International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001 Vol. 6, Issue 4, Aug 2016, 9-24 © TJPRC Pvt. Ltd

DESIGN AND ANALYSIS OF WIRELESS ARM

VIPUL M VASAVA 1 & PARTH B PRAJAPATI 2 1Assistant Professor, Department of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj, Gujarat, India 2Research Scholar, Department of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj, Gujarat, India ABSTRACT

Now a day in this fast growing industrial age every company needs speed in manufacturing to cope up with the customer’s requirements. Every industrialist cannot afford to transform his unit from manual to semi automatic or fully automatic as automation is not that cheap in India. The basic objective of this project is to design low cost Wireless welding arm which can be utilized in any industry for welding purpose. This Wireless welding arm is requiring 3 axial programming and controller. Wireless welding arm can be used in welding process by controller and the structure is designed in such a way that it is Wireless for welding process. Flexile welding arm would be used mainly where May human is not able to work. Example,Under water and underground welding. play a vital role in all the activities Original Article in human life including industrial needs. In modern industrial manufacturing process consists of precise and fastest proceedings. Human operations are needed to perform a variety of tasks in a robotic system such as set-up, programming, trouble shooting, maintenance and error handling activities

KEYWORDS: History of Welding, Recent Problems in Welding, Problem Specifiacation, Design Calculations, Dynamics Creo Model, Analysis

Received: Jun 19, 2016; Accepted: Jul 01, 2016; Published: Jul 13, 2016; Paper Id.: IJMPERDAUG20162

INTRODUCTION

The history of industrial automation is characterized by periods of rapid change inpopular methods. Either as a cause or, perhaps, an effect, such periods of change in automation techniques seem closely tied to world economics. Use of the , which became identifiable as a unique device in the 1960s, along with computer-aided design (CAD) systems and computer-aided manufacturing (CAM)systems, characterizes the latest trends in the automation of the manufacturing process. These technologies are leading industrial automation through another transition, the scope of which is still unknown. A major reason for the growth in the use of industrial robots is their declining cost robot prices dropped while human labour costs increased. Also, robots are not just getting cheaper, they are becoming more effective—faster, more accurate, more Wireless. If we factor these quality adjustments into the numbers, the cost of using robots is dropping even faster than their price tag is. As robot become more cost effective at their jobs, and as human labour continues to become more expensive, more and more industrial jobs become candidates for robotic automation.Modern industrial robot controls are build as multi-processor controls due to the multitude of parallel calculations and control functions. Figure shows the internal structure of such a control. Individual assemblies which are designed for special jobs and equipped with an own micro-processor are linked with the host computer via the system bus. The host controls and coordinates the actions of the components based on the operating system and the robot program. Examples of such

www.tjprc.org [email protected] 10 Vipul M Vasava & Parth B Prajapati assemblies, which are mostly installed on individual printed boards, are e.g. the axes computers. They are responsible for calculation of movement and for control of power unitsper axisare available which control speed and position of each axis.

Figure 1: Industrial Robot Control

A Robot welding is a specific new application of , although robots were first introduced into US industry during the 1960s.The use of robots in welding did not take off until the 1980s, when the automobile industry began to use robots for . Since then, both the number of robots used in industry and the number of their applications has grown greatly. Till 2005, more than 120,000semi or fully automated robots were in use in North American industry, about half of them for welding. Growth is initially limited by high equipment costs, and the resulting restriction to high- production applications. In 2014, FANUC America Corp. introduced a low cost robot which proved beneficial for small manufacturers with a cost-effective robotic arc welding solution. Robot arc welding has started growing quickly just recently, and already it holds about 20% of industrial robot applications. The major components that constitute the arc welding robots are the manipulator or the mechanical unit and the controller, which acts as the robot's “Brain”. Manipulator used to move the robot, and the design of these robots can be categorized into few common types, as SCARA and Cartesian coordinate robot, which uses different coordinate systems to direct the arms of the machine.

The robot is able to weld a pre-programmed position, guided by machine vision, or by a combination of the two methods. Vast benefits of robotic welding makes it importance such that industries accept it to make it a technology that helps many original equipment manufacturers increase accuracy, repeat-ability, and throughput The technology of signature image processing has been developed since the late 1990s for analyzing Electrical data in real time collected from automated, robotic welding, thus enabling the optimization of welds.

The robot parts as shown in the figure below.

