Theses supervised by Prof. Dr. Hira Karagülle
15 theses · Dokuz Eylül University
Evaluation of the strength of a three axis serial robot performing a task by integrated dynamic analysis
Three axis serial robots with different sizes are widely used for pick and place, welding and various operations in industry. Developments in mechatronics, which is the synergistic integration of mechanism, electronics and computer control to achieve a functional system, offer effective solutions for the design of such robots. The mechatronic design process involves solid modeling, assembly, rigid body dynamics, finite element rigidity analysis, motion control and computer programming. The integrated dynamic analysis of robots is usually used in design stage. In this study, it is offered that it can also be used in the application stage.In this study SolidWorks, CosmosMotion, ABAQUS is used with an integrated approach. The integration software is developed in VisualBasic by using the application programming interface (API) capabilities of these programs. ABB-IRB1400 industrial robot is considered for the study. Different trajectories are considered. Each task is evaluated by kinematic analysis first. If the task is out of the workspace then the task is canceled. This evaluation can be done also by robot programs like RobotStudio. It is offered in this study that the task must be evaluated by considering the limits for velocities, motor actuation torques, reaction forces, natural frequencies, displacements and stresses due to the flexibility. The results are shown on kinematic, kinetic and rigidity evaluation charts. The results of this work can be used for optimal usage of robots.
Trajectory planning of a six axis serial robot based on dynamic analysis
Serial robots are by far the most common robots used in industrial applications such as welding, pick and place, and various processes. Computers and engineering programs play important role to constitute motion analysis and design process. These days, engineers can analyze all parameters to produce the generous robots which are required for the process and find effective solutions quickly by using computer programs with the development of the technology.In this study, a six axis serial robot is produced by using integrated approaches with parallel analysis in SolidWorks, CosmosMotion,VisualBasic, Abaqus and Adlink Motion Control Card. The parts of the robot are modeled in SolidWorks, rigidity is verified with finite element analysis in Abaqus and produced the real model of the robot. Kinematic analysis is studied in CosmosMotion by defining the velocity profile to the end effector point through the software algorithm developed in VisualBasic, which uses the application programming interface (API) capabilities. Different tasks are given to the robot in this study. The kinematic workspace and maximum motor velocities are evaluated by inverse kinematic analysis for each task. The kinetic workspace and maximum motor torques are evaluated by forward kinetic analysis. The rigidity workspace is evaluated by finite element analysis. The optimum trajectory is chosen after reviewing dynamic analysis and finite element results and the same trajectory is generated using ADLINK motion control card. Velocity mode is used. The maximum deviation for each motor is determined which is between the sending velocity profile data and the receiving feedback velocity profile data and compared whether the deviation values are in acceptable ranges.
Design and analysis of a scara robot
In this study, the design of a Scara type manipulator is done and the solid model of it is obtained by Solidworks and its static and frequency analyses was done by Simulation software which is add-on of Solidworks. Afterward, motion analysis of Scara robot is done by Motion software that is also Solidworks? add-on. The parts of the Scara robot which are designed and analyzed were manufactured and assembled if they are working properly.Classification of industrial robots, selection requirements and programing methods are also discussed in this thesis.Keywords: Scara, solidworks, static analysis, natural frequency
Alüminyum döküm tezgahlari için metal besleme robotu tasarimi ve analizi
Today, robots are used at many industrial fields due to their flexibility, efficieny and accuracy. It is possible for man to increase quality of life by using robots for dangerous, dirty and hard labor jobs instead of human. For some production processes, it is not possible to be done by human because of its extreme enviroment conditions or sometimes accuracy of human is not enough. If introduced correctly, industrial robots can improve the job quality and cost savings thanks to their operation efficiency.It is great importance that right material is chosen and that work is determined correctly for industrial robots to be effective. Therefore for reliability of this kind of applications, it is of great importance that engineers involved follow up all design steps and analyse well obtained data. Basicaly, robots consist of two main units which are the mechanical and the control system. In this study, design of mechanical units of robot application will be discussed.In this study, principles to be considered for robot application were determined. A material feeding robot in order to be used at an aluminum die casting system is designed and analyzed. At the design process, environment and work conditions were considered and according to these data, appropriate modules were selected. Static and frequency analysis were handled through the use of Ansys and Solidworks. Results obtained from analyses were evaluated and design was updated.
Finite element analysis of a vertical machining center with aluminum profile framing
Nowadays, vertical machining centers are extensively used in industrial applications. Therefore, importance of design and analysis of vertical machining centers is increasing. Machine designers are commonly used computer aided engineering methods in the design process. In this study, for a vertical machining center with aluminum profile framing, a finite element model developed and finite element analyses are employed. Vibration analysis is a method which has been widely used in structural engineering for determining structural modal parameters, such as natural frequencies, mode shapes, etc. In this study, vibration analysis of a vertical machining center which constructed with modular aluminum profile systems is considered. For the vibration analysis, finite elements method is used. A finite elements model of the vertical machining center is developed by using ANSYS parametric design language (APDL). Then, vibration analysis results have been obtained. To validate accuracy of the finite element model experimental modal testing is carried out. Vibrations arisen after the motion is called residual vibrations. Residual vibrations significantly affect positioning achievement of the end point in flexible systems. To control the residual vibrations of the vertical machining center, trapezoidal velocity profile is applied with open loop control both experimentally and numerically. Keywords: Vertical machining center, aluminum profile, computer aided engineering, finite elements method, residual vibrations.
