2017 Rogue Rotary MODULAR ROBOTIC ROTARY JOINT DESIGN SEAN MURPHY JACOB TRIPLET TYLER RIESSEN Table of Contents 1 Introduction .......................................................................................................................................... 4 1.1 Problem Statement ....................................................................................................................... 4 2 Background ........................................................................................................................................... 5 2.1 Researching the Problem .............................................................................................................. 5 2.2 Researching Existing Solutions ...................................................................................................... 8 3 Objectives............................................................................................................................................ 10 3.1 Modularity ................................................................................................................................... 11 3.1.1 Time to assemble new configuration: ................................................................................. 11 3.1.2 Time to re-configure program: ........................................................................................... 11 3.1.3 Dynamic Range: .................................................................................................................. 11 3.2 Target Accuracy and Repeatability ............................................................................................. 11 3.2.1 Controller Steady State Error: ............................................................................................. 11 3.2.2 Deflection Under Given Load: ............................................................................................. 11 3.2.3 Back Lash: ............................................................................................................................ 12 3.2.4 Vibration: ............................................................................................................................ 12 3.3 Cost ............................................................................................................................................. 12 3.3.1 Safety specific equipment needed: ..................................................................................... 12 3.3.2 Cost to manufacture: .......................................................................................................... 12 3.3.3 Time to manufacture: ......................................................................................................... 12 3.3.4 Special Processes required: ................................................................................................ 12 3.4 Payload and Reach ...................................................................................................................... 13 3.4.1 Power Requirements .......................................................................................................... 13 3.4.2 Component Strength ........................................................................................................... 13 3.5 Non-Required Objectives ............................................................................................................ 13 3.5.1 Time to actuate: .................................................................................................................. 13 3.5.2 Back-Drive Ability: ............................................................................................................... 13 4 Our Solution ........................................................................................................................................ 13 4.1 Gear reduction ............................................................................................................................ 15 4.2 Motor Controller ......................................................................................................................... 15 4.3 Selected Motor ........................................................................................................................... 16 4.4 Wire management ...................................................................................................................... 18 4.5 Sensor Feedback ......................................................................................................................... 19 1 | Page 4.6 Cost breakdown .......................................................................................................................... 20 5 Analysis of Design ............................................................................................................................... 22 5.1 Spindle Stress and Deflection Analysis ....................................................................................... 22 5.2 Housing Stress and Deflection Analysis ...................................................................................... 22 5.3 Forward and Inverse Kinematics ................................................................................................. 23 6 Manufacturing .................................................................................................................................... 24 6.1 Housing ....................................................................................................................................... 24 6.2 Spindle ......................................................................................................................................... 24 6.3 Bearing Block ............................................................................................................................... 24 6.4 Assembly ..................................................................................................................................... 25 7 Testing ................................................................................................................................................. 25 8 Maintenance ....................................................................................................................................... 28 9 Conclusion ........................................................................................................................................... 29 10 Summary of Approach .................................................................................................................... 29 10.1 Defining the Problem .................................................................................................................. 30 10.2 Background Research .................................................................................................................. 30 10.3 Ideation and Trade-off study ...................................................................................................... 30 11 Design Process ................................................................................................................................ 30 11.1 Programming/Teaching Methods ............................................................................................... 30 11.2 Interdependencies Based on Teaching Method ......................................................................... 31 11.3 Component Selection through Pugh Matrix ............................................................................... 31 11.3.1 Teaching Method Selection ................................................................................................ 32 11.3.2 Gear Reduction Method Selection ...................................................................................... 32 11.3.3 Clutching and Braking Method Selection ............................................................................ 33 11.3.4 Method of Actuation Selection ........................................................................................... 34 12 References ...................................................................................................................................... 35 13 Appendix A: Quality Function Deployment .................................................................................... 36 14 Appendix B: Gantt Chart ................................................................................................................. 37 15 Appendix C: Vendor Contact Information per Component ............................................................ 38 16 Appendix D: Component Information ............................................................................................ 39 17 Appendix E Detailed Analysis .......................................................................................................... 53 17.1 FEA Analysis of Housing .............................................................................................................. 53 17.1.1 Loads on Housing Used in Abaqus Model ........................................................................... 53 2 | Page 17.1.2 Maximum Von Mises Stress found in Analysis.................................................................... 54 17.1.3 Maximum Deflection Found in Analysis .............................................................................. 55 17.2 Hand Calculations of Spindle .....................................................................................................