Conceptual and Mechanical Design of Master- Slave Robot for Painting Application

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA Conceptual and Mechanical Design of Master- Slave Robot for Painting Application Thesis submitted in accordance with the partial requirements of the Universiti

1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA Conceptual and Mechanical Design of Master- Slave Robot for Painting Application Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor of Manufacturing Engineering (Manufacturing Robotic and Automation) By Hairul Anuar bin Mohd Yusof B Faculty of Manufacturing Engineering April 2007

2 UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS TESIS* JUDUL: SESI PENGAJIAN : Saya mengaku membenarkan tesis (Sarjana Muda/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan Syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. **Sila tandakan (X)

3 APPROVAL This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Robotic and Automation). The members of the supervisory committee are as follow:. Main Supervisor En Mohd Samsi bin Saad Faculty of Manufacturing Engineering (Official Stamp & Date) Second Supervisor En. (Official Stamp & Date) i

4 DECLARATION I hereby, declare this thesis entitled Mechanical Design for master slave (parent-child) robot for painting application is the result of my own research except as cited in the references. Signature :. Author s Name :. Date :. ii

5 DEDICATION For my beloved mother and father. iii

6 ACKNOWLEDGEMENTS The contributions of En Mohd Samsi bin Saad, of the UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM) merits special acknowledgment for this excellent and careful review of the entire text and project. En Mohd Samsi has inspected the structure of every sentence and where necessary, has made modifications so that the project is clear, direct, concise, and friendly. He has carefully modified the heading structure of every sentence in order to make the text more easily readable and reorganized the project section especially my part of this project so that the student can efficiently survey what has be presented. En Samsi has worked under a number of constraints and has done so in a friendly and timely manner. Special recognition is again due to my friend, formerly of Robotic and Automation, for them continuing contribution in the form of invaluable suggestions and accurate idea and checking of this project. In addition to these individual, I wishes to thank the members that who responded to a questionnaire concerning these project. Also thanks to UTeM staff especially Manufacturing Department that given approval to this project. Finally, I wish to state the extremely significant contribution of my family in addition to providing patience and support for this project. I am extremely pleased to continue in next semester to build the project successful. In the interest of providing in any with the best possible educational materials over other semester, I encourage and welcome all comments and suggestions. iv

7 ABSTRACT In 1920, robotic be found when Czechoslovakian playwright Karel Capek introduces the word robot in the play R.U.R. - Rossum's Universal Robots. The word comes from the Czech robota, which means tedious labor. In 1938, the first programmable paintspraying mechanism is designed by Americans Willard Pollard and Harold Roselund for the DeVilbiss Company. In 1951, in France, Raymond Goertz designs the first teleoperated articulated arm for the Atomic Energy Commission. The design is based entirely on mechanical coupling between the master and slave arms (using steel cables and pulleys). Derivatives of this design are still seen in places where handling of small nuclear samples is required. This is generally regarded as the major milestone in force feedback technology. The main function of a master slave arm for a painting application is to paint some part that difficult to paint. Why robot arm are useful for painting is because the painting itself can be hazardous for human. The design of the arm robot can paint some other part by using arm robot and controlled by using master arm robot. Every movement can be controlled by master arm robot. Effectiveness of the proposed method is confirmed by experiments using a developed three-axis master-slave arm system. In this project, it was specially focused and involves in Conceptual and Mechanical design of Master Slave Robot for Painting Application that to design and choose the best of arm robot that will be build for prototyped. The proposed arm master system consists of a self-contained computing hardware with a potential motors at each arm joints. The purpose of this master unit is to measure the angular position of the joints of the user s arm. These angular positions are transmitted, as voltages, to the transducer interface. For Slave Robot, the mechanical arm can cover a range of human arm movements. The complexity of the human arm makes any attempt to mimic. v

