Design And Analysis On Mechanical Structure Of Climbing Robot Leg

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ANALYSIS ON MECHANICAL

STRUCTURE OF CLIMBING ROBOT LEG

Thesis submitted in accordance with the partial requirements of the

Universiti Teknikal Malaysia Melaka for the

Bachelor of Manufacturing Engineering (Robotic And Automation) with

Honours

By

MUHAMMAD KHOIRUDIN BIN ZAKARIA

Faculty of Manufacturing Engineering

UTeM Library (Pind.1/2007)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PSM

JUDUL:

DESIGN AND ANALYSIS ON MECHANICAL STRUCTURE OF CLIMBING ROBOT LEG

SESI PENGAJIAN:

Semester 2 2007/2008

Saya Muhammad Khoirudin b. Zakaria mengaku membenarkan laporan PSM / tesis (Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan

penulis.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. *Sila tandakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS) Alamat Tetap:

LOT 1113, KG.BADANG, JALAN PANTAI CAHAYA BULAN,

15350 KOTA BHARU, KELANTAN DARUL NAIM

Tarikh: _______________________

(TANDATANGAN PENYELIA) Cop Rasmi:

Tarikh: _______________________

DECLARATION

I hereby, declare this thesis entitled “Design and Analysis on Mechanical Structure of Climbing Robot Leg” is the result of my own research

Except as cited in the references.

Signature :……….

Author’s Name : Muhammad Khoirudin B. Zakaria

APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering

(Robotic And Automation) with Honours. The members of the supervisory committee are as follow:

……… Main Supervisor

( En. Khairol Anuar B. Rakiman ) Faculty of Manufacturing Engineering

ABSTRAK

ABSTRACT

DEDICATION

ACKNOWLEDGEMENT

Alhamdulillah, I’m grateful that by the power of Allah, Most Gracious, Most Merciful and with much guidance also support my final year project is now completed. First of all,I would especially like to thank to my beloved family especially my parent , Mr Zakaria b. Mat yusof and Selamah Bt. Che Mat who recently was passed away for showing love, support and advice when in truly need.

I would like to express my greatest appreciations to my wise supervisor, Mr. Khairol Anuar b. Rakiman . This thesis would not have been possible without his guidance and resources, and I am grateful for the opportunity to learn so much from him. And equally essential was Mr Hasan B. Atan, who has volunteered countless hours and untold energies on my behalf. I would like to thank him for agreeing to help me in the simulation process in Solid Word drawing.

TABLE OF CONTENTS

1. INTRODUCTION

1.1.Problem Statements 1.2.Objectives 1.3.Scope 1 2 2 3

2. LITERATURE RIVIEWS

2.1 Introduction 2.2 Design Concept

2.2.1 The Hierarchical Design

2.1.2 3D Computer modeling

2.2 Properties of climbing robots 2.2.1 Robot Legs 2.2.2 Leg Design

2.2.3 Types Of Robot Leg 2.3 Friction Force

2.4 Sliding Frame 2.5 Wall climbing robots

2.5.1 Mobile climbing robots

2.5.2 Climbing robots on magnetic wheels 2.6 Climbing robot mechanism

2.6.1 Adhesion Mechanism 2.6.2 Dry Adhesion

2.6.3 Surface Changing Mobil Robot 2.7 Simplification of Robot-environment Modeling 2.8 Robot Kinematics

3. METHODOLOGY

3.1 Introduction 3.2 Design Process 3.2.1 Function

3.2.2 Design requirement 3.2.3 Evaluation criteria 3.3 Flow Chart

3.3.1 Flow Chart Process 3.4 Project understanding

3.5 Planning of study

3.6 Design Analysis

3.7 Testing And Simulation

3.8 A Generic Development Process

30 30 30 31 31 32 33 34 34 35 36 37

4. LEG DESIGN: PRELIMINARY DESIGN

4.1 Planning

4.2 Concept Development

4.2.1 Design Concept 4.2.2 Grading Criteria

4.2.2.1 Direct Material cost 4.2.2.2 Market available 4.2.2.3 Standard part

4.2.2.4 Manufacturing view 4.2.2.5 Material

4.2.3 Concept in design (Generating Idea) 4.3 Conceptual Design

4.4 Detail design

4.4.1 Material Selection 4.4.1.1 Aluminum 4.4.1.2 DC Motor

4.4.1.3 Screws 4.4.1.4 Bearing 4.4.1.5 Suction Cup

4.4.1.6 Acrylic. 4.4.2 Design with SolidWorks

4.4.3 Robot Weight estimation 4.5 Testing And Simulation

52 52 53 53 54 58 62

4. RESULTS AND DISCUSSION

5.1 Design

5.1.1 Full Assembly Design 5.2 Design Analysis

5.2.1 Analysis of robot kinematics and torque 5.2.2 Analysis of suction lifts force

5.2.3 Stress Analysis 5.3 Simulation 5.4 Discussion 64 64 66 66 68 71 77 83 5. CONCLUSION 6.1 Conclusion

6.2 Recommendation and Future Work

REFERENCES APPENDICES

84

85

LIST OF FIGURES

Figure 2.1: Leg Configuration.

