UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Conceptual and Mechanical Design of Master-

Slave Robot for Painting Application

Thesis submitted in accordance with the partial requirements of the

Universiti Teknikal Malaysia Melaka for the

Bachelor of Manufacturing Engineering (Manufacturing Robotic and Automation)

By

Hairul Anuar bin Mohd Yusof

B050310006

Faculty of Manufacturing Engineering

April 2007

JUDUL: ________________________________________________________________

________________________________________________________________ ________________________________________________________________

SESI PENGAJIAN : _______________________ Saya ________________________________________________mengaku membenarkan tesis (Sarjana Muda/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan Syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk

tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara

institusi pengajian tinggi. **Sila tandakan (X)

BORANG PENGESAHAN STATUS TESIS*

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

i

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

(Manufacturing Robotic and Automation). The members of the supervisory committee

are as follow:

………………………………………….

Main Supervisor

En Mohd Samsi bin Saad

Faculty of Manufacturing Engineering

(Official Stamp & Date)

……………………………………………

Second Supervisor

En.

(Official Stamp & Date)

ii

DECLARATION

I hereby, declare this thesis entitled “Mechanical Design for master slave

(parent-child) robot for painting application” is the result of my own research

except as cited in the references.

Signature : ………………………………………….

Author’s Name : ………………………………………….

Date : ………………………………………….

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DEDICATION

For my beloved mother and father.

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ACKNOWLEDGEMENTS

The contributions of En Mohd Samsi bin Saad, of the UNIVERSITI TEKNIKAL

MALAYSIA MELAKA (UTeM) merits special acknowledgment for this excellent and

careful review of the entire text and project. En Mohd Samsi has inspected the structure

of every sentence and where necessary, has made modifications so that the project is

clear, direct, concise, and friendly. He has carefully modified the heading structure of

every sentence in order to make the text more easily readable and reorganized the

project section especially my part of this project so that the student can efficiently

survey what has be presented. En Samsi has worked under a number of constraints and

has done so in a friendly and timely manner.

Special recognition is again due to my friend, formerly of Robotic and Automation, for

them continuing contribution in the form of invaluable suggestions and accurate idea

and checking of this project. In addition to these individual, I wishes to thank the

members that who responded to a questionnaire concerning these project. Also thanks to

UTeM staff especially Manufacturing Department that given approval to this project.

Finally, I wish to state the extremely significant contribution of my family in addition to

providing patience and support for this project. I am extremely pleased to continue in

next semester to build the project successful. In the interest of providing in any with the

best possible educational materials over other semester, I encourage and welcome all

comments and suggestions.

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ABSTRACT

In 1920, robotic be found when Czechoslovakian playwright Karel Capek introduces the

word robot in the play R.U.R. - Rossum's Universal Robots. The word comes from the

Czech robota, which means tedious labor. In 1938, the first programmable paint-

spraying mechanism is designed by Americans Willard Pollard and Harold Roselund for

the DeVilbiss Company. In 1951, in France, Raymond Goertz designs the first tele-

operated articulated arm for the Atomic Energy Commission. The design is based

entirely on mechanical coupling between the master and slave arms (using steel cables

and pulleys). Derivatives of this design are still seen in places where handling of small

nuclear samples is required. This is generally regarded as the major milestone in force

feedback technology. The main function of a master slave arm for a painting application

is to paint some part that difficult to paint. Why robot arm are useful for painting is

because the painting itself can be hazardous for human. The design of the arm robot can

paint some other part by using arm robot and controlled by using master arm robot.

