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Mechatronics Design and Kinematic Simulation of
5 DOF Serial Robot Manipulator for Soldering THT
Electronic Components in Printed Circuit Boards
Owen Mejia
Professional School of
Mechatronics Engineering,
Universidad Ricardo Palma
Lima, Peru
owen.mejia@urp.edu.pe
José Cornejo, Senior Member IEEE
Universidad Tecnológica del Perú
Lima, Peru
c21944@utp.edu.pe
Diego Nuñez
Professional School of
Mechatronics Engineering,
Universidad Ricardo Palma
Lima, Peru
diego.nunezv@urp.edu.pe
Jack Rázuri
Professional School of
Mechatronics Engineering,
Universidad Ricardo Palma
Lima, Peru
jack.razuri@urp.edu.pe
Ricardo Palomares, Senior Member IEEE
Professional School of
Electronics and Telecommunications,
Universidad Nacional Tecnológica
de Lima Sur-UNTELS
Lima, Peru
rpalomares@untels.edu.pe
Abstract—Universities must have properly implemented and
qualified laboratories for the comprehensive training of
students. There are laboratories with laser cutters and 3D
printers but very few with a robotic system that can be used by
students. For this reason, the innovative research was carried
out in 2021 under the supervision of the School of Mechatronics
Engineering at Ricardo Palma University, it was creating a
robotic system that allows soldering THT electronic components
on printed circuit boards, to help students to perform this
process. The robotic system will be able to adapt to different
sizes of circuit boards in a specified workspace, defined by 23
cm x 17 cm, and reach the farthest points of the circuit boards
due to the 5 degrees of freedom that compose it. This study
presents mechatronics conceptual design and kinematic analysis
simulation of the structure, which is a set of a translation joint
with reference to the cartesian robot movement and rotation
joints that compose a manipulator. In addition, the end effector
will be a soldering iron beside a pipe for the tin output which
will be connected to a pair of gears controlled by a stepper motor
to dispense the filler material. The robot is pretended to be
applied to laboratories of Ricardo Palma University. In
conclusion, favorable results were achieved; consequently, the
next step of the project is to apply a camera for the solder path
recognition and expand its use for SMD electronic components.
Keywords—serial robot, robotic soldering, kinematic analysis,
Matlab simulation, manipulator, mechatronics
I. INTRODUCTION
Currently there are many engineering laboratories without
new technologies for educational soft soldering, so
universities must seek to create spaces for students to improve
their skills. The project aims at being implemented in the
future in the laboratories of the Ricardo Palma University, for
undergraduate students to interact with the robotic system and
to help them with the soft soldering of the circuits seen in the
first academic term of mechatronics and electronics
engineering careers. Also, to familiarize them with robotic
systems and innovation of these [1].
For a quality soldering process, the cleaning of the
soldering iron tip and its temperature should be considered, so,
is essential to have a station that controls this parameter for an
ideal temperature to soldering THT (Through Hole
Technology) electronic components in a range of 250 °C to
375 °C, therefore, a temperature regulator allows working
with different applications. For the cleaning of the tip in the
soldering tool, the robotic system has a small station located
in the back of the workspace, having the position coordinates
already defined by a previous program [2].
The design of the robotic system is a combination between
a cartesian and manipulator robot, being considered a serial
robot with a similar structure to a 3D printer machine, adding
rotational joints and links to cover a greater workspace. In
addition, the end effector is composted by a soldering iron tip
and the tin applicator pipe. Finally, a small mechanical system
controls the amount and the output flow required to solder the
components, being the final design in Fig. 1 [3].
Fig. 1. Serial Robot Manipulator - Design
II. MATERIAL AND METHODS
A. Mechatronics Design
The support structure has aluminum profiles, 45°
connectors for profiles, M5 aluminum spacers and V bearings,
materials commonly used in a 3D printer. In Fig. 2. The shape
of the structure is based on a cartesian robot together with the
supports, allowing to maintain the stability of the robotic
system and the movement of the manipulator in the “Z axis”
through toothed belts using NEMA 17HS1538 motor.
Moreover, the base has a space where the electronic system
for the robot operation will be located.
2022 First International Conference on Electrical, Electronics, Information and Communication Technologies (ICEEICT) | 978-1-6654-3647-2/22/$31.00 ©2022 IEEE | DOI: 10.1109/ICEEICT53079.2022.9768447
Fig. 2. Support Structure
The design of the extrusion aims at the application of the
correct amount of the filler material conformed by a pair of
gears and a pulley to generate the necessary tension for the
route of the tin, adding a spring-loaded lever to control the
pressure of the gear's grip on the material. This process has a
duration of 3 second, the gear system allows outflow and has
an actuation time of 2 seconds in total. Finally, to complete
the mechanism is adding a stepper motor 28BYJ48, coupled
with the gears, as is presented in Fig. 3. The complete
soldering process has a maximum time of 5 seconds, the
soldering iron must initially heat the connection pin and the
circuit point to the board.