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Figure 2: Robot Parts

Recent Problems in Welding

Modern manufacturing era faces two main challenges: improved quality at lower price and the need to improve productivity. These are the vital requirements to keep manufacturing plants in developed countries. Other very important characteristics of the manufacturing systems to survive the market are flexibility and agility of the manufacturing process, since companies are required to deal with a very fast growing market involving products having very short life-cycles due to worldwide competition. Consequently, manufacturing companies are needed to respond to market requirements efficiently, keeping their products competitive. This requires a very efficient and controlled manufacturing process, where option is automation, computers and software. a huge number of products require welding operations in their assembly processes. The welding process is Complex, difficult to parameterize and to monitor and control effectively. We have visiting a workshop of an industry and observe that it is difficult task for to welding a job or two metals. It should more take care during welding. It is also dangerous to welding while it affects eyes and also breathing problems in that environment. Sometimes due to shake hands of worker during welding it can't weld perfectly and it may occur imperfections in welding and it results into failure.

In those cases it is very useful to done welding by a robot. This is the reasons why we are using a welding robot which is as follows:

• Manganese in Welding Fumes

Biggest on–the–job risk is open contact to the manganese contained in fumes that are produced during welding. Manganese is able to cause very serious damage to the brain and nervous system. Many workers who are in direct contact with welding fumes suffer from Parkinson’s disease, a major problem affecting movement and balance. They tend to develop “Manganese,” a disease closely related to Parkinson’s that also makes it difficult to walk and move properly. Both manganese and Parkinson’s disease cause tremors, shaking, and loss of muscle control. These conditions can become more severe as time passes.

• Other Harmful Metals in Welding Fumes

When the welding rod used is either base metal iron or mild steel, iron oxide may be produced in the welding fumes in addition to manganese. Breathing in iron oxide can damage nasal passages, throat, and lungs. Working with produces fumes having nickel and chromium and caused to face problems like asthma. Nickel can make illness worse. www.tjprc.org [email protected] 12 Vipul M Vasava & Parth B Prajapati

• Hazardous Coatings

Welding on some plated or painted metals may be especially hazardous. If cutting a metal that has been coated with paint which contains lead, it may produce welding fumes having lead oxide. Inhaling these welding fumes can cause lead poisoning, a condition in which worker becomes weak and develop anemia (a low red blood cell count). Lead also harms your nervous system, kidneys, and reproductive system

• Heat, Light, and Mechanical Injuries

Arc welding uses ultraviolet light. If welding is carried out near solvents containing chlorinated hydrocarbons, the ultraviolet light can react with the solvents to form phosgene gas, which is deadly in even small amounts.

Spécifications

Weld penetration is the distance that the fusion line fills the weld metal below the surface of the material being welded. Incomplete root fusion is defined as the weld material fails to fuse one side of the joint in the gap. Incomplete root penetration arises when both sides root region of the joints are prepared with typical imperfection.

An Excessively Thick Root Face in a Butt Weld Too Small A Root Gap

Misplaced Weld Power Supply Too Low

Arc Input too Low Figure 3: Specification

Material/Tool Required

There is number of choices are available for to selecting the building materials for Wireless ram. But not every material is a good choice. There are some materials or tools which are as follows:

• CAD Software

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• Thin sheet metal

• Cardboard

• Sheet metal

• Steel

Robot Dynamics

This will gives a brief idea about Design of Wireless arm including parameters used in design. Also it gives an idea about methods used for calculating parameters and analysis.Machine manufacturers have to manufacture machine which posses’ convenient design for The customer’s requirements due to increasing competition between the manufacturers inrecent years. It is not an effective solution to respond to this demand by producing several Machine models. It is important that the design of the machine is carried out so as to satisfy the customer’s specific requirements to decrease the manufacturing cost and increase thequality of the product. The design process must be completed rapidly in order to proceed withthe manufacturing of the machines which fulfils the customer’s requirements. Necessity forquick design has created the Wireless design concept. Wireless design can be defined asaccomplishing the whole design which fulfils all the requirements in a quick and reliable Manner.

A or say Wireless arm can be designated using two main parameters.

• Reach

The robot workspace (reachable space) indicates the places that the end gripper can reach. The workspace varies with change in Degree Of freedom angle/translation limitations, the arm link lengths, the angle of work piece to be picked up, etc. The workspace is depends highly on the robot configuration. To identify the workspace, we have to calculate all locations that the gripper can reach.