Figure 2.2: Roverwax Wheeled Robots. Figure 2.3 : Titan iv Legged Robots

Figure 2.4: hybrid biped leg wheeled robot. Figure 2.5: lynx motion tracked robot.

Figure 2.6 : Vacuum rotor package to generate aerodynamic attraction Figure 2.7: Exploded view of the vacuum chamber with flexible bristle skirt seal.

Figure 2.8: The pressure force isolation rim is made of re-foam. Figure 2.9: Left: Robtank immersed in a water tank while inspecting the tank floor;Right: Robot climbing on a glass wall after transition from floor to wall.

Figure 2.10 Left: Solid drawing of RobTankRight: Vehicle climbing on curved wall (3 metre Diameter)

Figure 2.11: Transit gait of robot from ground to wall. Figure 2.12: World coordinate system

Figure 2.13: Foot tip trajectories

Figure 2.14: Rotation method of two virtual and limitation. Figure 2.15: Set of serial links connected by joints.

Figure 3.1: Flow Chart. Figure 4.1: Sketch robot 1. Figure 4.2: Sketch robot 2 Figure 4.3: Sketch robot 3.

Figure 4.4: This figure show the step by step in the design concept Where from a cube, it will transform to become object.

Figure 3.6: This figure show from step by step how the object Designed are transform and become a climbing robot. Figure 4.6: This figure show the finish of climbing robot sketching. Figure 4.7: Sketch for climbing robot design.

Figure 4.8: Sketch of view climbing robot design.

Figure 4.9: Sequence movement of climbing robot in side view A. Figure 4.10: Aluminum.

Figure 4.11: DC motor Figure 4.12: Screws Figure 4.13: Bearing. Figure 4.14: Suction Cup Figure 4.15: Acrylic

Figure 4.16: One of the parts of components is draw in parts file. Figure 4.17: Parts was mate in assembly files.

Figure 4.18 : The climbing robot assembly Figure 4.19: Robot leg parts

Figure 4.20: Suction cup assembly as foot Figure 4.21: Body parts.

Figure 4.22 : Bracket Figure 4.23: Dc Motor. Figure 4.24: Body joint. Figure 4.25: Robot shaft.

Figure 4.26: Body joint for suction cup.

Figure 5.1: The Overview design of climbing robot. Figure 5.2: The orthographic view of climbing robot. Figure 5.3: The climbing robot attaches the wall. Figure 5.4: Suction cups used for lift a flat sheet Figure 5.5: Load Location for shaft

Figure 5.6: Stress for shaft

Figure 5.7: Stress result table for shaft

Figure 5.8: Displacement for shaft

Figure 5.9: Displacement result table for shaft Figure 5.10: Design Check for FOS

Figure 5.11: Start simulation with choose the mechanism. Figure 5.12: Direction chooses with suitable parts. Figure 5.13: Simulation in calculate.

Figure 5.14: Simulation start to run. Figure 5.15: Simulation in progress.

Figure 5.16: Simulation still in progress and waiting to finish

LIST OF ABBREVIATIONS

DC PSM

- -

Direct current

CHAPTER 1

INTRODUCTION

Robotic systems are invariably formed of multiple bodies that interact with each other and with the environment in a variety of modes. Design and analysis of such systems are challenging for number reasons; these include the complexities of deriving models of motion resulting from the applied actuation, composing controllers to achieve the desired motions and forces, and, choosing the correct design parameters. Deriving motion models is especially difficult if effects of system dynamics are considered. The derivation of forces resulting from the body accelerations is complex, especially, when multiple bodies and multiple environmental contacts are involved. For these reasons dynamics is often ignored and quasi-static motions are implemented in robots.

what design choices critically affect the constraints and also what design changes are advantageous. In the design and analysis of climbing robot, there is a need for better understanding of the relation between the design choices and critical constraints. For example there is no unified approach for determining under what environmental conditions (eg. ground friction) a robot will walk reliably and what design choices can be made to improve the performance. Study of robot dynamics has been identified to be important and open problem.

1.1 PROBLEM STATEMENTS

customer is improved. Therefore a customer driven solution should be lightweight and modular.

1.2 OBJECTIVE / OUTCOME

The objectives of this project are the following:

a) To create and design a climbing robot leg.

b) To analysis the joint and link of climbing robot leg. c) To analyses mechanical designs of leg climbing robot.