8 TABLE OF CONTENTS Approval Declaration Dedication Acknowledgement Abstract Table of Contents List of Figures List of Tables Sign and Symbols List of Appendices i ii iii iv v vi x CHAPTER INTRODUCTION Background of Project Problem Statements Objectives of the Research Scope and Limitation 8 CHAPTER LITERATURES REVIEW What a Robot Types of Robots Servo and Non-Servo Type of Path Generated Robot Component 13 vi

9 CHAPTER METHODOLOGY Design the robot Robot Modules and Parameter Forward Kinematics Inverse Kinematics Dynamic Speed Considerations Types of Inputs Desired Frequency of the Control system Error Analysis Optimal Design of Robot Manipulator Special Computer Architecture for Robotic Design Issues Master Slave Robot Manipulator Analysis Stage Controller Design The Optimal Design Constructing the Optimization Problem Structural Length Index Manipulability Accuracy The User Interface Design Selections Design Design Design 3 30 vii

10 CHAPTER RESULT Arm Robot System Features How It Works Slave Arm Master Arm Servo Motor Design Analysis Slave Robot Design Consideration Design Members Paint Holder Design Members Paint Holder Design Material Selection Other Parts 52 CHAPTER FINAL RESULT Mechanical Design Slave Robot Base Stand 1, 2 and Upper Stand Stand Arm Robot Master Robot 61 viii

11 5.2 Process Analysis Calculations Discussion Problem Occurs Solution Overall Process Robotic Sprayer Conclusions Contribution Others Applications 73 REFERENCES 74 APPENDICES Gantt Chart 79 ix

12 LIST OF FIGURES CHAPTER Conceptual figure of systems The interaction between the members activity 4 CHAPTER Robot Arm Design Configuration Arm Robot 13 CHAPTER Kinematics Analysis Three different configurations of the robot manipulator The optimal design cycle (interfaces) Flow chart for mechanical design Articulated Arm Robot SCARA Robot Arm Robot 30 CHAPTER Master slave working flow Slave Arm Master Arm Mapping the joints of a human hand The Conceptual of Master Slave Robot Design Link member Link member Link member 3 43 x

13 4.6.4 Paint holder Design Link member Link member Link member Paint holder Design Cross section of middle part of arm member Cross section of end part of arm member Back View Of Arm Member 1 49 CHAPTER Final design The Final Design The Final Design In Different View The Conceptual Design The Different View Of Design Of Base Arm Robot Mechanical design for base arm robot The dimension of base The dimension of stand upper stands, and stands The dimension of support the base The arm robot First arm robot Second arm robot Types of servo motor The different view prototypes of master robot Limit switch placed in master Robot The Dimension Of Master Robot Problem in Servo Motor 68 xi

14 LIST OF TABLES CHAPTER The different between Master and Slave Arm Robot 8 CHAPTER System feature in Master Salve Arm Robot Types of Material Selection Types of Aluminum Cost for Other Part 52 xii

15 LIST OF APPENDICES 1.1 Gant chart xiii

16 CHAPTER 1 INTRODUCTION 1.0 INTRODUCTION In the master-slave control, the slave robot (teleoperator) exactly replicates the movements of the master robot. Master slave robot is technology for tele-operation using master-slave robot systems in the field of medical, welfare, extreme-environment, spaceenvironment and virtual reality. Many sophisticated master-slave robot systems have been proposed. Some of them are already commercialized. For example, PHANT om by SensAble Technologies is a device for measuring six degrees of freedom motion of an arm and, at the same time, giving a force feedback of three axes, which is usually used for the input devise for virtual reality and for the master robot for the telerobotics. Da Vinci by Intuitive Surgical is a surgical master-slave robot system having two fingers on two arms and can realize highly dexterous manipulation. History of master robot stated at 1920, when Czechoslovakian playwright Karel Capek introduces the word robot in the play R.U.R. - Rossum's Universal Robots. The word comes from the Czech robota, which means tedious labor. In 1938, the first programmable paint-spraying mechanism is designed by Americans Willard Pollard and Harold Roselund for the DeVilbiss Company. In 1942, Isaac Asimov publishes Runaround, in which he defines the Three Laws of Robotics. Master slave robot has been stated in 1951 in France, Raymond Goertz designs the first teleoperated articulated arm for the Atomic Energy Commission. The design is based entirely on mechanical 1