Every movement can be controlled by master arm robot. Effectiveness of the proposed

method is confirmed by experiments using a developed three-axis master-slave arm

system. In this project, it was specially focused and involves in Conceptual and

Mechanical design of Master Slave Robot for Painting Application that to design and

choose the best of arm robot that will be build for prototyped. The proposed arm master

system consists of a self-contained computing hardware with a potential motors at each

arm joints. The purpose of this master unit is to measure the angular position of the

joints of the user’s arm. These angular positions are transmitted, as voltages, to the

transducer interface. For Slave Robot, the mechanical arm can cover a range of human

arm movements. The complexity of the human arm makes any attempt to mimic.

vi

TABLE OF CONTENTS

Approval i

Declaration ii

Dedication iii

Acknowledgement iv

Abstract v

Table of Contents vi

List of Figures x

List of Tables

Sign and Symbols

List of Appendices

CHAPTER 1

1.0 INTRODUCTION 1

1.1 Background of Project 5

1.2 Problem Statements 6

1.3 Objectives of the Research 7

1.5 Scope and Limitation 8

CHAPTER 2

2.0 LITERATURES REVIEW 9

2.1 What a Robot 9

2.2 Types of Robots 10

2.3 Servo and Non-Servo 11

2.4 Type of Path Generated 12

2.5 Robot Component 13

vii

CHAPTER 3

3.0 METHODOLOGY 15

3.1 Design the robot 15

3.2 Robot Modules and Parameter 16

3.2.1 Forward Kinematics 16

3.2.2 Inverse Kinematics 17

3.2.3 Dynamic 18

3.3 Speed Considerations 19

3.3.1 Types of Inputs 19

3.3.2 Desired Frequency of the Control system 20

3.3.3 Error Analysis 20

3.4 Optimal Design of Robot Manipulator 21

3.5 Special Computer Architecture for Robotic 22

3.6.1 Design Issues 22

3.6.2 Master Slave Robot Manipulator 22

3.6.2.1 Analysis Stage 22

3.6.2.2 Controller Design 23

3.7 The Optimal Design 24

3.7.1 Constructing the Optimization Problem 24

3.7.1.1 Structural Length Index 25

3.7.1.2 Manipulability 25

3.7.1.3 Accuracy 25

3.7.2 The User Interface 26

3.7.3 Design Selections 28

3.7.3.1 Design 1 28

3.7.3.2 Design 2 29

3.7.3.3 Design 3 30

viii

CHAPTER 4

4.0 RESULT 31

4.1 Arm Robot 31

4.2 System Features 33

4.3 How It Works 34

4.3.1 Slave Arm 35

4.3.2 Master Arm 37

4.4 Servo Motor 38

4.5 Design Analysis 41

4.5.1 Slave Robot 41

4.5.1.1 Design Consideration 41

4.5.1.2 Design 1 41

4.5.1.2.1 Members 42

4.5.1.2.2 Paint Holder 44

4.5.1.2 Design 2 45

4.5.1.2.1 Members 46

4.5.1.2.1 Paint Holder 47

4.5.1.3 Design 3 48

4.6 Material Selection 51

4.7 Other Parts 52

CHAPTER 5

5.0 FINAL RESULT 53

5.1 Mechanical Design 55

5.1.1 Slave Robot 55

5.1.1.1 Base 57

5.1.1.2 Stand 1, 2 and Upper Stand 58

5.1.1.3 Stand 3 58

5.1.1.4 Arm Robot 59

5.1.2 Master Robot 61

ix

5.2 Process Analysis 63

5.2.1 Calculations 63

5.3 Discussion 68

5.3.1 Problem Occurs 68

5.3.2 Solution 69

5.3.3 Overall Process 70

5.4 Robotic Sprayer 71

5.5 Conclusions 72

5.6 Contribution 73

5.7 Others Applications 73

REFERENCES 74

APPENDICES 78

1. Gantt Chart 79

x

LIST OF FIGURES

CHAPTER 1

1.1 Conceptual figure of systems 2

1.2 The interaction between the members activity 4

CHAPTER 2

2.1 Robot Arm Design Configuration 11

2.2 Arm Robot 13

CHAPTER 3

3.1 Kinematics Analysis 17

3.2 Three different configurations of the robot manipulator 23

3.3 The optimal design cycle (interfaces) 26

3.4 Flow chart for mechanical design 27

3.5 Articulated Arm Robot 28

3.6 SCARA Robot 29

3.7 Arm Robot 30

