By Aveka 11601002
BACHELOR’S DEGREE in
Mechanical Engineering - Mechatronics concentration Faculty of Engineering & Information Technology
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
July 2020
Revision after Thesis Defense on 10 July 2020
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
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_____________________________________________
Student Date
Approved by:
Leonard P. Rusli, M.Sc., Ph.D.
_____________________________________________
Thesis Advisor Date
Steven Jonathan, S.T., B. Eng.
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium S.Kom., M.Sc.
_____________________________________________
Dean Date
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DELTA ROBOT FOURTH AXIS
By Aveka
Leonard P. Rusli, M.Sc., Ph.D., Advisor Steven Jonathan, S.T., B. Eng., Co-Advisor
SWISS GERMAN UNIVERSITY
A traditional delta robot uses three arms to move with three degrees of freedom. This design makes the movement of the robot to be faster than most other designs.
However, because of its speed the weakness of the design is a rotation actuator cannot be put on the end factor as it will be too heavy. A fourth axis will solve this problem and enable the robot to do rotational movement on its end factor therefore reducing the complication of adding another system and its cost. The fourth axis has to be able to adjust to any given position that the three axis are able to reach. This means it has to be able to shorten and lengthen while transferring torsion to the end factor. Because of its speed, the friction within the fourth axis has to be minimized and the moment of inertia also minimized. With the addition of the fourth axis, a gripper will also be added on the end factor, so the robot can be used for pick and place demonstration.
The servomotor on the fourth axis and the gripper will then be synchronized with the existing PLC system, making the whole system integrated.
Keywords: Mechatronics, Delta Robot, IGUS, Beckhoff, Kinematic, Synchronisation
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© Copyright 2020 by Aveka All rights reserved
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DEDICATION
I dedicate this works for the advancement of automation in Indonesia
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ACKNOWLEDGEMENTS
I wish to thank each individual of my class for their support, understanding and genuinity. Their unspeakable spirit has carried me through the high and low of universities. Mr. Leonard Rusli was particularly helpful in guiding me through the complications of many design and mechanical flaws. IGUS Indonesia for providing enormous support toward the project. Finally, I would like to thank Mr. Steven Jonathan and Beckhoff Indonesia, who from the beginning, has fully supported the automation side of the project.
In addition the amount of useful and practical coursework from all of SGU staff that proved to be very helpful and inspirational during the time of this project.
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Page
STATEMENT BY THE AUTHOR 2
ABSTRACT 3
DEDICATION 5
ACKNOWLEDGEMENTS 6
TABLE OF CONTENTS 7
LIST OF FIGURES 9
CHAPTER 1 - INTRODUCTION 11
1.1 Background 11
1.2 Objectives 12
1.3 Hypothesis 12
CHAPTER 2 – LITERATURE REVIEW 13
2.1 Delta Robot 13
2.2 IGUS Delta Robot 14
2.3 Universal Joints 15
2.4 Bushing and Bearing 17
2.5 Servo Motor 18
2.6 Mechanical Gripper 19
CHAPTER 3 – RESEARCH METHODS 20
3.1 Design Justification 20
3.1.1 Mechanical Sliders 20
3.1.1.1 Telescopic Sliders 21
3.1.1.2 Two Sliders in Series 22
3.1.1.3 Multiple Shaft Sliders 22
3.2 Components of Design 24
3.2.1 Universal Joints 24
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3.2.1.2 Industrial Grade Universal Joint 28
3.2.1.3 Constant Velocity Joint 28
3.2.1.4 Custom Made Universal Joints 29
3.2.2 Bushing and Bearing 29
3.2.2.1 Deep Groove Ball Bearing 29
3.2.2.2 Fluid Bearing 29
3.2.2.3 Bushing 30
3.2.3 Mechanical Gripper 30
3.2.4 PLC Control Modules 32
3.2.4.1 PLC using Beckhoff 33
3.2.5 PLC Software using TWINCAT 3 35
3.2.5.1 Servo Motor Monitoring 38
3.3 Analytical Method 38
3.3.1 Motor Rating Calculation and Motor Selection 38
CHAPTER 4 – RESULTS AND DISCUSSIONS 41
4.1 Final Design Discussion 41
4.1.1 Motor Bracket Discussion 41
4.1.2 Mechanical Sliders Design 42
4.1.3 Mechanical Gripper Discussion 42
4.2 Test Results 44
4.2.1 Reach Capability of the Fourth Axis 44
4.2.2 Torque and Speed 46
4.2.3 Mechanical Error 47
4.2.4.1 Motor Positional Error 49
CHAPTER 5 – CONCLUSION AND RECOMMENDATIONS 51
5.1 Conclusions 51
5.2 Recommendations 51
GLOSSARY 53
REFERENCES 55
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LIST OF FIGURES
Figures Page
1. Rotational Delta Robot 13
2. IGUS Delta Robot Workspace 14
3. Universal Joint Speed Change Calculation 15
4. Constant-velocity Joint, US Patent US6120382A 16
5. IGUS 12mm Bushing 17
6. Ball Bearings 18
7. AM8111 Beckhoff Servomotor 18
8. Types of Gripper 19
9. Telescopic Slider Design 21
10. Two Sliders in Series Design 22
11. Retracted Multiple Shaft Design 22
12. Extended Multiple Shaft Design 23
13. Multiple Shaft Design 23
14. Speed Changes of One Universal Joint at 20 degree Bend Angle 25 15. Speed Changes of One Universal Joint at 50 degree Bend Angle 25 16. Speed Changes of Two Universal Joint at 20 degree Bend Angle 26 17. Speed Changes of Two Universal Joint at 50 degree Bend Angle 27
18. Servo-actuated Gripper 31
19. Solenoid-actuated Gripper 31
20. Final Solenoid Gripper Design 32
21. Beckhoff’s 24V Digital Output Module 33
22. Example of the Sequencing Program using Ladder Diagram 35
23. Move Absolute Box 36
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25. Delta Robot XYZ Positioning 37
26. Servo Motor Monitoring using TWINCAT 38
27. Speed Rating Calculation 39
28. Moment of Inertia Calculation 39
29. Motor Selection 40
30. Version 1 of Motor Bracket 41
31. Version 2 of Motor Bracket 42
32. Mechanical Gripper as the End Factor 43
33. Reach Capability of the Fourth Axis; Shortest Distance 44 34. Reach Capability of the Fourth Axis; Longest Distance 45 35. Reach Capability of the Fourth Axis; Extreme Angles 45 36. Fourth Axis Precision Test on Extreme Angles 46 37. 3D Printed Universal Joint with Embedded IGUS Bushings 47 38. Pin Mechanism between Universal Joint and Slider 48
39. Set Screws Embedded on the Universal Joint 48
40. Small Gaps in between Bolt, Bushing and Outer Slider Shell 49 41. Recording of Servo Motor Position during Sequence 49
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