Figure 4: Free Body Diagram

The above figure shows the free body diagram of Wireless welding arm.

Where, Motor used to provide translational motion

Motor Used For rotational motion.

If we change the link lengths we workspaces can obtain the different work space. Any location outside of this space is a location that arm can’t reach. So from this point of view the Reach is said to be major parameter for designing the Arm. The reach can be calculated through stretching the links to its maximum condition. www.tjprc.org [email protected] 14 Vipul M Vasava & Parth B Prajapati

Payload

Payload can be defined as the maximum weight that can be lifted or moved by the end gripper of the Wireless arm. A payload is usually termed as a weight unit kg or Lbs. This parameter is the sum of mass of the end gripper and mass of welding torch moved by the robotic arm. For example, an arc welding torch is lighter in weight compared to a spot welding gun, which differs in a different payload total. So, the robot selection could be different for these two applications. The weight of arc welding torch is hardly 0.8 to 0.9 kg. So using these two parameters we can say that Reach of robot is far more important than the payload criteria.Wireless arm is made from mechanical links as well as the electronics components. The parts being used to make this Wireless arm as listed as follow.

Table 1 Mechanical Parts Electronic Parts Base plate D.C motor Rigid Links Stepper motor End effecter Sensors Shaft Ardiuno processer Spacer Mega at 8085 circuit

Electronics Parts

This Wireless welding arm is designed by relating it to a specific product. Thus this equipment is product oriented designed. In pressure vessel steel sheet is bent and joined by weld which is known as long seam. So, to weld these shells with the hollow cylinder arc welding is used. This is the main application of Wireless welding arm. The arm is designed such that it can weld in long seam.

Mechanical Parts Base Plate

Base plate is made from Cold Rolled steel.Base plate is designed such that it can with stand the stresses generated during working conditions as well as to withstand the weight during stationary conditions. The base plate assembly is having two parts which are connected with each other by nut. The part one base plate dimensions are of 400mm long and 200mm wide made of 5 mm thick plate.The part two of base plate are connected using 4 circular pipes on which 1 st link relies.

Figure 5: Base Assembly

• Link 1 Assembly

Link 1 compromises two CRC material strips which are connected by using spacers. It also compromises a c cup in which stepper motor is mounted. Motor is connected to the link through simple shaft mechanism.

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Figure 6: Link 1 Assembly Figure 7: Base Clamp

Figure 8: 2-D Drawing of Arm

• Rigid Links

In this particular Wireless arm 2 links are used which are made of CRC so the desirable durability is achieved as well as Stainless Steel is Economical.Link 1 is designed in such a way that it can lift the weight of link 2 and gripper holding the welding torch. The dimension of the link 1 is as follows.0.15m length CRC strips seam welded at distance of 0.10m to 0.25 m so it do not bend during its angular motion. The angular movement of link 2 is 180 degrees in north-east direction. The rigid links are powered by High Torque and less RPM stepper Motor.In link 2 all parts are to be joined using spacer.

• End Effecter

End effecter is used to hold the weld torch during the process. It is essential that the torch should not be move during the process so it is designed in such a way that it fits completely the weld torch. The weight of weld torch is low as 0.8 kg to 0.9 kg so there are less chances that effecter bends in downward movement due to result of weight. If we use gripper type end effecter than Wireless arm can be also used as pick and place robot.

• Spacers

Spacers are used in link 2 at regular interval to make sure that link is connected in linear position and do not bend at any ends due to torque.

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Figure 9: Spacer (Diameter 4mm Hollow Steel Pipe)

Figure 10: D.C Motormotor Mounting

• Motor

Electric motors are used to “actuate” something in your robot: its wheels, legs, tracks, arms, fingers, sensor turrets.

Stepper Motor

In between those 1.8 In Stepper motor the standard angle for 1 step is 1.8 degree.so it means that we cannot stop the operation degree. If we want to weld 8 degrees on any circle periphery the motor will use 5 steps

1.8*5 = 9 degrees.

This means that the arm will weld 1 more degree on that periphery. So in case of stepper motor inaccuracy problem may arise.

Servo Motor:

A special part of continuous motors is the servo motor, which in typical cases combines a continuous DC motor with a feedback loop to ensure accurate positioning. There are various types of servo motors; a communally found in radio-controlled cars and planes.