CHAPTER 4

4.1 Master slave working flow 34

4.2 Slave Arm 35

4.3 Master Arm 37

4.4 Mapping the joints of a human hand 37

4.5 The Conceptual of Master Slave Robot 38

4.6 Design 1 42

4.6.1 Link member 1 43

4.6.2 Link member 2 43

4.6.3 Link member 3 43

xi

4.6.4 Paint holder 44

4.7 Design 2 45

4.7.1 Link member 1 46

4.7.2 Link member 2 46

4.7.3 Link member 3 47

4.7.4 Paint holder 47

4.8 Design 3 48

4.8.1 Cross section of middle part of arm member 49

4.8.2 Cross section of end part of arm member 49

4.8.3 Back View Of Arm Member 1 49

CHAPTER 5

5.1 Final design

5.1.1 The Final Design 53

5.1.2 The Final Design In Different View 54

5.1.3 The Conceptual Design 55

5.1.4 The Different View Of Design Of Base Arm Robot 55

5.2 Mechanical design for base arm robot 56

5.3 The dimension of base 57

5.4 The dimension of stand upper stands, and stands 2 58

5.5 The dimension of support the base 58

5.6 The arm robot 59

5.7 First arm robot 59

5.8 Second arm robot 60

5.9 Types of servo motor 60

5.10 The different view prototypes of master robot 61

5.11 Limit switch placed in master Robot 62

5.12 The Dimension Of Master Robot 62

5.13 Problem in Servo Motor 68

xii

LIST OF TABLES

CHAPTER 1

1.1 The different between Master and Slave Arm Robot 8

CHAPTER 4

4.1 System feature in Master Salve Arm Robot 33

4.2 Types of Material Selection 51

4.3 Types of Aluminum 51

4.4 Cost for Other Part 52

xiii

LIST OF APPENDICES

1.1 Gant chart

1

CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

In the master-slave control, the slave robot (teleoperator) exactly replicates the

movements of the master robot. Master slave robot is technology for tele-operation using

master-slave robot systems in the field of medical, welfare, extreme-environment, space-

environment and virtual reality. Many sophisticated master-slave robot systems have

been proposed. Some of them are already commercialized. For example, PHANT oM by

SensAble Technologies is a device for measuring six degrees of freedom motion of an

arm and, at the same time, giving a force feedback of three axes, which is usually used

for the input devise for virtual reality and for the master robot for the telerobotics. Da

Vinci by Intuitive Surgical is a surgical master-slave robot system having two fingers on

two arms and can realize highly dexterous manipulation.

History of master robot stated at 1920, when Czechoslovakian playwright Karel Capek

introduces the word robot in the play R.U.R. - Rossum's Universal Robots. The word

comes from the Czech robota, which means tedious labor. In 1938, the first

programmable paint-spraying mechanism is designed by Americans Willard Pollard and

Harold Roselund for the DeVilbiss Company. In 1942, Isaac Asimov publishes

Runaround, in which he defines the Three Laws of Robotics. Master slave robot has

been stated in 1951 in France, Raymond Goertz designs the first teleoperated articulated

arm for the Atomic Energy Commission. The design is based entirely on mechanical

2

coupling between the master and slave arms (using steel cables and pulleys).

Derivatives of this design are still seen in places where handling of small nuclear

samples is required. This is generally regarded as the major milestone in force feedback

technology. Although the system has advantage to have simple mechanism and

controller, it has disadvantage not to have force feedback needed for dexterous

manipulation. The latter is to apply a force feedback control electrically.