1.3 SCOPE

The scopes of this study are:

a) To design a leg climbing robot.

CHAPTER 2

LITERATURE REVIEWS.

2.1 Introduction

A Literature review is a body of text that aims to review the critical points of current knowledge on a particular topic. Most often associated with science-oriented literature, such as a thesis, the literature review usually precedes a research proposal, methodology and results section. For this Thesis, the step how the climbing robot leg design and analyze is explained.

2.2 Design Concept

product designer combines art, science and commerce for tangible non-perishable items. This evolving role has been facilitated by digital tools that allow designers to communicate, visualize and analyze ideas in a way that would have taken greater manpower in the past. . As with most of the design fields the idea for the design of a product arises from a need and has a use. It follows certain method and can sometimes be attributed to more complex factors such as association and Telesis.

Aesthetics is considered important in Product Design but designers also deal with important aspects including technology, ergonomics, usability, human factors and material technology. The values and its accompanying aspects which product design is based on vary, both between different schools of thought and among practicing designers. [ Holm, Ivar.(2006)]

Product designers are equipped with the skills needed to bring products from conception to market. . They should also have the ability to manage design projects, and subcontract areas to other sectors of the design industry. Also used to describe a technically competent product designer or industrial designer is the term Industrial Design Engineer.

2.2.1 The Hierarchical Design

based on the observation that simple physically based rules can eliminate large sections of the design space to greatly simplify the search. The process consists of tests and filters various levels. The tests and filters exploit the physical nature of the system and the task.

At the first level, individual modules are considered. If a module can be removed early in the design process, it will eliminate a vast number of sub-assemblies and an even larger number of assemblies. Hence, filters at the early stages are very effective in reducing the size of the design space later in the process. At a second level a group of modules, or sub-assembly, can be considered. [Farritor, S.On. (2000)]

2.1.2 3D Computer modeling

In the past decade, the dominant mode of representing design has shifted dramatically from drawing, often created using a computer to 3D computer Models. These model represent designs as collection of 3D entities, each usually constructed from geometric primitives, such as cylinder blocks and holes. The advantages of 3D computer include:

a) The ability to easily visualize the three dimensional form of the design.

b) The ability to automatically compute physical properties such as mass and volume.

c) Efficiency arising from of one creation of one and only one canonical description of the design.

model of an entire product is known, depending of the industry setting, as a “digital mock up”, ”digital prototype” or “virtual prototype”. [Karl T. Ulrich. (2003)]

2.2 Properties of climbing robots

Climbing robots represent a specific kind of walking robots, which are useful while operating in environments unfriendly or harmful for a human. Moreover, climbing robots are specially designed for moving on sloping or vertical surfaces, as Well as on horizontal ones( e.g. ceilings). In such situations, the influences of gravitational forces become very important - the design of the legs should assure reliable fastening to the working surface. There are generally two ways so fastening the climbing robot to the surface:

a) Durable mechanical connection between the robot’s grippers (legs) and the environment, using pliers-like grippers; this is typical for robots climbing on constructions made of metal profiles (pipes, T-profiles, etc.)

b) making use of adhesive forces between the gripper’s surface and the working surface; the tightening force is produced by under pressure or — for robots climbing on surfaces made of ferromagnetic materials—electromagnetic grippers. [ P. Dutkiewicz, K. Kozłowski and W. Wroblewski ( 2004)]

2.2.1 Robot Legs

adhesive foot for the robot like suction cup or other type of adhesive. [Garth Zeglin. (2002)]

Dynamical stability can be defined that the system which allows something in the system to be stable like in the big place, to support the centre of mass of body to stabile without collapse. With this dynamic stability, dynamic gaits can stay in case stable to back up something burden with identify the steps to make sure his stability.

In general, in many design process those aspects should be taken into consideration, among its consideration as the loss stability, stability over end and attraction land to work face locomotion on uneven terrain. However, a designer can control the number of DOF that are retained and eliminated. There are three step to control DOF by changing types of articulation, joint and links likes introducing rigid connection, retaining one DOF by introducing a single lower-pair joint and retaining the full two DOF by introducing at least two lower-joint pairs. The increasing of DOF which consist chain must be control either actively by actuation, semi actively using springs and dampers or passively by adding some form of structural equilibration using hardware constraints.[Wallace,D (1994)]

2.2.2 Leg Design

In the designing process, the leg of a walking and wall-climbing robot must be designed to have the following capabilities:

a) Supporting the robot on ground.

b) Gripping the walls and ceilings not allowing the robot to fall down especial during climbing motion.

c) Performing maneuverability left or right.

d) Changing the posture of the robot while on transition movement.