Phase 1 of Articulated Arm 6-Axis Robot

Cory NannMechanical

Kris MagriMechatronic

Cole ChristensenMechatronic

Michael TominMechanical

Joshua DugoMechatronic

Faculty Advisor: Ramesh Varahamurti

Project Sponsor: Micro-Vu

Project Team Members

Project Background

The Problem:

• Loading/unloading Micro-Vu's vision measuring machines is labor-intensive and

time-consuming

• Small fraction of products can be checked for quality

The Purpose:

• Design, build, and test a prototype articulated arm 6-axis robot.

• Can provide 100% quality checking when used in conjunction with a Micro-Vu vision

measuring machine

Maximum Payload 9 kg

Nominal Payload 5 kg

Cycle Time < 10 s

Horizontal Reach 700 mm

Repeatability ±500 µm

Deflection < 50 µm

Power Source 120 VAC

Must be Aesthetically Pleasing

Specifications

“Must Do”

Cycloidal and

Planetary Gearboxes

Brushless Servo Motors

6061-T6 Aluminum Body

Electrical/ Pneumatic

EOT Interface

Robotic Arm Design and Fabrication

• Designed In Solidworks

• Machined from 6061-T6 Aluminum

• Complex Geometry Performed on

5 Axis CNC by Micro-Vu (Thanks!)

Cycloidal and

Planetary Gearboxes

Brushless Servo Motors

6061-T6 Aluminum Body

Electrical/ Pneumatic

EOT Interface

Gearbox Selection

Axis Gear ratioBacklash (arc-

min)

Peak Torque of

motor (Nm)

Peak Torque at

Output (Nm)

Speed of motor

(rpm)

Output Speed of

Load (rpm)

1 57:1 1 5 80.6 1470 25.8

2 105:1 1 3.8 159.2 802 7.6

3 105:1 1 1.9 165.2 2126 20.3

4 25:1 16 0.9 4.4 3000 120

Axis

Calculated

Moment

Load [Nm]

Allowable

Moment Load

[Nm]

Thrust

Load [N]

Factor of

Safety

1 135 882 400 6.5

2 23 882 150 38.3

3 14 195 250 13.9

Nabtesco Gearhead Bearing Loading

Axis

Allowable

Radial Load

[N]

Allowable

Axial Load [N]

Calculated

Radial Load

[N]

Calculated

Axial Load

[N]

4 550 1200 530 370

Neugart Gearhead Bearing Loading

Cycloidal and

Planetary Gearboxes

Brushless Servo Motors

6061-T6 Aluminum Body

Electrical/ Pneumatic

EOT Interface

Brushless Servo Motors

Axis Manufacturer Model Frame Size [mm] Power [W] Feedback

1 Tamagawa TS4613 80 600 17-bit Absolute Multi-Turn

2 Tamagawa TS4609 60 400 17-bit Absolute Multi-Turn

3 Tamagawa TS4607 60 200 17-bit Absolute Multi-Turn

4 Tamagawa TS4606 60 100 17-bit Absolute Multi-Turn

TOTAL POWER 1300

Cycloidal and

Planetary Gearboxes

Brushless Servo Motors

6061-T6 Aluminum Body

Electrical/ Pneumatic

EOT Interface

Electrical –Pneumatic EOT Interface

QTY PART FUNCTION

1x SMC 4 Station Body Mounted Manifold Allows For Expansion Up to 4 Solenoids (8 Ports)

2x SMC 5 way-3 Port Solenoids Allows Pneumatic Control for End of Arm Tooling

1x 6 Pin 3.5A Connector - 3 Twisted Control Pairs Shielded Allows Electrical Control for End of Arm Tooling

Precise Automation Guidance Controller

Controller Specifications

• Precise Automation Guidance 2000C

• Four 20A + Two 10A Amplifiers

• 2000 W Power Supply + 24VDC

• Integrated Kinematics

• Accessible Via Computer Web

Browser or Tablet

Custom Control Box

• Rack Mountable 3U Server Case

• Laser Cut Back Plates for Panel

Mount Encoder/Power Connectors

• Two 120mm + Two 90mm 24V

Cooling Fans

Configuration and Tuning

• PID Loops for Each Axis

• Joint to Motor Scaling Factors

• Configuring a 6 Axis Robot w/ only 4

Axes

• GPL Programming Environment

Testing

Preliminary Test Results

• Deflection: 107 μm

• Repeatability: ± 15 μm

• Cycle Time: ~ 2.3 seconds

Cost of Components: $25,316Cost of Man-Hours (1246 Hrs): $50,190

GRAND TOTAL: $75,506

Budget

Controller $6,350

Labor$50,190

Pneumatics $266

Servo Motors $2,340

Gearheads$10,135

Electrical Components & Wiring$1,380

Material & Hardware$4,845

Reflection

Problems Encountered

• Welded Robot Arms

• Internal Wire Routing

• Cracked Base

• Manufacturing and Shipping

Delays from Outside Vendors

Solutions

• Bolted Arms w/ Alignment Pins

• IGUS External Wire Routing

Recommended Design Changes

• Specific Application of IGUS Products for

External Wire Routing

• Make Assembly Easier-More Accessible

• Consider Required Service Access

• Consider Breakdown of Parts for Easy

Replacement

Conclusion

Mitsubishi Kuka FanucChico State

Project Outlook

• First year prototype is competitive with industry robots

• Can be manufactured in quantity

• Addition of 5th/6th Axes will provide fully functioning 6 Axis Articulated Arm

• Experience gained and lessons learned to be passed on

Questions

Thanks to our Sponsor, Advisor, and all other faculty and students who helped our project succeed.