of control system.

Testing For performance



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To actualize the objectives of the project stated above, the following methods and process will be

employed:

3.1. Data CollectionLiterature Data: data involving numerical numbers and standard such as how to develop

mathematical models for the 3 DOF PKM, methods of solving the equations and obtain solution

of the kinematics structure, types of joint design, actuation and controlling methods and the likes

will be refer to from Robotics journals, books, and magazine.

3.2. Material DataWhen the mathematical models has been solve and the parameters use for the design such as

weight and size are to be considered, journals from the mineral metals and material society

(TMS) will be considered for reference materials and properties. For the purchase of the

material, shops in Pudu, and ChanChowlin will be considered.

3.3. MachinesThe machines that will be used for the fabrication are: lathe machine for cutting, welding

machines, filling machines and other machining operations machines. Many of which are in the

school’s mechanical workshop. Screws are to be design with standard size and will be purchase

from retailers. Measuring instruments such as tape, gauges are in the mechanical workshops and

will be used.

3.4. ExperimentationThe experiment that will be conducted will be to determine if the structure is a parallel

manipulator. The test for the number of degrees of freedom and a test for the speed.

3.4.1.Test for Parallel Manipulator : Parallel manipulator generally has specific characteristics

(distinctive features) which include: Parallelism, high payload capacity, high throughput

movement (acceleration), high mechanical rigidity, and low moving mass.



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3.4.2. Structural and Kinematics test

1. Test for Parallelism: the robot will be operated and the structure will be observed for the

parallelism criteria. For this test, the links must be parallel and connected to a single fixed

base and a moving platform.

2. Payload test: Objects of various weights will be picked by the manipulator, and the

weight ratio of the pick object will be measured.

3. High through put Movement (acceleration): The time taken for the manipulator to pick

and place and object will be measured and the distance covered, the speed and

acceleration will be measured or calculated.

3.4.3. Control test The robot will be operated and the desirable position as well as the time taken to reach this

position will be measured. The position error will be calculated. This will be use to compare with

the control simulation result.

3.5. DesignThe design for this robot is in four steps.

1. Cad Modeling: the robot will be model using solidworks mechanical automation

software. Each component will be modeled and an assembly of the entire system will be

produce and motion analysis will be carried out. Also structural analysis of some of the

components especially the base to determine if the actuator can be attached directly, if it

can bear the weight.

2. Mathematical Analytical model: the system will be model analytically; the workspace as

well as orientations, and forces will be determined.

3. Fabrication: In this design phase the components of the manipulator will be fabricated

and assembled together. Various machining operations will be carried out at this stage of

the design.



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4. Control system design: this involves the design of the controller to be use, such as PD, PI

and PID. The design of the circuit for the entire system. The programming of the

microcontroller. Though this project priority is the kinematics and static analysis of the

parallel manipulator. This control design is necessary for demonstration of the

capabilities and working principle of the system.

Generally in this design phase, the workspace must be know, the torque of various links and

platform. The method of actuation and the type of end effectors that will be utilize. The

material properties such as yield strength will be considered.

3.6. Data Analysis and InterpretationThe data use or collected at various stage will be analyze .The experimental data will be

compare to the simulation as well as the analytical results obtain. The workspace calculationand the simulated result will be compared. The torque required will be calculated. Graphs

will be plotted to illustrate or compare data. Result obtain will also be listed in table manner

for adequate understanding.

4.0. EXPECTED RESULT [5 marks]

This project is a fabrication project as such; the mechanical structure of the robot will be

built. It is expected that a parallel manipulator is fabricated. Parallel manipulator has two or

more links that connect a moving platform to a single base. (Ayssam Elkady, 2008). The

design of the parallel manipulator should fulfill this requirement links joining base and

moving platform).

Payload Capacity: The manipulator should be able to carry a reasonably load to its

structure. More on this will be determine after the first meeting with my supervisor

when the project commences.

The robot achieved the desirable trajectory with a position error less than 20 × 10 − 3

m after 5 seconds. This is a test for the positioning accuracy of the robot as well as

the programming and the acceleration. Since this robot will be use for the packaging

industry, it is necessary that this positional accuracy is achieved.