Conceptual figure of the bilateral system is shown in Fig. 1.1(a). Although the

mechanism and controller become complicated, dexterous manipulation can be

conducted using the bilateral one. Conceptual figure of proposed methodology is shown

in Fig. 1.1(b). Large and stable stationary limiting torque can be applied by use of the

ultrasonic motor because it is a frictionally driven motor and need no electric power to

keep it stationary. So the ultrasonic motor is suitable for the switching element because

it can make the master arm stationary when the slave arm is in contact with an object.

Mechanical clutch is also suitable for the switching element. The force feedback to the

operator is applied mechanically as an elastic force of the elastic elements instead of

electrical feedback control. This method also utilizes a feature of human factor that is

displacement information from visual feedback is superior to that from one’s sensation.

Lightweight and well-controlled master-slave robot can be supplied using the proposed

method.

Figure 1.1: Conceptual figures of systems

3

In designing and building a robot manipulator, many tasks are required, starting with

specifying the tasks and performance requirements, determining the robot configuration

and parameters that are most suitable for the required tasks, ordering the parts and

assembling the robot, developing the necessary software and hardware components

(controller, simulator, monitor), and finally, testing the robot and measuring its

performance.

Our goal is to build a framework for optimal and flexible design of robot manipulators

with software and hardware systems and modules which are independent of the design

parameters and which can be used for different configurations and varying parameters.

This environment is composed of several subsystems. Some of these subsystems are:

Design.

Simulation.

Control.

Monitoring.

Hardware selection.

CAD/CAM modeling.

Physical assembly and testing.

For conceptual and mechanical design are more focused in designing the CAD/CAM

model for the robot using Solid Work or AutoCAD, analysis stage, selection of motor,

torque of motor, forces of arm robot, particularly, in making the decision of using

hardware vs. software solutions, manufacturing and assembly of the robot and selecting

the required components for the robot. These reports are also take part in the design and

analysis of the prototyping environment with the required communication protocols and

database analysis. Some part of this project was involved in selecting the electrical and

electronic components and helping out in the overall design and testing procedures for

the robot manipulator. For another part was involved in the Motion Card that mean the

card is to control the movement and measure the voltage from robotic from analog to

digital.

4

Figure 1.2: The interaction involved in the prototyping activity.

In figure 1.2 shows that how to make 3 link robot arm and for this task are more focus in

CAD model, design and build prototyping environment. In CAD model, there is several

type of model that used CAD software like AutoCAD. In this task, AutoCAD are

commonly used in design. For design part, there is several design that been selecting

depend on several factor that make good design. Then from design, it will make

prototyped to see this design are suitable in any criteria.

5

1.1 Background of Project

The main purpose of this project master slave robot is to communicate between master

and slave robot. The main objective is when master robot gives some movement and

slave robot follows the movement. The other function of a master slave arm is a painting

application is to paint some part that difficult to paint. For this project, we design that we

can paint some other part by using arm robot and controlled by using master arm robot.

Purpose of this master slave robot is to remove human from hazardous like painting. The

material in painting is hazardous to human health. So this master slave robot is more

useful when work that are harmful to human well being. Human can use master robot to

conduct the slave robot to follow what are being commands. For this prototype, there are

using 3 axis movements because depend on calculate the cost, stability, knowledge and

design we take to make this project complete. Mostly, the painting application has large

proportion in automotive painting works in automation industry, robotic painting

application widely used to painting the mostly products like car. The development of

master slave painting robot is regarded as a highly developed production technology

which requires a concentration of potentials of global technologies such as CAD/CAM,

robots, electronic and electrical, mechanical and IT.

Typically in paint shops, robots wield paint spray guns. The guns throw out a lot of paint

at high volumes. Bells are usually fitted on the top and side of the booth. The paint bells

provide a better surface quality. Everything required for a paint system. The main

application of robots in the commercial sector has been concerned with the substitution

of manual human labor by robots or mechanized systems to make the work more time

efficient, accurate, uniform and less costly. One may argue the social implications of

such developments. Increased demand on growers has begun to be met with increased

specific automation in many fields, as producers believe that automation is a viable and

sometimes necessary method to ensure maximum products with minimum costs.

