PREFACE It is humans phenomenon that he wants innovate something in his mind & apply his ideas practically.

With the same ideology we have also tried our best to apply knowledge about Mechanical Engineering, since last two years we have learned from our lectures, we have tried to cover all those points to be exposed through our project. Though there may many projects that may be made as major, but our intention to take the Multidiode Robotic Welding Arm in our project is only that it covers all the ideas concepts about both practical & theoretical knowledge. There are may be certain mistakes in this project report, may be recording the details which should be neglected on account of fact that maximum care precautionary measures wherever possible had been taken. We hope you all readers will appreciate our effort & any comment on our project is heartily welcomed, & we will be very thankful to them.

CONTENTS:
1. CHAPTER 1 1.1 Introduction 1.2 Purpose of selection of project
2. CHAPTER 2

PAGE NO.
8-10

11-19

2.1 What is Robot? 2.2 What is Welding? 2.2.2 Types of welding. 2.3 Arc welding. 2.4 Spot welding. 2.4.1 Spot welding guns 2.5 power sources. 3. CHAPTER 3 3.1 Types of welding robot 3.1.1 Specification of welding robot 3.2 Spherical robot 3.3 Material selection 4. CHAPTER 4 4.1 Welding torch 4.2 Electric Welding Accessories 4.2.1 Electrode Holders 4.2.2 Earthing Clamps 4.3 Synchronous Electric Motor 4.3.1 Stepper Motor 4.3.2 Advantages 5. CHAPTER 5 5.1 5.2 5.3 5.4 5.5 5.6 What is Degree of Freedom? Robot workspace Force calculations Forward Kinematics Inverse kinematics kinematics equation for robot motion 5.6.1 Motion calculation of two joint 33-43 26-32 20-25

6. CHAPTER 6 6.1 Screw Jack System 6.2 Electrode 6.2.1 Welding Electrode 6.2.2 Uses of electrodes 6.3 Gear system 6.3.1 Advantages & Disadvantages of Gear 6.3.2 Gear ratio 6.3.3 Spur gear 7. CHAPTER 7 7.1 Specifications of Parts 7.1.1 Base 7.1.2 Gear 7.1.3 Synchronous Motor 7.1.4 Lower arm 7.1.5 Upper arm 7.1.6 Screw jack 7.2 Step of construction 8. CHAPTER 8 8.1 Design and Construction of the Robotic Welding Parts

44-49

49-55

56-66

9. CHAPTER 9 9.1 Conclusion 9.2 Bibliography

67-69

CHAPTER 1
1.1 1.2 Introduction Purpose of selection of project

Introduction:The Robot has given a powerful automation tool to industries. Robots are very popular elements of todays industry. A single Robot with an industrial life time of 15 years can perform a wide range of applications from material handling, to finishing, to packaging, painting, welding, inspection, the list goes on and on. They do not require common safety and comfort working condition unlike humans. To make a robot function properly, much effort and many resources are requiring. Most companies that made robots in the mid- 1980s no longer exists and only company that made industrial robot remain in the market, such as Adept Robotics, Staubli Robotics and Fanuc Robotics. Robot flexibility comes at a price, and who has learn new programming language or the money to hire experiences contractors every time there is a product change over? Robots are programmable machines with some human like capabilities. They are made of mechanical parts, a control system and computers. They are available in wide variety of types, performing variety of tasks. It depends upon many parameters like mechanical configuration, degree of freedom, type of drive, types of sensors and control system, degree of intelligence, etc. robot are controlled by variety of hardware and software system.

Purpose of selection of project:

These days the ancient welding techniques are more prompt to accident and unable to execute the desired quality of weld. So our concept is step beyond mechanization in which human operators are replaced by machines to execute the job. We are trying to create the technological improvement with the application of mechanical and electronic based system to operate and control the process. Our motive is to create automatic operation and the control of process by devices such as robots that can do the work as per specification. And the following objectives can be achieved:

Time Reduction Safety High accuracy

Minimum rejection

Minimum labor Minimum cost

CHAPTER 2
2.1 What is Robot? 2.2 What is Welding? 2.2.2 Types of welding. 2.3 Arc welding. 2.4 Spot welding. 2.4.1 Spot welding guns 2.5 power sources.

ROBOT:
The robotic industries association defines a robot as a manipulator design to move particles, parts, tools, or specialized devices, through variable programmed motions for the performance of a variety of tasks. With this definition, attention here is focused on industrial manipulators arms, typically mounted on a fix pedestal base. Mobile robots and hard automation (CNC Machines) are excluded. The emphasize here is on serial chain manipulator arms, which consists of a serial chain of linkages, where each link is connected to exactly two other links, with the exception of the first and the last, which are connected to only one other link. Additionally, the first three links, called the major linkages, are focused on, with only a brief mention of the last three links, or wrist joints, also called the minor linkages.