Design and analysis of a hexapod with upur structure
In this study, a hexapod with universal- prismatic- universal- revolute (UPUR) structure is designed and analyzed. Parallel manipulators have high stiffness and accuracy, and they are used in medical, aviation and astronomy. Universal joints, parallel motion actuators (linear actuators) and revolute joints (rolling element bearings) are available in the market with competitive prices and thus, hexapods with UPUR structure can be produced with low costs.SolidWorks is used for modeling and assembly, CosmosMotion is used for rigid body dynamics and ANSYS is used for the finite element rigidity analysis. A program developed in MATLAB is also used for the rigid body dynamics analysis. A control system is developed for the system having linear actuators with step motors. PC-based motion control is used.It is observed that MATLAB results are in agreement with CosmosMotion results. The natural frequencies and the static deflections of the system are given for various positions. Hexapod motions are analyzed considering kinematic, kinetic and rigidity limits.Keywords: Hexapod, simulation, parallel manipulators, CosmosMotion, ANSYS, SolidWorks.
Desing and analysis of an auto spray robot for an aluminum die casting system
Today, a variety of industrial applications, robots are used extensively in all areas. Selected to work as a truly efficient applications of this robot is the robot system must have the work done in the most appropriate structureIn such applications within the established system of elements both fixed and moving elements, the selection of materials and product design at the correct results up to take advantage of the theoretical knowledge they need to quickly convert practice. The system can be applied to every stage of design calculations and analysis results obtained with a standardized design increases the ease and reliability of the project. This systematic designs made in the robot in question is the fast and accurate solution.In this study determined the principles to be considered for Cartesian robot applications. Linear module selection program prepared in accordance with these principles, with the appropriate modules are selected for the actual design and the prototype was used to verify compliance with the modules. The Cartesian robot with the design of the selected modules in the computer environment, analyzed the frequency and static. The resulting designs are compared with practical applications.Keywords : Spray Robot, Cartesian Robot, Linear Module
Computer aided analysis of a plate subjected to a circular moving load
Moving load problem is investigated by engineers in various engineering structures such as beams and plates. In this thesis, vibration analyses of plates subjected to a circular moving load are realized by using the finite element method. ANSYS parametric design language is used to create the finite element model of the plate considering circular trajectory. A single point load is moved over the circular trajectory. The amplitude of the circular moving load changes harmonically on the plate. The two excitation frequencies corresponding to the first two natural frequencies of the plate are used in the harmonic circular moving load. The dynamic time response is obtained from the middle point of the plate. Natural frequencies of the plate are found with the modal analysis. The results are compared with the reference study. The effects of the radius of the circular path, forcing frequency and rotating speed of the moving load are investigated.
Investigating the effect of misalignment on rotor-bearing systems connected with helical coupling
In this thesis, helical coupling is modeled with the gemetrically exact beam theory in order to investigate the effect of misalignment on rotor-bearing systems. A new approach based on using constitutive equations as constraint was developed. Comparison with previous results showed that proposed approach was able to predict the frequency components associated with misalignment. Results indicated that misalignment causes driven shaft velocity to fluctuate around that of driving shaft for any misalignment type. However variations observed in velocity are not constant for given misalignment value but dependent on inertia and coupling geometry. Large inertia causes rotor velocity to converge to that motor. Results showed that reaction loads are also dependent on inertia and coupling geometry.
Integrated design analysis and control of an hexapod
In this study, the aim is to implement integration of design analysis and control procedures of an hexapod planned to use medical operations whereas required micro positioning. Hexapods with their high accuracy, high stiffness and dynamic properties are widely used parallel robots in such areas, medical, aviation, astronomy. In this study a method is developed to integrate all required engineering procedures for design and control of robots and applied to hexapod. In solid modeling SolidWorks, in machine dynamics analysis, CosmosMotion, in finite element rigidity analysis CosmosWorks software packages and in motor control software of ADLINK company are used. With VisualBasic software package integration is established by using API (?Application programming interface?) of software and ActiveX control properties. Using this method parametric modeling software is developed and hexapod prototype is designed, then manufactured. Again with this method point to point and trajectory motion control software is developed. In addition in this study a mechanical solution for reducing backlash has been designed and applied to the prototype.