6

1.2 Problem Statement

The first main idea of this project is from first robot having been built. Although master

slave robot are long been used in manufacturing, not many people know the function of

master slave robot itself. Then we apply the master slave robot function to develop this

idea in painting application. Mostly, there are a lot of methods that have been used by

industry in painting application. There are using arm robot that only programmable in

computer and then the robot follow the programmable of the movement in program. By

using arm robot mater slave painting, we can painting the part that we need that can’t be

done by programming.

Despite the problem above, there is one more and the most important point that had been

in the painting field. There are being dangerous when people using paint sprayer to paint

something. The gas that produced in paint have chemical that can make human sick or

die. So some safety equipment is human used mask when painting. Other method is used

robot like master slave robot. It’s more safety for human because human can painting

outside the part that can be painting and remove from paint itself.

7

1.3 Objectives

The objective of this research project is to explore the basis for a consistent software and

hardware environment, and a flexible framework that enables easy and fast

modifications, and optimal design of robot manipulator parameters, with online control,

monitoring, and simulation for the chosen manipulator parameters. This environment

should provide a mechanism to define design objects that describe aspects of design, and

the relations between those objects.

For this project, we separate painting application and arm robot. We more focus on

about arm robot first and for the painting application, we take some different

programmable control. Another goal is to build a prototype of painting system arm robot

that is part of our project. In other part, we analyze the system of circuit and

programmable that painting need. This will help determine the required subsystems and

interfaces to build the prototyping environment, and will give us hands-on experience

for the real problems and difficulties that we would like to address and solve using this

environment.

The importance of this project arises from several points:

This framework will facilitate and speed the design process of robots.

The prototype robot will be used as an educational tool in the robotics and

automatic control classes.

This project will establish a basis and framework for design automation of robot

manipulators.

8

Table 1.1: The different between Master and Slave Arm Robot

Master Slave

- Request to move robot

- Request to stop robot

- Request to send current robot position

- Measure the movement of the mouse

- Complicated Computation with Parallax Basic

Stamp

- Control robot to move to desired position

- Control robot to stand still

- Measure robot’s current configuration

- Measure robot’s joint velocities

- Measure forces and torques at the end effected

1.4 Scope and limitation

Developing structure analysis for the conceptual design of the master slave robot

arm for painting application.

Developing the requirement for the structure due to the completion of the

prototype.

Research for the methodology used to define equilibrium of the structure in static

and dynamic.

9

CHAPTER 2

LITERATURE REVIEW

2.1 What are robots?

A robot is an electro-mechanical device that can perform autonomous or preprogrammed

tasks. A robot may act under the direct control of a human (e.g. the robotic arm of the

space shuttle) or autonomously under the control of a programmed computer. Robots

may be used to perform tasks that are too dangerous or difficult for humans to

implement directly (e.g. nuclear waste clean up) or may be used to automate repetitive

tasks that can be performed with more precision by a robot than by the employment of a

human (e.g. automobile production.)

The word robot is used to refer to a wide range of machines, the common feature of

which is that they are all capable of movement and can be used to perform physical

tasks. Robots take on many different forms, ranging from humanoid, which mimic the

human form and way of moving, to industrial, whose appearance is dictated by the

function they are to perform. Robots can be grouped generally as mobile robots (e.g.

autonomous vehicles), manipulator robots (e.g. industrial robots) and self reconfigurable

robots, which can conform themselves to the task at hand.

Robots may be controlled directly by a human, such as remotely-controlled bomb-

disposal robots, robotic arms, or shuttles, or may act according to their own decision

making ability, provided by artificial intelligence. However, the majority of robots fall

in-between these extremes, being controlled by pre-programmed computers. Such robots