17 coupling between the master and slave arms (using steel cables and pulleys). Derivatives of this design are still seen in places where handling of small nuclear samples is required. This is generally regarded as the major milestone in force feedback technology. Although the system has advantage to have simple mechanism and controller, it has disadvantage not to have force feedback needed for dexterous manipulation. The latter is to apply a force feedback control electrically. Conceptual figure of the bilateral system is shown in Fig. 1.1(a). Although the mechanism and controller become complicated, dexterous manipulation can be conducted using the bilateral one. Conceptual figure of proposed methodology is shown in Fig. 1.1(b). Large and stable stationary limiting torque can be applied by use of the ultrasonic motor because it is a frictionally driven motor and need no electric power to keep it stationary. So the ultrasonic motor is suitable for the switching element because it can make the master arm stationary when the slave arm is in contact with an object. Mechanical clutch is also suitable for the switching element. The force feedback to the operator is applied mechanically as an elastic force of the elastic elements instead of electrical feedback control. This method also utilizes a feature of human factor that is displacement information from visual feedback is superior to that from one s sensation. Lightweight and well-controlled master-slave robot can be supplied using the proposed method. Figure 1.1: Conceptual figures of systems 2

18 In designing and building a robot manipulator, many tasks are required, starting with specifying the tasks and performance requirements, determining the robot configuration and parameters that are most suitable for the required tasks, ordering the parts and assembling the robot, developing the necessary software and hardware components (controller, simulator, monitor), and finally, testing the robot and measuring its performance. Our goal is to build a framework for optimal and flexible design of robot manipulators with software and hardware systems and modules which are independent of the design parameters and which can be used for different configurations and varying parameters. This environment is composed of several subsystems. Some of these subsystems are: Design. Hardware selection. Simulation. CAD/CAM modeling. Control. Physical assembly and testing. Monitoring. For conceptual and mechanical design are more focused in designing the CAD/CAM model for the robot using Solid Work or AutoCAD, analysis stage, selection of motor, torque of motor, forces of arm robot, particularly, in making the decision of using hardware vs. software solutions, manufacturing and assembly of the robot and selecting the required components for the robot. These reports are also take part in the design and analysis of the prototyping environment with the required communication protocols and database analysis. Some part of this project was involved in selecting the electrical and electronic components and helping out in the overall design and testing procedures for the robot manipulator. For another part was involved in the Motion Card that mean the card is to control the movement and measure the voltage from robotic from analog to digital. 3

19 Figure 1.2: The interaction involved in the prototyping activity. In figure 1.2 shows that how to make 3 link robot arm and for this task are more focus in CAD model, design and build prototyping environment. In CAD model, there is several type of model that used CAD software like AutoCAD. In this task, AutoCAD are commonly used in design. For design part, there is several design that been selecting depend on several factor that make good design. Then from design, it will make prototyped to see this design are suitable in any criteria. 4

20 1.1 Background of Project The main purpose of this project master slave robot is to communicate between master and slave robot. The main objective is when master robot gives some movement and slave robot follows the movement. The other function of a master slave arm is a painting application is to paint some part that difficult to paint. For this project, we design that we can paint some other part by using arm robot and controlled by using master arm robot. Purpose of this master slave robot is to remove human from hazardous like painting. The material in painting is hazardous to human health. So this master slave robot is more useful when work that are harmful to human well being. Human can use master robot to conduct the slave robot to follow what are being commands. For this prototype, there are using 3 axis movements because depend on calculate the cost, stability, knowledge and design we take to make this project complete. Mostly, the painting application has large proportion in automotive painting works in automation industry, robotic painting application widely used to painting the mostly products like car. The development of master slave painting robot is regarded as a highly developed production technology which requires a concentration of potentials of global technologies such as CAD/CAM, robots, electronic and electrical, mechanical and IT. Typically in paint shops, robots wield paint spray guns. The guns throw out a lot of paint at high volumes. Bells are usually fitted on the top and side of the booth. The paint bells provide a better surface quality. Everything required for a paint system. The main application of robots in the commercial sector has been concerned with the substitution of manual human labor by robots or mechanized systems to make the work more time efficient, accurate, uniform and less costly. One may argue the social implications of such developments. Increased demand on growers has begun to be met with increased specific automation in many fields, as producers believe that automation is a viable and sometimes necessary method to ensure maximum products with minimum costs. 5

