IMPLEMENTING INDUSTRIAL ROBOTICS ARMS FOR MATERIAL HOLDING PROCESS IN INDUSTRIES

Abstract

Because of its high accuracy work and simplicity of carrying out heavy operations, the Articulated Robotic Arm was gaining a lot of traction in the industry. The modeling and study of an adaptable robotic arm that can be used for material management activities are the subject of this research. SOLIDWORKS® software was used to design and simulate the articulated robotic arm with an object handling effector. In the early stages of modeling, an examination such as research of the finite element approach would be extremely beneficial. The analysis' findings will reveal the design's strengths and weaknesses. The numerical simulation analysis was performed on the prototype of a robotic arm using the ANSYS® software workstation to investigate alternative components and loading situations. The findings of the investigation are examined to select the appropriate material and to ensure that the articulated robotic arm was feasible.

Full text

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IMPLEMENTING INDUSTRIAL ROBOTICS ARMS FOR MATERIAL HOLDING
PROCESS IN INDUSTRIES
Manikandan Ganesan1, Ganesh Babu Loganathan2, J.Dhanasekar3, K. R. Ishwarya4,
Dr.V.Balambica5
1,4Department of Electromechanical Engineering,
1,4 Faculty of Manufacturing, Institute of Technology, Hawassa University, Hawassa,
Ethiopia
2 Assistant Professor, Department of Mechatronics Engineering, Tishk International
University, Erbil, KRG, Iraq
3Assistant Professor, Department of Mechatronics, Bharath Institute of Higher Education and
Research, Chennai – 600 073, Tamilnadu, India.
5Professor & Head, Department of Mechatronics, Bharath Institute of Higher Education and
Research
ABSTRACT
Because of its high accuracy work and simplicity of carrying out heavy operations, the Articulated Robotic Arm
was gaining a lot of traction in the industry. The modeling and study of an adaptable robotic arm that can be
used for material management activities are the subject of this research. SOLIDWORKS® software was used to
design and simulate the articulated robotic arm with an object handling effector. In the early stages of modeling,
an examination such as research of the finite element approach would be extremely beneficial. The analysis'
findings will reveal the design's strengths and weaknesses. The numerical simulation analysis was performed on
the prototype of a robotic arm using the ANSYS® software workstation to investigate alternative components
and loading situations. The findings of the investigation are examined to select the appropriate material and to
ensure that the articulated robotic arm was feasible.
Keywords: Finite Element, Material Handling Gripper, ANSYS® Robotic Arm, SOLIDWORKS®.
1. INTRODUCTION
Robotics is an enthralling branch of science concerned with the design, modelling, analysis, and implementation
of robots. Robots are employed in a wide range of industries and production processes. Robots are employed in
manufacturing operations like the welding process, spray coating, chopping, machining, assembly, cutting, place
and pick, stacking, product checking, and experimenting in today's industries [1]. Many technological
disciplines of today's production and industry choose lightweight architecture. However, the majority of studies
are limited to the automobile and aerospace industries [2]. The substitution of a widely used material with a
substance that can perform the same functions while being lighter is a common strategy. Various studies have
been conducted to evaluate the efficiency or performance of robots using various parameters and approaches.
Pupaza et al [3] used the information from these investigations to reduce the amount of material used by making
geometrical adjustments to the robotic arm's second plane and conducting a strength-based study. The robot arm
got lighter as a result of this analysis, and there was no distortion for the same kind of load. New materials and
arm topologies were investigated in additional investigations by Chong et al.[4] and Rueda [5] by evaluating the
stress and shear deformations created on the robotic arm. These studies yielded the appropriate motor and
weight quantity. Industrial robots are remote control systems that include connectors, joints, motors, detectors, a
processor, and a hardware or software emulator. The robot base is attached to one end of the arm, while the
other is equipped with a 'tool,' which can be a hand, a grip, or any other end effector that resembles a human
hand [6 ]. A robot was an electromechanical machine that is guided by many computers and electronic software.
The robot was attached to a PC, which is configured to drive the motors on the robot movements, allowing it to
do various tasks [7]. The arm was the part of the robot that directs the final grabber arm to complete the tasks it
has been given.This placement may not be possible if the arm architecture is too large or small [8]. The purpose
of using a robotic arm is to reduce human mistakes and effort. On the tips of the robotic arm, mechanical
grippers are utilized to select and position objects or perform materials management activities [9].
DOI: 10.11720/JHIT.5392021.2