D.C motor:

In a continuous DC motor, application of power causes the shaft to rotate continually. The shaft stops only when the power is removed, of if the motor is stalled because it can no longer drive the load attached to it. D.C motor can be used to move heavy load by using low RPM high torque motors.From Evaluation of all available motors we have selected the D.C motor and servo motor selected.

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• Processor

There are two processors available in the market for mainly for robotics programming

Ardiuno Processor

An Arduino is a micro-controller board built with the 8-bit AmtelAVR micro-controller. These has between 32K and 512K of on-board flash able memory, run at clock speeds of 8-84MHz and run off voltages of 2.7-12V. They have about 2K of RAM. An Arduino takes about 7 seconds to boot. It is programmed using a special part of C and has no operating system. These are programmed by writing the programs on a computer and uploading the written code over a USB cable. Depending on the model, they are available with 9 and 54 digital I/O pins and 6-12 analog input. Power consumption of ardiuno is < 0.5W.Among these two boards the ardiuno is selected as per the guidance of the electronics professor.

ARDIUNO PROCESSOR Raspberry Pi An Arduino is a micro-controller board built with the 8-bit AmtelAVR micro-controller. These has between 32K and 512K of on-board flash able memory, run at clock speeds of 8-84MHz and run off voltages of 2.7-12V. They have about 2K of RAM. An Arduino takes about 7 seconds to boot. It is programmed using a special part of C and has no operating system. These are programmed by writing the programs on a computer and uploading the written code over a USB cable. Depending on the model, they are available with 9 and 54 digital I/O pins and 6-12 analog input. Power consumption of ardiuno is < 0.5W.Among these two boards the ardiuno is selected as per the guidance of the electronics professor.

Speed

Speed is the amount of distance per unit time at which the robot can move, usually specified in inches per second or meters per second. The speed is usually specified at a specific load or assuming that the robot is carrying a fixed weight. Actual speed may vary depending upon the weight carried by the robot.

Load Bearing Capacity

Load bearing capacity is the maximum weight-carrying capacity of the robot. Robots that carry large weights, but must still be precise are expensive

Accuracy

Accuracy is the ability of a robot to go to the specified position without making a mistake. It is impossible to position a machine exactly. Accuracy is therefore defined as the ability of the robot to position itself to the desired location with the minimal error (usually 0.001 inch).

Repeatability

Repeatability is the ability of a robot to repeatedly position itself when asked to perform a task multiple times. Accuracy is an absolute concept, repeatability is relative. Note that a robot that is repeatable may not be very accurate. Likewise, an accurate robot may not be repeatable.

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Work Envelope

Work envelope is the maximum robot reach, or volume within which a robot can operate. This is usually specified as a combination of the limits of each of the robot's parts. The figure below shows how a work-envelope of a robot is documented

Figure 11: Circuit Work Flow

• Arduino connected to esp8266 module & module connected cloud based website.

• Arduino connected to motor driver which drives various motors & controls them.also connected to ultrasonic sensor.

• Ultrasonic sensor measures the distance of gun from workpiece.it’s data is send to be plotted on cloud based website

• Cloud based website offers various control for controlling th machine & it’s links

• Arduino works as control of circuit while esp8266 & cloud based website is used to monitor & gather data & helps user give command to arduino

Calculations of Arm Joints

The requirement of these force calculations is for motor selection. We must make sure that the motor we choose do not only support the weight of the robot arm, but also what the robot arm will carry. The first step for calculation is labeling FBD which is drawn with the robot arm stretched out to its maximum length. Next step is moment arm calculation, multiplying downward force times the linkage lengths. This calculation must be done for each motor.

Impact Factor (JCC): 5.7294 NAAS Rating: 2.45 Design and Analysis of Wireless Welding Arm 19

Figure 12: F.B.D of Arm Indicating Loads Applied on It

From The figure the torque at different joints is calculated. To Calculate torque following parameters are used,

• Weight of each linkage

• Weight of each joint

• Weight of object to lift

• Length of each linkage

Torque Calculation

• Torque about Joint 1

Joint 1 is welded.

• Torque about Joint 2

M2 = L2/2 * W2 + L3 * W3

= 15*1.12

= 16.8 kg.cm

The length and working space of the arm is derived from the top shell part dimensions of the pressure vessel. The Following figure shows the figure of top head of the Pressure vessel.

