Design And Simulation Studies Of 3-Axis Articulated Robotic Arm With PID Controller

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND SIMULATION STUDIES OF 3-AXIS

ARTICULATED ROBOTIC ARM WITH PID

CONTROLLER

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Robotics & Automation) with Honours

by

TONG CHEE KIET B051210052 920403-08-5267

DECLARATION

I hereby, declared this report entitled “Design and Simulation Studies of 3-Axis Articulated Robotic Arm with PID Controller” is the results of my own research except as cited in references.

Signature : ………..

Author’s Name : TONG CHEE KIET

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotics & Automation) (Hons.). The member of the supervisory is as follow:

i

ABSTRAK

ii

ABSTRACT

iii

DEDICATION

iv

ACKNOWLEDGEMENT

I would like to express my gratitude to Universiti Teknikal Malaysia Melaka, who provides me the opportunity to further my studies in order to earn Bachelor Degree. Same thanksgiving is applied to the Faculty of Manufacturing Engineering, for offering a study environment that filled with knowledge and core values.

Besides, I would like to thanks to my supervisor of final year project, En. Shariman bin Abdullah, for his guidance, wisdom and advice that helped me solve the uncertainties and difficulties, which I faced during the time of conducting final year project.

Furthermore, I’m grateful that my friends who had served as good companion for these years, that always expand their willingness to help and encourage to me during hard times.

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TABLE OF CONTENT

ABSTRAK i

ABSTRACT ii

DEDICATION iii

ACKNOWLEDMENT iv

TABLE OF CONTENTS v

LIST OF TABLES ix

LIST OF FIGURES x

LIST OF ABRREVAITIONS, SYSMBOLS AND NOMENCLATURES xiv

CHAPTER 1 INTRODUCTION

1.2 Problem Statement 2

1.3 Objectives 3

1.4 Scope 3

CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 4

2.2 Robot 5

2.2.1 History of Robot 5

2.2.2 Definition of Robot 6

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2.2.3.1 Cartesian Robot 7

2.2.3.2 Cylindrical Robot 8

2.2.3.3 Spherical Robot 9

2.2.3.4 SCARA Robot 9

2.2.4 Articulated Robot 10

2.2.5 Application of Robot 12

2.3 Simulation 13

2.3.1 Definition of Simulation 13

2.3.2 Co-simulation 14

2.3.3 3D Modeling Prior to Simulation 19

2.4 Modeling 25

2.4.1 Kinematic Modeling 26

2.4.2 Dynamic Modeling 27

2.5 Control 29

2.5.1 Background of Controller Applied on Articulated Robot 29

2.5.2 Open loop and closed loop system 30

2.5.3 Type of Controller 32

2.5.4 Composite Control Mode 34

2.5.5 Comparison of Type of Controller 36

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CHAPTER 3 METHODOLOGY

3.1 Introduction 38

3.2 Project Planning 38

3.3 Flow Chart of the Overall Project 40

3.4 Background Studies 42

3.5 Software used 42

3.5.1 SolidWorks 42

3.5.2 ADAMS 43

3.5.3 MATLAB Simulink 44

3.6 Modelling of Articulated Robot 46

3.6.1 Mechanical Design of Articulated Robot 48

3.7 Transfer Model into ADAMS 49

3.8 Configuration in ADAMS Prior to Simulation 49

3.8.1 Robot Simulation with and without Disturbance 51 3.9 Establishment of Inputs, Outputs and Plants in ADAMS 53

3.10 Mathematical Model of Articulated Robot 54

3.11 Mathematical Model of PID Controller 55

3.12 Controller Design based on PID Algorithm by MATLAB Simulink 56

3.13 Co-simulation of 3 Axis Articulated Robot 59

3.14 Tuning of Controller 62

3.15 Data Gathering from Co-simulation Result 63

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CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 66

4.2 Simulation Parameters 66

4.3 Simulation Result 67

4.3.1 Result obtained from co-simulation of articulated robotic arm

without disturbance 67

4.3.2 Result obtained from co-simulation of articulated robotic arm

with disturbance 74

4.4 Discussion 81

4.4.1 Comparison of Input Torque 82

4.4.2 Comparison of Joint Angle 85

4.4.3 Comparison of Tracking Error 88

4.5 Summary 92

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Introduction 93

5.2 Conclusion 93

5.3 Sustainability Development 94

5.4 Recommendations 95

REFERENCES 96

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LIST OF TABLES

Table 3.1: Mass properties of respective robot’s parts 50

Table 3.2: Relationship between idealized joint and robot’s part 51

Table 3.3: Relationship between ADAMS inputs/outputs with the actual

robot part 54

Table 3.4: Characteristic of different types of controller mode in PID 57

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LIST OF FIGURES

Figure 2.1: Cartesian Robot 8

Figure 2.2: Cylindrical Robot 8

Figure 2.3: Spherical Robot 9

Figure 2.4: SCARA robot 10

Figure 2.5: Articulated robot 11

Figure 2.6: Control structure chart of co-simulation 16

Figure 2.7: Control diagram for co-simulation by using RecurDyn and

MATLAB Simulink 17

Figure 2.8: Flowchart of co-simulation of rigid flexible coupling system 18

Figure 2.9: A. Created model in CATIA, B. real Staubli ©TX40 robot 20

Figure 2.10: Assembly Drawing of the spot welding robot 20

Figure 2.11: Mechanical model of tomato harvesting robot 21

Figure 2.12: Simulation model in CATIA 22

Figure 2.13: Model of water strider robot 22

Figure 2.14: Assembled CAD model of mobile surveillance robot 23

Figure 2.15: Differentially driven configuration 24

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Figure 2.17: Block diagram of Open-loop Control System 31