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Grippers are used for a variety of functions, including the unloading and loading of workpieces like metal
sheets, pallets, food products, and so on [18-26]. In the industry, unloading and loading of heavy items are done
physically; to execute these types of tiresome activities constantly, we need to use a robotic arm [10]. The
purpose of this project is to build a six-jointed articulated robotic arm with a single mechanical grip movement
and to select a suitable material that can handle a large weight. The SOLIDWORKS® program will be used to
design the entire robotic arm [27-38]. The main job is to use the ANSYS® software workbench to do numerical
simulation on selected materials to optimize the robotic arm. It will aid in selecting the critical assembly
portions as well as the right materials for robotic arms utilised in industry [39-49]. Moreover, the findings of this
research support the strategy and growth of the robotic arm [50-55].
2. METHODOLOGY
a. To begin, the needs for the robotic arm are gathered and developed in the form of a drawing, which is
expressed in a very 2D sketch.
b. The complicated created 3D solid view will then be generated in SOLIDWORKS® employing
instructions and limiting conditions.
c. Open the model in the ANSYS® program workstation and import it.
d. The input parameters will be decided by determining the right materials for this type of industrial
application after the data has been imported.
e. Now we'll make a mesh and apply boundary conditions to it.
f. The mechanical assessment of the robotic arm would be carried out under various load scenarios to get
distortion and stress patterns that will be used to investigate the design.
2.1. Kinematic analysis
RoboAnalyzer 3D Model-based robotics program is used to determine the basic design parameters of a specified
kind of robot, which determines the location and rotations of its End-effector, speeds of various articulation, and
length of the required link by resolving the analysis of the nonlinear equations. RoboAnalyzer collects Serial
robot's DH data. As an input, the manipulator uses their revolute articulation. It then generates a 3D model of
the robots for each of the DH values. The 3D tracking window provides zoom, pan, and tilt capabilities that can
be used. The dynamic CAD prototype is developed by observing the 3D model from multiple perspectives.
2.2. CAD modeling
According to the conclusions of the inverse dynamical analysis of the 3D Model, a dynamic CAD modelling is
created on the Solid Works application, which can replace the time-consuming process of architectural
remodelling. The structure knows how to parametrically generate a model with one of the tools in a way that
the model's shape cannot be changed by changing the constraints. As a result, a CAD model can be employed in
the design. The effective architecture of the robot could be done by changing the model restrictions in each
iteration. In technological design challenges, parametric modeling has become a competent and vital tool.
Fig. 1. Base Model of older version Fig. 2. The base model of the newer version
Figure 1 and 2 shows the base model sample of an industrial robot with the older version and new version of it.

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Fig. 3. Top view of the rack and pinon Mechanism
Figure 3 shows The material holding region of the industrial robots' top view. In this part where the robot can
carry the weight and distribute it to the other region without any manual effort.
Fig. 4. Connector 2 Model Fig. 5. Gripper Model
Figure 4 shows the robot with 2 point connector which can carry more number of objects whereas figure 5
shows the gripper model because the gripper plays an important role while carrying a material if the gripper
model of the robot fails to carry material from the destination properly.
Fig. 6. Arm Assembly
Figure 6 gives a detailed description of the Robot Arm assembly. The robot's arm is made up of the wrist,
elbow, gripper, shoulder, and the base.
All of the components of the robotic arm are created separately in SOLIDWORKS® and then combined using
conditions and restrictions. SOLIDWORKS® was chosen because it has recently been utilized by several
studies and has been shown to assist cut robot development and design time, enhance designer efficiency, and

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increases the performance and quality of robot modeling. Figures 1–5 depict the various components of the
robotic arm. Figure 6 depicts the assembling of these various elements into a fully articulated robotic arm.
2.2. Structural Analysis
The findings of the FE analysis define the pressure condition of a structure under a certain load. The input data
for FE study includes the arm shape with the FE analysis, model parameters, and loading criteria. The loading
factors are determined by the direction and position of each weight input to the element. To solve different
linkages under pressure due to loading situations, the finite element approach was used. The material qualities
and component behaviour are considered to be linearly flexible [12].
The usage of FEA is a fantastic method. Simulation has the advantage of taking less time, costing less money,
and being easier to compare to the experiment technique.
The robotic arm's SOLIDWORKS® assembly is changed to STEP or IGS file format before being imported
into the program. The structural analysis toolbox in ANSYS® software is used to estimate component pressures
and distortion.
2.3. Meshing
The practise of splitting a model into a number of parts such that when a load is applied to it, the weight is
distributed uniformly was known as meshing.Typically, it is discretization. A finite number of items must be
discretized from the continuum.
Fig. 7. Combination of Robotic Arms Fig. 8. Gripper symbiosis
With a change in the number of components and component size, the structure of the FEA findings can be
significantly altered. Triangular pieces are used to fine-tune the robotic arm's meshing. The entire number of
elements is 46193, while the total number of nodes is 76424. The meshing was depicted in Fig. 7 and 8.
2.4. Properties
Because of their high strength and ability to withstand huge forces, steel plate and Aluminum Composite 356
have been chosen as the robotic arm materials. The features of both materials are shown in tables 1 and 2 below.
Tab. 1: Structural Steel Properties
Properties
Tensile Yield
Strength
Tensile
Ultimate
Strength
Compressive
Yield Strength
Density
Values
2.5×108Pa
4.6×108Pa
2.5×108Pa
7850Kg/m3
Table 1 shows the structural analysis of the steel with certain important properties like tensile yield
strength, tensile ultimate strength, Compressive yield strength, and density.
Tab. 2: Aluminum Alloy 356 Properties
Properties
Tensile Yield
Strength
Tensile
Ultimate
Strength
Shear
Strength
Density