Figure 13: Top Head

DIMENSIONS

• Nominal thickness, t = 20mm

• Height of ellipsoidal head, h = D/4= 250mm

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Design of Parts Used in Wireless Arm Reach

Figure 14 From figure

=45*cos 40 + 30*cos -40

=57.45 cm

So the reach of the arm is Limited to 57.45 cm ~57cm

Forward Kinematics

Figure 15: Forward Kinematics

Assume that the base is located at x=0 and y=0. The first step would be to locate x and y of each joint.

• Joint 0 (With X And Y At Base Equaling 0)

x0=0 y0 = L0

• Joint 1

x1= 45*COS (40) = 34.47 J1 (28.92, 34.47)

y1= 30*SIN (40) = 28.92

• Joint 2

x2= 30*COS (-40) =22.98

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y2= 30*SIN (-40) = -19.28 J2 (-19.28, 22,98)

• Joint Locations

J0 (0,0)

J1 (28.92, 34.47)

J2 (-19.28, 22,98)

Final Designassembly of Wireless Welding Arm

Figure 16: Final Assembly

Analysis Results

Analysis is carried out in ANSYS 16.1.In Deformation and stress analysis the Assemblyis sufficiently safe. The analysis results are as given below.The ANSYS program has many finite element analysis capabilities, ranging from a simple, linear, static analysis to a complex, nonlinear, transient dynamic analysis. The analysis guide manuals in the ANSYS documentation set describe specific procedures for performing analyses for different engineering disciplines.

The Load of 20 N ( Ramped) is applied on the top face of secondary link. Factor of Safety achieved for the structure is 15. At 20 N Load the structure deforms by 0.02 mm. Structure Will Break at the Load of 250 N. Mashing used for analysis: For First Link Hex Meshing,For Second Link Triangular mashing.

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Figure 17 Deformation Analysis

Deformation analysis is carried out with predefined design and load data. At the end of the link 2 loads is applied in downward direction. Result is as shown in Figure.

Figure 18: Deformation Analysis Figure 19: Stress Analysis

Final Assembly After Analysis

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Figure 20

CONCLUSIONS

The purpose of Wireless arm is for limited mobility. A schematic design of the each component is given in Design Chapter. A brief description is given for function and construction of each component. Research papers, related patents and devices which have working principle similar to this Wireless welding arm was conducted and is presented in this report.The Wireless arm would be able to confront routine challenges occurred in weldingevery day. This Wireless arm is designed to fulfill the tasks with less difficulty and reduce defect cause by worker. The Wireless welding arm reduces the effort required. Same products are available in the market but with bit high cost. Wireless welding arm is designed to perform special purpose task.Wireless welding arm is designed in terms ofproduct data and shape.According to research, Wireless Arms are designed to overcome individual challengeswhich have proven to be valuable. No matter what type of impairment is being faced by the consumer, anyone who has the capability to use a keypad and controller can control the device.The device will prove beneficial to the production line manager and workers since it has the ability of ease understanding of the device quickly along with an operation.Wireless arm increases productivity significantlyand safety advantages, even for small operations. It is possible to get fastest return in the industry by implementing automation investment.

ACKNOWLEDGEMENTS

Authors are greatful to GMM pfaduler Limited,v.v.nagar for providing useful knowledge about the whole project.

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REFERENCES

1. GMM pfaudler pvt ltd.v.u.nagar,anand.

2. Gunnar Bolmsjö, Magnus Olsson and Per Cederberg (2001)Robotic Arc Welding — Trends and Developments for Higher Autonomy.

3. pi-cheng tung, ming-chang wu, yean-ren hwang.(2004) an image-guided mobile robotic welding system for smawvrepair processes.

4. J norberto piresa,*,se´rgio(2005)paulcomplete robotic inspection line using pc-based control,supervision and parameterization software .

5. A. ollero, s. boverie, r. goodall, j. sasiadek, h. erbe, d. zuehlke mechatronics,(2005) robotics and components for automation and control ifac milestone report.

6. Anurag Verma and M. M. Gor (2008). “Computer Aided Dynamic Modeling of a Manipulator”, Proceeding of the National Conference on Emerging Trends in Mechanical Eng., G. H. Patel College of Engg. & Technology, V. V. Nagar, Gujarat, India.

7. Anuragverma (2010) “actuator design arc welding robot”.

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