Figure 2.18: Closed-loop control system 31

Figure 2.19: Pose tracking control of the mobile robot by using PID controller 35

Figure 3.1: Gannt Chart of PSM 1 39

Figure 3.2: Gannt Chart of PSM 2 39

Figure 3.3: Flow chart of overall project 1 40

Figure 3.4: Flow chart of overall project 2 41

Figure 3.5: MATLAB Command Window 45

Figure 3.6: Flow chart of modeling of articulated robot 47

Figure 3.7: SolidWorks that is used to perform 3D modelling 47

Figure 3.8: Mechanical design of articulated robot 48

Figure 3.9: Transferring of model to ADAMS 49

Figure 3.10: Robot simulation without disturbance 52

Figure 3.11: Robot simulation with disturbance 52

Figure 3.12: Closed loop system between ADAMS and control system 53

Figure 3.13: Mathematical model of articulated robot 54

Figure 3.14: Procedure of construct the mathematical model of control 55

Figure 3.15: PID Control Scheme 58

Figure 3.16: Co-simulation process 60

Figure 3.17: Subsystems of Adams block 61

Figure 3.18: Control structure chart of co-simulation 61

Figure 3.19: The result obtained after the tuning procedure had been applied

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Figure 3.20: Result displayed on ADAMS postprocessor 64

Figure 3.21: Result displayed on MATALAB environment 65

Figure 4.1: Overall Input Torque vs Time 67

Figure 4.2: Input Torque 1 vs Time 68

Figure 4.3: Input Torque 2 vs Time 68

Figure 4.4: Input Torque 3 vs Time 69

Figure 4.5: Overall Joint Angles vs Time 70

Figure 4.6: Joint Angle 1 vs Time 70

Figure 4.7: Joint Angle 2 vs Time 71

Figure 4.8: Joint Angle 3 vs Time 71

Figure 4.9: Overall Tracking Error vs Time 72

Figure 4.10: Tracking Error 1 vs Time 73

Figure 4.11: Tracking Error 2 vs Time 73

Figure 4.12: Tracking Error 3 vs Time 74

Figure 4.13: Overall Input Torque vs Time 75

Figure 4.14: Input Torque 1 vs Time 75

Figure 4.15: Input Torque 2 vs Time 76

Figure 4.16: Input Torque 3 vs Time 76

Figure 4.17: Overall Joint Angles vs Time 77

Figure 4.18: Joint Angle 1 vs Time 77

Figure 4.19: Joint Angle 2 vs Time 78

Figure 4.20: Joint Angle 3 vs Time 78

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Figure 4.22: Tracking Error 1 vs Time 80

Figure 4.23: Tracking Error 2 vs Time 80

Figure 4.24: Tracking Error 3 vs Time 81

Figure 4.25: Comparison of input torque applied on robot joint 1 on two

different cases 83

Figure 4.26: Comparison of input torque applied on robot joint 2 on two

different cases 84

Figure 4.27: Comparison of input torque applied on robot joint 3 on two

different cases 85

Figure 4.28: Comparison of joint angle of robot joint 1 on two different cases 86

Figure 4.29: Comparison of joint angle of robot joint 2 on two different cases 87

Figure 4.30: Comparison of joint angle of robot joint 3 on two different cases 88

Figure 4.31: Comparison of tracking error of robot joint 1 on two different cases 89

Figure 4.32: Comparison of tracking error of robot joint 2 on two different cases 90

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LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURES

3D - 3 Dimensions

BC - Before Christ

AFC - Automatic Frequency Control

CNC - Computer Numeric Control

2D - 2 Dimensions

CAD - Computer-aided design

PID - Proportional–integral–derivative

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CHAPTER 1

INTRODUCTION

1.1 Background

Robot is widely used in various field of industry since it has been invented centuries ago. The word robot is originates from the screenplay “Rossum’s Universal Robots (R.U.R.), which is wrote by a Czechs, Karel Capek. It is translated from Czech word, Robota, which means the force labor that perform manufacturing task in Capek’s play (Angelo, 2007).

In 1956, Unimation acquired the first ever robotics patents and thus it was the first company that produced robot. It is followed by the participation of Europe companies in this sector, where ABB Robotics and KUKA Robotics, have developed robot for the commercial usage for the first time in 1973. As the times goes by, there are more companies that involved in the sector of producing robot, most notably Adept Technology, KUKA Robotics and Comau (Hashmi, 2014).