21 1.2 Problem Statement The first main idea of this project is from first robot having been built. Although master slave robot are long been used in manufacturing, not many people know the function of master slave robot itself. Then we apply the master slave robot function to develop this idea in painting application. Mostly, there are a lot of methods that have been used by industry in painting application. There are using arm robot that only programmable in computer and then the robot follow the programmable of the movement in program. By using arm robot mater slave painting, we can painting the part that we need that can t be done by programming. Despite the problem above, there is one more and the most important point that had been in the painting field. There are being dangerous when people using paint sprayer to paint something. The gas that produced in paint have chemical that can make human sick or die. So some safety equipment is human used mask when painting. Other method is used robot like master slave robot. It s more safety for human because human can painting outside the part that can be painting and remove from paint itself. 6

22 1.3 Objectives The objective of this research project is to explore the basis for a consistent software and hardware environment, and a flexible framework that enables easy and fast modifications, and optimal design of robot manipulator parameters, with online control, monitoring, and simulation for the chosen manipulator parameters. This environment should provide a mechanism to define design objects that describe aspects of design, and the relations between those objects. For this project, we separate painting application and arm robot. We more focus on about arm robot first and for the painting application, we take some different programmable control. Another goal is to build a prototype of painting system arm robot that is part of our project. In other part, we analyze the system of circuit and programmable that painting need. This will help determine the required subsystems and interfaces to build the prototyping environment, and will give us hands-on experience for the real problems and difficulties that we would like to address and solve using this environment. The importance of this project arises from several points: This framework will facilitate and speed the design process of robots. The prototype robot will be used as an educational tool in the robotics and automatic control classes. This project will establish a basis and framework for design automation of robot manipulators. 7

23 Table 1.1: The different between Master and Slave Arm Robot Master - Request to move robot - Request to stop robot - Request to send current robot position - Measure the movement of the mouse - Complicated Computation with Parallax Basic Stamp Slave - Control robot to move to desired position - Control robot to stand still - Measure robot s current configuration - Measure robot s joint velocities - Measure forces and torques at the end effected 1.4 Scope and limitation Developing structure analysis for the conceptual design of the master slave robot arm for painting application. Developing the requirement for the structure due to the completion of the prototype. Research for the methodology used to define equilibrium of the structure in static and dynamic. 8

24 CHAPTER 2 LITERATURE REVIEW 2.1 What are robots? A robot is an electro-mechanical device that can perform autonomous or preprogrammed tasks. A robot may act under the direct control of a human (e.g. the robotic arm of the space shuttle) or autonomously under the control of a programmed computer. Robots may be used to perform tasks that are too dangerous or difficult for humans to implement directly (e.g. nuclear waste clean up) or may be used to automate repetitive tasks that can be performed with more precision by a robot than by the employment of a human (e.g. automobile production.) The word robot is used to refer to a wide range of machines, the common feature of which is that they are all capable of movement and can be used to perform physical tasks. Robots take on many different forms, ranging from humanoid, which mimic the human form and way of moving, to industrial, whose appearance is dictated by the function they are to perform. Robots can be grouped generally as mobile robots (e.g. autonomous vehicles), manipulator robots (e.g. industrial robots) and self reconfigurable robots, which can conform themselves to the task at hand. Robots may be controlled directly by a human, such as remotely-controlled bombdisposal robots, robotic arms, or shuttles, or may act according to their own decision making ability, provided by artificial intelligence. However, the majority of robots fall in-between these extremes, being controlled by pre-programmed computers. Such robots 9

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