Fig. 3. Group of Gears for the Filler Material Outlet
The movement of all the joints are made up of a
transmission through toothed belts represented in Fig. 4. This
type of transmission was chosen for the ease of maintenance
performed on the belts, keeping a compact and aesthetic
design. The transmission system allows to double the torque
on the pinion as it has a dimension of half the drive shaft
located in specific NEMA motors such as NEMA 23 that can
apply 150 N.cm minimum being doubled depending on their
transmission ratio. Along with the NEMA 14 which have a
high-power density capable of offering high micro stepping
resolution and quiet operation. Then there are the NEMA 8
and NEMA 11 which function to provide movement at certain
degrees of inclination for better precision in the desired spots
solder on the printed board, as they have a low noise level,
small volume, and smooth operation for its structure.
Fig. 4. Transmission System
For the design of the end effector, an aluminum support
piece is implemented acting as a grip for the soldering iron and
the filler material outlet pipe as is shown in the Fig. 5. Besides,
use a cork liner as a thermal insulator to fill the spaces between
the aluminum piece and the two tools, preventing the tin from
melting due to the heat of the soldering iron before starting the
process. The soldering tip is interchangeable by uncoupling
the screws from the end of the soldering iron, adapting to
different electronic components to be soldered.
Fig. 5. End Effector
Robot parts would be produced by a 3D printing to reduce
the weight of the robot system and the cost of implementation.
Additionally, the structure has carbon fiber plates of 2
millimeters thick to increase their resistance and is also
improving the support of the links with shafts of 8 millimeters
of diameter in the 2nd and 3rd joint with their respective
bearings. Finally, the maximum size of the plates to be
soldered is taken as a reference, which has a measurement of
23 cm x 17 cm, shown in Fig. 6. with the dimensions of the
robotic soldering station.
Fig. 6. Main Dimensions
B. Workflow Development
Fig. 7. Shows the flowchart about the principal sequences
and operations of the robot, expressing the decisions which are
considered to have an ideal temperature control in the
soldering iron tip by the relay solid state and the PT 1000
sensor. On the other hand, the diagram also explains the logic
of the robot movement related to the soldering process.
Fig. 7. Robot Operation Flowchart
The robot’s degrees of soldering are shown in Fig. 8.
Enable to adjust the required angles for a correct coupling
between the THT electronic component and the printed circuit
board, emulating the tool position in the soft soldering manual
process, improving its precision and efficiency. Before the end
effector there is a temperature sensor, Pt 1000, since to the
movements of the manipulator have a considerable length of
cables that generate errors in the measurements, compared to
the PT 100 sensor, this one has an error of ±0.1 °C, being
controlled correctly the heat transfer to the tip during the
soldering process.
Fig. 8. Degrees of Freedom Serial Robot Model
At the base of the structure are all the electronics devices
and components that allow the serial robot function as shown
in Fig. 9. The chosen controller is Raspberry pi 4, since it has
40 GPIO pins which allow to improve noise immunity, in
addition to the possibility of activating drivers in parallel and
these can be programmed as inputs, outputs or different
functions described in the data sheet. Also, an SSR (Solid
State Relay) used as an on/off controller for a higher load,
these have fast switched speeds. Furthermore, three DRV
8825 and two Tb 6600 drivers allow the control of bipolar
stepper motors. Finally, a power switching supply of
12 Volts - 15 Amperes for the system that allows to regulate
the necessary voltage output for the different components.
Fig. 9. Electronic Devices
III. KINEMATIC ANALYSIS AND SIMULATION
A. Forward Kinematics
The mathematical description of the serial manipulator of
5 DOF robot is represented by a kinematic model shown in
Fig. 10. considering the perspective of an initial position. The
following formulation is based on forward kinematics by the
Denavit-Hartenberg algorithm [4-18].
Fig. 10. Kinematic Diagram of 5 DOF Robot
The Table I. of kinematic parameters are based on Fig. 10.
with their respective variable angles and distances for each
joint. Describing the variable parameters with the
terminology *.
TABLE I. DENAVIT-HARTENBERG
Link
(i)
Kinematic Parameters
1
u
*
0
2
*
-
u
0
0
3
*
-
90°
0
-
90°
4
*
0
-
90°
5
*
0
0
Consider the following variables to replace in the
transformation matrices.
!!!!
""""
Where the initial values to each parameter are:
##$##%&&'$())*+))
##$##%&&#$#)),-))
##$##%&#$.))/+,$.(%
.#$##%-#))
Implementing the parameters in the Denavit-Hartenberg
algorithm to the final transformation matrix is going to be the
multiplication of each matrix considering the 5 degrees of
freedom.