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to another, without hindrance or overcome the obstacle by any means. As a result, it is demanded highly in the manufacturing field such as assembly, welding and so on.

1.2 Problem Statement

Nowadays, articulated robot is broadly implemented in the industry, where it is employed to perform tasks which are previously conducted by human workers. In conventional design method, 3D modelling of the robot is carried out initially by using modelling software such as SolidWorks or Catia, along with the inclusion of kinematic modeling. Through this software, the appearance of the robot is presented in the physical form. Yet, there are certain limitation, where the dynamic and control aspect of the robot design procedure is beyond the capability of the 3D modeling software. In real life, most of the design process of the robot requires the fabrication of the actual prototype, follow by the experimental testing that performed on it in order to obtain the information regarding the dynamic and control feature of the robot. The actual prototyping consumes high cost and manpower resource, together with the highly chances to reproduce the prototype if there are occurrence of errors that caused it. Concern to the problem that is raised above, a numbered of researchers have implemented virtual prototyping of the robot which includes the simulation of the dynamic and the control model of the robot in the development stage of the robot.

In this study, there is a unique method of virtual prototyping which is known as co-simulation, was suggested to simplified and accelerate the design process of the 3-axis articulated robot.

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1.3 Objective

The objectives for the projects are:

 To design 3-axis articulated robotic arm using the co-simulation technique which utilizes the Adams and MATLAB Simulink software

 To analyze and evaluate the main parameter obtained from the co-simulation of 3-axis articulated robot arm such that the effectiveness of co-simulation technique can be justified.

1.4 Scope

The scope of this study is defined as:

 To design an articulated robot with 3 degree of freedom without specific end-effector

 Construct 3D modeling of the articulated robot with SolidWorks in condition where the fabrication of the model is excluded

 Conduct simulation of the articulated robot by using MSC ADAMS and Matlab Simulink

 Implement the control of the articulated robot with PID controller

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

In this chapter, there will be discussion and description of information that is related to the objectives of studies. The section includes the following elements such as the robot, simulation, modelling and control. In the robot section, history, definition, type and application of robot will be described. Issue regarding the theory of simulation, co-simulation and 3D modelling prior to simulation are going to be illustrated at simulation part. Kinematic modeling and dynamic modeling will be depicted under the subtopic of modelling. Lastly, the field of control is going to cover about the background of the controller implemented in articulated robot, type of controller and composite control mode.

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The background of the reading materials are about the co-virtual prototyping of the articulated robot. Elements obtained from the materials, provide hindsight and clearer understanding regarding the project which is going to be studying.

2.2 Robot

Robot is a programmable machine that is tasked to replace humans in order to perform duties which they are conducted. In this section, there is detailed explanation regarding the history of robot, definition of robot, types of robot and eventually the application of robot.

2.2.1 History of Robot

History of robot can be traced back to 1300 BC, where one of the first automated machines was built. In Theban necropolis of Egypt, two massive stones statues (known as Colossi of Memnon) had been made by Amenhotep, which could produce sounds by its own (Patel, 2011).

In 428 BC, Greek mathematician Archytas had invented a self-propelled flying mechanical bird, which was known as “The Pigeon”. The Pigeon was designed based on the structure of bird as well as the flying mechanism of bird (Haughton, 2009)

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different designs via three sets of cams home. The Musician was able to perform the instruments based on the melodies that are composed by Henri-Louis Jaquet-Droz (Kim, 2013)

In 1958, General Motors designed a robot for the application of heated die casting machines and welding. It was the first robot designed for this type of application. Three years later, it was installed on one of the Unimate factories and its usage was widely expended in multiple factories in 1968 (Faust, 2007). In the research of the simulation and experimental work of manipulator, KUKA KR 5 SIXX R650 robot was used as the subject for the studies. It is a six degree-of-freedom manipulator. The robot was tasked to perform movement in three different paths (Sulaiman et al., 2013). In the investigation of the tracking control of a robot arm, a two degree-of-freedom robot arm was modelling in the virtual environment and simulated (Luo et al., 2013).

2.2.2 Definition of Robot

The word of “robot” originates from the drama which was created by Karel Capek, a Czech playwright that direct the science fiction play titled “Rossunis Universal Robot” in 1921. In the drama, the robot was the slave worker that was made of artificial synthesized organic material which was similar to protoplasm. From the drama, the term “Robota” was introduced and subjected to the meaning of “slavery work”. “Robota” was translated into English, which is the term Robot that is known commonly today (Wilson et al., 2011)

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The British Association (BRA) defines a robot as a reprogrammable device to both manipulate and transport parts, tools, or specialized devices through variable programmed motions for the performance of specific manufacturing tasks (Kuttan, 2007).

2.2.3 Type of Robot

In the industry, robot is categorised into a few types based on the different types of arm geometry, power sources, applications, control techniques, and path control. It is due to the fact that robots are designed to perform required tasks in any particular situation. However, the types of robot that would be discussed below is the types of robot which is classified based on the arm geometry.

2.2.3.1 Cartesian Robot