Dynamic analysis of planar manipulators with linearly tapered beams
In this thesis, two-link planar robot manipulator configurations with linearly tapered beams are considered. The manipulators have flexible joints and flexible links. The dynamic modeling of the studied manipulators for modal and transient analyses are done with MatLAB codes using the finite element theory. Also, experimental results are presented for the studied different manipulator systems. In the studies, the end point vibration signals are simulated by developing a MatLAB code based on the finite element theory and Newmark numerical integration. The mass and stiffness matrices are time dependent because the angular positions of the links change during the motion. Trapezoidal velocity profiles for the actuating motors are used. The time dependent inertia forces are calculated by using the rigid body dynamics. Residual vibrations that occur after the robot arms stop are minimized by setting of deceleration time values in the trapezoidal velocity profile as proposed. The root mean square (rms) acceleration values of the vibration signals after stopping are calculated. Many starting and stopping positions are examined. It is observed that simulation and experimental results are in good agreement. It is shown that by setting of the deceleration time as proposed, the residual vibration of a two-link manipulator with linearly tapered beams can be controlled.
Condition monitoring of seal defects in pneumatic cylinders
The target in this study is determining the possible seal defects before they occur in pneumatic cyliders which are widely used in plastics, food, textile, chemical and mechanical industries. By this advantage in hand, the operator can eliminate the sudden system shut downs and as a result also eliminates the loss of man power, time and costs. For this purpose an extra program is downloaded to the programmable logic controllers (PLC) which are controlling almost the whole system in many automatic controlling applications including pneumatic cylinders and the possible defects can be promptly realized by PLC. In this thesis, the possible defects are determined by vibtation analysis and velocity calculation. Two proximity switches are mounted to the lowest and highest limits of the cylinder. Time of the stroke movement is measured and the velocity is calculated by the measured data. Also a 5 cm long beam is installed to the cylinder body with a piezo-electric transducer bonded on it. By this transducer the vibration data are routed to the PLC as a low voltage signal. As a result of this study, it is observed that the extent of the seal defect in pneumatic cylinders is proportional to the stroke time, vibration amplitude and vibratrion energy .
Computer aided design of a macro-positioning robot for an hexapod
In this thesis, computer aided design of a macro-positioning robot for an hexapod is considered. The macro-positioning robot is designed to manipulate the hexapod precisely. Hexapod robots have micron-precision motion capability. On the other hand, their limited workspace is not enough for some applications. There are some solutions to extend this limited workspace. Combination of two different robots can be considered as a solution for having macro-positioning and micron precision features both in one system. These types of robot system combinations are defined as hybrid robots in the literature. In this thesis, integrated design approach is used to design, analysis and control of the macro-positioning robot. API (?application program interface?) capabilities of SolidWorks, CosmosMotion, CosmosWorks and PC-based motor control software are used to develop integrated software by VisualBASIC. After completing all the analyses, a prototype of the robot was built. This prototype consists of two axes. Most of the robot parts are manufactured except the actuators. Actuators of the robot are Harmonic Drive AC servo units. As an additional study, this thesis includes developing interface between a robotic system and a vision system.
3500X2500 model hurda presinin entegre tasarımı
The Scrap Balers are used for the recycling of metal scraps. Metal scraps are compressed by the effect of hydraulic forces in the baling presses. In the production of these machines, process requirements should be determined, hydraulic and mechanical calculations should be made according to these requirements. In the scrap press subject to this study, chamber dimensions were determined as 3500 millimetre length 2500 millimetre width and outlet dimensions, the scrap outlet dimensions are in the form of a prism with an edge length of 600 millimetres. Our objective in this thesis is to propose a practical method for constructing the analysis model of the industrial baler. In this study, structural calculations of the hydraulic cylinders of the balers are made. The hydraulic cylinder wall thicknesses and forces required for the process are calculated. After the determination of the hydraulic cylinders, the cycle time of the system is calculated. Hydraulic pumps and electric motors are selected. In addition, a procedure for automating the design of the metal scrap balers is provided. Balers of different sizes can be designed easily and quickly with this process. A solid model of a prototype baler is created in SolidWorks. The frame is considered in this work and modelled as assembly of parts in SolidWorks. Each section is modelled as multiple body modelling using a graphical user interface (GUI). The method uses the computer program developed in Visual Basic. The dimensions that are subject to change for each section are saved in an Excel file. The program reads the dimensions to be changed and automatically makes changes to the SolidWorks model using the commands of the application programming interface (API). Within the scope of the study, models made with GUI are analysed with SolidWorks. This analysis is then evaluated and developed by applying the latest model improvements.
Kartezyen robot kullanarak manyetik akının haritalandırılması
The permanent magnet circuits is becoming increasingly important to produce. The general purpose is to separate the ferromagnetic parts in the intended bulk (garbage, wheat, etc.). However, there is no standardized control in their production. However, the magnets coming from the manufacturers those can show variability in attraction forces. This situation becomes important when large and sensitive magnet circuits are made. The control of the magnet circuit to make the intended performance is very important. These magnet circuits are used to protect very expensive devices in the mining and recycling sector. Failure or unplanned maintenance of these devices may results very high costs. Here we have worked on a Cartesian robot with features similar to the CMM to give this control. In this study, a CAD model of system has been developed and analyzed in Solidworks. The chassis of Cartesian Magnetic Flux Mapper (CMFM) has been assembled from laser cut and on the shelf part.