development of 3-axis delta robot in synchronising with

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DEVELOPMENT OF 3-AXIS DELTA ROBOT IN SYNCHRONISING WITH ROTARY TABLE

By Steven Jonathan

11501067

BACHELOR’S DEGREE in

MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

July 2019

Revision after the Thesis Defense on 17^th of July 2019

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DEVELOPMENT OF 3-AXIS DELTA ROBOT IN SYNCHRONISING WITH ROTARY TABLE

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.

Steven Jonathan

_____________________________________________

Student

24 June 2019 Date

Approved by:

Benny Widjaja, S.T., M.T.

_____________________________________________

Thesis Advisor

24 June 2019 Date

Dr. Maulahikmah Galinium, S.Kom., M.Sc.

_____________________________________________

Dean

24 June 2019 Date

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ABSTRACT

By Steven Jonathan

Benny Widjaja, S. T., M. T., Advisor

SWISS GERMAN UNIVERSITY

Many delta robots has been developed nowadays, but a combination between the mechanic of the IGUS delta robot with the electrical from Beckhoff to be a system of working delta robot has never been done before. In this thesis project, the main purpose is to develop a working delta robot with the component provided from those two companies until the delta robot could have a synchronisation movement with a rotary table. To approach the goal, several movements of the delta robot are also created such as, joint movement, and circular movement. As the result, the synchronisation movement has been fully developed and successfully works. The synchronisation movement has an accuracy of ±0.14 mm in a angular velocity of one revolution per second. For the further recommendation, a servo motor is recommended to replace the stepper motor as the actuator for the rotary table, so that the both the delta robot and the rotary table could be compiled in one system to reach higher accuracy of the synchronisation.

Keywords: IGUS, Beckhoff, Delta Robot, Kinematic, Synchronisation

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DEDICATION

I dedicate this works for the future of the country I loved: Indonesia

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ACKNOWLEDGEMENTS

Firstly, I thank God for the health and grace given during the whole semester to complete this thesis successfully.

I am also very grateful to my parents and my siblings who always give me support when I am down during this thesis works so I could finish this thesis on time.

Also I wish to give my special thanks to my one and only advisor Mr. Benny Widjaja for being very helpful and patient in helping me alone to finish this thesis without any co-advisor XD. I am really helped by all “black magic” he used so that this thesis could finish on time with satisfying result. I am very impressed with his patience and fortitude in helping me throughout this thesis smoothly even with a disturbance of

“you know who”. I am also impressed with his problem solving skill to solve any problem occurred in this thesis in a quick time and of course also to find a solution to eliminate all “useless routine” along with the “culprit” in this thesis.

I would also like to say thank you to Ibu Nyit-Nyit (Nitahey) for being the friendliest lecturer in SGU. She is always available when I need a place for “curhat” or when I am in stress because of my works. Without her, the atmosphere of the lab will not be as alive as today. You are the best Bu.

I also thank all of my friends from inside or outside SGU especially to Michael Kosastra, Benny Wiryawan, Sukrisrich Putra, and Francis Stiven Lie for being my best buddies for more than 10 years and going. I will not be as who I am now without them. Thanks for your supports and time.

I also give my thanks to all lab assistant (Kak Arum, Mas Freddy) and lecturers in guiding me for the past 4 years, also to my competition partner in crime Felicia Kristy. Even though we lose 5 times in a row in one year, she never gives up. Not forgotten are my special friends in SGU, all Basecamp member, and Onomah Group.

Without all of them above, I will not survive in my life until now ^_^.

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TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 10

LIST OF TABLES ... 12

CHAPTER 1 - INTRODUCTION ... 13

1. 1. Background ... 13

1. 2. Thesis Objectives ... 13

1. 3. Thesis Problem ... 14

1. 4. Thesis Scope ... 15

1. 5. Thesis Limitation ... 15

1. 6. Significance of Study ... 15

1. 7. Research Questions ... 16

1. 8. Hypothesis ... 16

1. 9. Thesis Structure ... 17

CHAPTER 2 - LITERATURE REVIEW ... 18

2. 1. Delta Robot ... 18

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2. 2. IGUS Delta Robot ... 19

2. 3. Kinematics ... 20

2. 4. TwinCAT 3 ... 20

2. 5. Rotary Encoder ... 21

2. 6. Beckhoff Industrial PC ... 22

2. 7. Beckhoff DC Servo Motor ... 22

CHAPTER 3 - RESEARCH METHODS ... 24

3. 1. Introduction ... 24

3. 2. General Methodology ... 24

3. 3. System Overview ... 24

3. 4. Design Justification ... 26

3. 4. 1. Mathematical Modelling ... 26

a. Forward Kinematic ... 26

b. Inverse Kinematic ... 29

3. 4. 2. Synchronisation System ... 32

3. 5. Components of Design ... 32

3. 5. 1. Delta Robot Electronics Design ... 32

a. AM8132-0J10 DC Servo Motor ... 33

b. EL7221-9014 DC Servo Motor Driver ... 34

c. EL9576 Brake Chopper Terminal ... 35

3. 5. 2. Delta Robot Program Design ... 36

a. Motor Configuration ... 36

b. Delta Robot Initialisation ... 37

c. Axis Initialisation Calibration ... 39

d. Joint Movement Algorithm ... 42

e. Circular Movement Algorithm ... 44

f. Center Point Calibration to the Rotary Table ... 46

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g. Synchronization with Rotary Table ... 47

3. 6. Performance Test ... 50

3. 6. 1. Synchronisation Test ... 50

CHAPTER 4 - RESULTS AND DISCUSSIONS ... 51

4. 1. Forward Kinematic and Inverse Kinematics ... 51

4. 1. 1. Kinematics Calculation ... 51

4. 1. 2. Analysis of Variance ... 51

4. 2. Robot Calibration ... 54

4. 3. Joint Movement ... 58

4. 4. Circular Movement Analysis ... 63

4. 5. Synchronisation movement ... 64

4. 5. 1. Center Point Calibration ... 64

4. 5. 2. Synchronisation movement. ... 68

a. Performance Test for Accuracy and Reliability ... 69

b. Synchronisation Result ... 70

CHAPTER 5 - CONCLUSIONS AND RECCOMENDATIONS ... 72

5. 1. Conclusions ... 72

5. 2. Recommendation ... 72

GLOSSARY ... 73

REFERENCES ... 74

APPENDIX A ... 75

CURRICULUM VITAE ... 83