Design of a 3D printed industrial robotic manipulator

Abstract

Industrial robotic manipulators are a whole family of industrial machinery whose purpose is to, accurately and precisely, position and orient tools called end-effectors from one location to another. These so-called end-effectors come in the form of grippers, welding torches, power tools and countless other devices that are designed to accomplish specific industrial operations. This project explores the possibility of designing an original industrial robotic manipulator and subsequently transforming the design into an operational prototype through the application of 3D printing technologies. The finished product was to replicate the performance observed in a real-life manipulator as accurately as possible, with all limitations considered. The methodology adopted was based on ‘The Basic Design Cycle’ of engineering design theory. During the problem analysis stage, the quantifiable, physical, safety and technological requirements were drawn up in a Product Design Specifications (PDS) chart. Once these requirements were formulated, the design process was branched into two sections, so that the solution could be developed in stages. In preparation of the design processes, the torques required at each joint were estimated through a static model analysis, which was based on the quantifiable requirements set in the PDS. The results obtained could then be used as a general guideline throughout the following design process sections. The first section involved the design, prototyping and optimization of the first joint prototype, which determined the fundamental elements of the entire robotic manipulator. The second section featured the incorporation of the optimized robotic joint design into the whole scheme of the project. Having defined the main elements in the first section, the second stage focussed more on the selection of concepts, configurations, and actuators. The assembly as well as the control system of the whole industrial robotic manipulator were designed based on the decisions made. Finally, once the complete prototype was produced and assembled, evaluation and testing were carried out as to define its performance. Strengths, limitations and possible improvements of both design and physical prototype were also specified.