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Cad Model: there should be proof of the cad model of the system. 2D draft as well as

3D models of each individual components and there assembly. The Cad models will

be printed and use for both the poster presentation as well as the final report.

5.0. Project Cost [5 marks]

Economists, engineering managers, project managers, and indeed any person involved in

decision making must be able to analyze the financial outcome of his or her decision. The

decision is based on analyzing and evaluating the activities involved in producing the outcome of

the project. These activities have either a cost or a benefit. Financial analysis gives us the tools to

perform this evaluation. Often the decision to make is to proceed or not to proceed with a

project. In cases involving investment, we want to know if the project is economically viable in

order to proceed. In effect, we compare the net benefit of proceeding with the project against the

consequences (good or bad) of not proceeding (the null alternative). Sometimes we are

confronted with two or more courses of action (alternatives); in this situation, we want to know

which alternative produces the greatest net benefit. To be able to make the go/no go decision or

to compare different projects, systems, or courses of action, we have to find a common measureto reflect all the costs and benefits and their time of occurrence. Financial analysis methods will

give us this capability (Abol Ardalan, 2000).

The cost estimate below is an overview of the cost of this project and is presented in table 2

below.

Table2: Cost Estimate

S/No QUANTITY DESCRIPTION UNIT COST

(RM)

DISCOUNT TOTAL

(RM)

1 1 Material for base 225 - 225

2 4 AL bars for links 100 - 400

3 1 AL sheet, moving part 100 - 100

4 24 nuts 1.5 - 36



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5 24 screws 1.5 - 36

6 24 washer 0.5 - 12

7 4 Cutting operation 10 - 40

8 2 Microcontroller IC 150 - 300

9 4 Servo motors 200 - 800

10 1 Soldering Iron 25 - 25

11 1 toolbox 45 - 45

12 30 Tool hiring 5 10% 135

13 4 Welding 15 5% 57

14 6 transportation 45 - 270

15 2 Software hiring 200 - 400

16 3 Paint 20 - 60

17 1 Spray gun 150 - 150

18 1 Miscellaneous 500 - 500

Total 3,591

The estimate above does not include some of the labor cost, such as the machining, the handling,

the assembly etc. Those operations will be carried out by the student (Nangi Ebughni.). However

I have included a miscellaneous of Rm 500. This is to cover any unforeseen rise of materialprices. Also the project will commence next year, meaning there might be increase in tax or cost

of labor or fixed cost like rent and these might leads to rise in prices, to avoid the effects of those

increases, I have included the miscellaneous. The total cost for this project is worth Rm 3591

which is approximately Rm 3600.



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6.0. Project Planning. [10marks]

The entire project has been broken down into finitely individual tasks so as to be able to estimate

the time and resources needed for this project. First, the work breakdown structure. Then the

table showing the list of task and then project management tools like gannt chart and network

diagram has been use for adequate planning.

6.1. Work Breakdown Structure for my Project

Fig.2. WBS for the project. (James P. Lewis, 2007) Check appendix 1 for a compete draft of the

WBS.

6.2. Project Work Plan.The list of table 3 bellow has been use to prepare the gannt chart and the network diagram.

Table 3. Project Work plan (Work break down Table)

S/No Task Assigned letter Predecessor Duration (days)

1 Research A - 15

2 1 st Progress Presentation B A 1

3 Workspace Calc. Data Sum. C A,B 5

4 2 nd Progress presentation D B 1

5 Cad Modeling E A 4

6 Kinematics Simulation F E 4

7 Robot Simulation G A,C 7

8 Analytical Solutions H A,F,G 15

9 3 rd Progress Presentation I H 1

FABRICATION OF3 DOF PKM

Research Design of System

Fabricate Modeling &Simulation

ControlDesign



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10 Conceptual design J D 2

11 Purchase of Materials K J 10

12 Fabrication of Components L J,K 19

13 Assembly M L 5

14 4 th Progress Presentation N L 1

15 Control System Design O G,H 5

16 Implementation of control system P O 18

17 5 th Progress Presentation Q P 1

18 1 st Testing R M,P 1

19 2 nd Testing S R 1

20 Redesign, Ergonomics etc T R,S 4

21 6 th Progress Presentation U T 1

22 Aesthetics & Finishing V R,S 6

23 Experimentation & Testing W V 5

24 Result Analysis: Interpretation X H,M,P,S W 8

25 Poster Design, Viva, PPP Y X 5

26 Report Compilation, Thesis Z T,U,V,W,X,Y 12

The figure below shows the gannt chart the complete chart is attached on the appendix.