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Values
2.05×108Pa
2.5×108Pa
2.05×108Pa
2680Kg/m3
Likewise table 1, table 2 shows the properties for Aluminum alloy of 356 value. The properties of aluminum
356 alloys includes tensile yield strength, tensile ultimate strength, Compressive yield strength, and density.
3. RESULTS AND DISCUSSION
3.1 Investigation of kinematics
Kinematics is a term that refers to how things move. Manipulator is a major issue in the automated control of
robot manipulators. People talked about the theoretical foundation in this section. Among. Kinematics of an
instructional robotics arm using the KUKA KR5. Here we offer the Joint, which is a six-rotation revolution
robot. Offset (b): The length of the baseline perpendicular to the connections on the joint axis. The connection's
length (a) was determined by. The length between the perpendicular axis of the two objects is measured. The
torsion angle is the angle formed between the orthogonal. (a). Predictions in a plane perpendicular to the
conventional standard along the pivot axis. Joint: Perpendicular projections are those that are not parallel to the
standard. The pivot axes plane is perpendicular to it. Each DE factor, referred to as the joint factor, is
changeable for each type of connection, while the three remaining variables are referred to as connection and
constant variables.
3.2 Analysis of Force
The analysis is carried out using two various materials, Structural Steel and Aluminum Alloy 356, to apply
varying forces to the robotic arm's end effector or gripper. Total distortion and total identical results Stresses of
300N, 400N, 500N, and 600N are applied to 4 different loading circumstances. The structure will collapse if the
ultimate tensile value exceeds the shear stress. Fig. 9-12 show the Structural Steel robotic arm's deformation and
stress fluctuation. Fig. 13-20 depicts the deformation and stress fluctuation on the robotic arm made of
Aluminum Composite 356.
Fig. 9. Deformation in the 300N range with stress analysis at 300 N
Figure 9 shows the robot arm with a weight of 300 N through which the stress analysis of the robot with this
weight must be analyzed.

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Fig. 10. Deformation in the 400N range with stress analysis at 400 N
The above figure 10 describes the weight carrying capacity of the robot at 400N where the stress estimation of
the robot with 400 N is also analyzed.
Fig. 11. Deformation in the 500N range with stress analysis of 500 N
Figure 11 shows the robot arm with a weight of 500 N through which the stress analysis of the robot with this
weight must be analyzed.
Fig. 12. Deformation in the 600N range with stress analysis of 600 N
As shown in figure 12 the robot is carrying more weight when the weight of the material get increased its load-
carrying capacity also increases and more stress may arise in the region.

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Fig. 13. Deformation in the 300N range Fig. 14. Stress Analysis at 300N
Figure 13 and 14 shows the robot which a square shaped weight as a sample for testing its stress with the same
range of 300N. when the weight of the material increases the stress in the arm may increase.
Fig. 15. Deformation in the 400N range Figure 16. Stress Analysis at 400N
Figure 15 and 16 shows the old mechanism and the new mechanism of load carriage by a robot. The stress
evaluation may vary based on the mechanism.
Fig. 17. Deformation in the 500N range Fig. 18. Stress Analysis at 500N

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Figures 17 and 18 show the load-carrying capacity of a robot with 500 N using the old and the new mechanism
where the stress analysis for this process is analyzed to know the capacity of the robot for carrying weight.
Fig. 19. Deformation in the 600N range Fig. 20. Stress Analysis at 600N
Figures 19 and 20 show the robot with maximum weight carriage when the weight of the load increases in
such case the stress in the arm region of the robot may increase.
Tab. 3. Results of Structural Steel Analysis
Sr. No.
Force (N)
Max Equivalent
Stress (MPa)
Max Deformatio
(mm)
1
350
90.9089
0.13578
2.
450
145.98
0.78589
3.
580
156.98
0.98753
4
650
165.98
0.86456
Tab. 4. Analysis Results for Aluminum Alloy 356
Sr. No.
Force
(N)
Max Equivalent Stress
(MPa)
Max Deformation (mm)
1.
400
89.097
0876542
2.
380
143.87
2.9867
3.
490
178.87
2.0968
4.
540
167.98
3.08689
Tables 3 and 4 show that all strain distribution statistics for both components are within authorised limits, i.e.,
they are less than the maximum shear stress. However, for the same weight, the SSA outperforms the
Aluminum Alloy Arm. In the case of the Aluminum Alloy Arm, the distortion is slightly larger. As a result, a
structural steel robotic arm is the most reliable option. Furthermore, both results suggest that the structural
integrity of both flexible robotic arms satisfied the operational needs and that they are suitable for further
research.
4. CONCLUSION
Today's generation requires a versatile and low-cost robotic hand that mimics the human hand. An articulated
robotic arm was built using SOLIDWORKS®, a 3D CAD application, and then exported to ANSYS® for
material analysis. This robotic arm could be utilized in a variety of sectors for operations like picking and
placing, assembling, and so on. The structural analysis was shown to be correct. The arm appears to be meeting

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design specifications and capable of carrying a variety of payloads. This is appropriate for hazardous areas in
companies and will aid in production. The simulation will be possible in the future in the chosen workspace.
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