0
1#
#
# # &
# # # & 2 0
1#
#
# # & #
# # # & 2
0
1#
#
# & # #
# # # & 2 0
1# #
# #
# & #
# # # &2
0
1#
#
# # & #
### & 2
Where the final transformation matrix is:
0
0
3 0
3 0
3 0
3 0
… (1)
Solving (1) the transform matrix results in:
0
1456
57
58
# # # &2
Where is conform by:
0
9:;<<=>6 :5=<=>6
# & ? … (2)
From (2) the position coordinates of the end effector are
described by:
5@44A4
B … (3)
5C4444A
B … (4)
5D4EFGABGHIAB … (5)
Replacing the initial values in the equations number (3), (4)
and (5) to obtain the position of the end effector.
56&,($..&& ˰ 57,+$J,(. ˰ 58*+$####
B. Jacobian
The following mathematical calculation is the geometric
Jacobian matrix, shown the relate between the joint velocities
and the linear and angular velocity of the end effector respect
from the variable parameters by each joint, is represented by
the equations:
K:KLMKN> , “n” is the number of joints … (6)
KLOPL
#
Q
R
S , if it is a prismatic joint. … (7)
KLOPL3ATNTLB
PL S , if it is a rotary joint. … (8)
Using in (6) the equations (7) and (8) with the respective
parameters to calculate the geometric Jacobian, is described
by:
KOKU
KVS
W
X
X
X
X
Y
#
#
&
#
#
#
Z
[
[
[
[
\
K
W
X
X
X
X
Y
A4BAB
A4B4AB
#
#
#
&
Z
[
[
[
[
\
K
W
X
X
X
X
Y
A4BAB
A4B4AB
#
#
#
&
Z
[
[
[
[
\
K
W
X
X
X
X
Y
AB
AB
]4^4
#
Z
[
[
[
[
\
K
W
X
X
X
X
Y
AB
AB
AB
Z
[
[
[
[
\
The previous matrices conform to the geometric Jacobian.
_K:KKKKK>
Finally, the variable parameters in the Jacobian matrix are
replaced with the initial values to obtain the next matrix.
Where is shown the linear and angular velocities considering
the initial position to this study [19-31].
K
W
X
X
X
X
Y
# &#$.## &#$.## # #
# &'-$### &-$### # -#$###
& # # -#$### #
# # # & #
# # # # #
# & & # &
Z
[
[
[
[
\
The las t Jacobian matrix shows how the angular velocity
in the “Z axis” is related by the 2nd, 3rd and 5th joints. Also,
how the robot cannot apply angular velocity in the “Y axis” in
this configuration [32-39].
C. Matlab Simulation
The simulation of the robot is adapted from the application
of homogeneous matrices. Then, using the equations and
results obtained from the robot kinematics checking the
position represented by a product of vectors, according to the
respective translation and rotations, in this way a graphic
representation of the initial position is obtained from the
simulation in Fig. 11. that was previously defined for the
application of the Denavit Hartenberg algorithm. Finally, a
graph of the total workspace that the robot has is shown in
Fig. 12 [40-47].
Fig. 11. Matlab plot-3D Simulation
Fig. 12. Workspace Simulation
IV. RESULTS, CONCLUSIONS AND FURTHER WORK
The present work shows the design and kinematic analysis
of a robot that allows the welding of THT components and is
intended to support undergraduate students that so not have
experience in soft soldering. The robotic system structure
based on a cartesian and manipulator robot allows varying
angles of the end effector that resembles the position of the
hand with the soldering iron. Additionally, the temperature
range for a correct soldering is considered to allow the process
to be carried out with different components without damaging
them.
The design of the robot was made taking into account the
workspace that was initially proposed through the 5 DOF,
necessarily counting with a structure that supports the weight
of the manipulator along with the motors. For this reason, the
NEMA 23 HS7430 motor was chosen by its torque of 150
N.cm, Moreover, in the design of the transmission the size of
the pinion was reduced to almost half the dimensions of the
wheel that is connected with the drive shaft to the motor,
doubling the torque in the joints.
The simulation code was made in Matlab to verify the
solution of the Denavit-Hartenberg algorithm and the position
of the end effector, introducing the main parameters used in
the kinematic analysis, a graph is obtained showing the robot
links that coincide with the defined initial position.
The robotic system could be implemented for soldering
components of surface mount devices, as there is a tip
exchanger, a very fine tip T18-D08 to perform soldering in a
small space, flat tips D16, D24; and a temperature controller
circuit that would become a soldering station by adding a
control system for each type of components that work together
with a camera for solder path recognition and quality
inspection of SMD electronic components.
ACKNOWLEDGMENT
Thanks to the Robotics Engineering Department in the
Professional School of Mechatronics Engineering at
Universidad Ricardo Palma, Lima, Peru. Also, thanks for the
supervision to the Department of Physics and Engineering at
the Bioastronautics and Space Mechatronics Research Group
(https://sites.google.com/view/bio-sm).
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