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Figure 6. The gannt Chart (detail copy is on the appendix)



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Fig. 6.1 Network diagram (A more clear copy is attached on the appendix).



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7.0 Conclusion.This proposal presents the work schedule, the resources as well as the result that will be achieved

upon the completion of this project. The fabrication of the PKM, its control and the analytical as

well as numerical solutions are the methods that will be use for the actualization of this project.

Tools like matlab, Robot studio and solid works will be use. Tools like matlab, solidworks

cosmos simulation and other Robotics kinematics Simulator will be use for this project.

I am sincerely grateful to my supervisor for the guidelines throughout this project proposal. I beg

you indulgence sir to help reach out to the technicians and permit me to use the mechanical

works of Legenda educational group so as to complete this assignment within the stipulated

resources on my cost estimates.



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8.0. References. Abol Ardalam., 2000. Economics & Financial Analysis for Engineers & Project

Managemnt.

Anatoly Pashkevich, D. Chablat, P.Wenger, R. Gomolisky, 2009. Parallel Manipulator,

New development.I-tech Publisher, Austria.

Andreas Muller, 2008. Redundant Actuation of parallel manipulator. I-tech towards new

application, Book pp506, Vienna Austria.

Ayssam Elkedy, Galal Elkobrosy, Sarwat hanna, Tarek Sobh, 2008. Cartesian Parallel

Manipulator modeling and Control. Parallel Manipulator towards new applications,

ISBN 978-3-902613-40. Pp506. I-Tech Education and Publising Vienna, Astria.

Charman Lal Sabharwal. January, 2009. Introduction to Robotics Lecture series. .

Daniel Glozman, Moshe Shoham, 2009. Robotica pg1-5. Cambridge University Press.

Cambridge England.

Houssem Abdellatif, Bodo heiman, Jens Kotlarski, 2008 Institute Robotics Hannover

Centre of Mechatronics. Leibniz University. I-Tech. Croatia.

Jagdish M. Prasapati, Feb., 2011 Synthesis of parallel mechanism based robot

manipulator from structural point of view. International Journal of Engineering Science

and Technology (IJEST). Vol.3. No.2. pg 1227-1232. Jan Baksa, Anton Dekret, 2010. Asymptotic Motion of three Parametric Robot

Manipulator. Acta Universitatis Matthiae Belli Ser. Mathematics, pg 3-19.

J.P Merlet, D. Dany, 2004. Appropraite Design of Parallel Manipulator. INRIA Sophia-

Antipolis. France.

K. Chen, J.S. Wong & J.C.1999. Ho, A heuristic algorithm to minimize tardiness for

parallel machines Proceedings of ISMM\International Conference. ISSM-ACTA Press,

Anaheim CA, USA pp. 118-121.

Larry Ross, S.Fardo, J.Masterson,R.Tower,2011. Robotics Theory and industrial

application. 2 nd edition. Goodheart Wilcox Publisher.

Masahiro Takaiwa, Toshiro Norifsugu,2008 Positional Control of Pneumatic Parallel

Manipulator. International Journal of Automation Technology. Vol.2. No.1.



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Richard Eugene Stamper. 3-DOF parallel Manipulator with only translational degrees of

freedom. Institute for system research. University of Maryland. Maryland.

Saeed B.Niku, PhD, 2001. Introduction to Robotics Analysis, Systems and applications.

San Luis Obispo, California. Parentic Hill.

Stefan Uhlar, Peter Betsch, 2008. Conserving Integrators for Parallel Manipulators. I-

tech publishing,. Austria.

Tarik Cakar, 2008. Parallel Robot Scheduling with Genetic Algorithms. I-tech

Publishing. Austria.

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