Welding:
Welding is a fabrication or structure process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld puddle) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.

This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the work pieces to form a bond between them, without melting the work pieces.

Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, underwater and in outer space. Regardless of location, however, welding remains dangerous, and precautions must be taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light. Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used for centuries to join metals by heating and pounding them. Arc welding and oxyfuel welding were among the first processes to develop late in the century, and resistance welding followed soon after. Welding technology advanced quickly during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods.

Types of Welding:
There are several types of welding process has been used for welding. Types of welding are given below:
1. 2. 3. 4.

Forge welding Oxy-acetylene welding Resistance welding Arc welding: There are some types of ARC welding given below:
a. b. c. d. e.

Shielded metal arc welding Gas metal arc welding Submerged arc welding Flux-cored arc welding Electro slag welding

5. Laser beam welding 6. Electron beam welding 7. Robot welding

Arc Welding:
Arc welding is a method for joining two metal parts through melting themselves or welding wire between them, using the heat generated from an arc of high electricity between the parts and the tip of welding torch. The process may or may not require the use of filler metal. The welding arc is struck between the work piece and the tip of an electrode. The electrode will either be a consumable wire or a nonconsumable carbon or tungsten rod which carries the welding current. When a nonconsumable electrode is used, filler metal can be supplied by a spare rod or wire if needed. A consumable electrode, however, will be designed not only to conduct the current that sustains the arc but also to melt and supply filler metal to the joint. Arc welding uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct( D.C) or alternating (A.C) currents and consumable or non consumable electrodes. The melting region is sometimes protected by some type of inert gas, known as shielding gas, and evaporating filler material. The process of arc wielding because of its low capital and running costs.

Basic Welding Circuit:

An AC or DC power source is connected by a work cable to the work piece and by a "hot" cable to an electrode holder of some type, which makes an electrical contact with the welding electrode. An arc is created across the gap when the energized circuit and the electrode tip touches the work piece and is withdrawn, yet still with in close contact. The arc produces a temperature of about 6500F at the tip. This heat melts both the base metal and the electrode, producing a pool of molten metal sometimes called a "crater." The crater solidifies behind the electrode as it is moved along the joint.

F Figure1.1: welding circuit

Robotic Arc Welding:

Robot welding means welding that is perform and control by robotic equipment. In general equipment for automatic arc welding is designed differently for that used for manual arc welding. Automatic arc welding normally involves high duty cycles and the welding equipment must be able to operate under those conditions. In addition, equipment components must have the necessary features and control to interface with the main control system.

A special kind of electric power is require to make an arc weld. The special power is provided by a welding machine, also known as power source. All arc welding processes use an arc wielding gun or torch to transmit welding current from a welding cable to a electrode. They also provide for shielding the weld area from the atmosphere. Welding fixtures and work piece manipulators hold and positions parts to ensure precise welding by the robot. The productivity of robot welding cell is speeded up by having an automatically rotating or switching fixture, so that the operator can be fixing one set of parts while the robot is made another.

To be able to guarantee that the electrode tip and the tool frame are accurately known with respect to each other, the calibration process of the TCP (Tool Center Point) is important. An automatic TCP calibration device facilitates this time consuming task.

Spot welding
Spot welding is one of the oldest welding processes. It is used in a wide range of industries but notably for the assembly of sheet steel vehicle bodies. This is a type of resistance welding where the spot welds are made at regular intervals on overlapping sheets of metal. Spot welding is primarily used for joining parts that are normally up to 3 mm in thickness. Thickness of the parts to be welded should be equal or the ratio of thickness should be less than 3:1. The strength of the joint depends on the number and size of the welds. Spot-weld diameters range from 3 mm to 12.5 mm.

Figure 3: spot welding

How spot welding works:

Spot welding is one form of resistance welding, which is a method of welding two or more metal sheets together without using any filler material by applying pressure and heat to the area to be welded. The process is used for joining sheet materials and uses shaped copper alloy electrodes to apply pressure and convey the electrical current through the work pieces. In all forms of resistance welding, the parts are locally heated. The material between the electrodes yields and is squeezed together. It then melts, destroying the interface between the parts. The current is switched off and the "nugget" of molten materials solidifies forming the joint. To create heat, copper electrodes pass an electric current through the work pieces. The heat generated depends on the electrical resistance and thermal conductivity of the metal, and the time that the current is applied. The heat generated is expressed by the equation: E=I2*R*t Where E is the heat energy, I is the current, R is the electrical resistance and t is the time that the current is applied. Figure 3.1: spot weld

Copper is used for electrodes because it has a low resistance and high thermal conductivity compared to most metals. This ensures that the heat is generated in the work pieces instead of the electrodes.

Materials suitable for spot welding:

Steel has a higher electrical resistivity and lower thermal conductivity than the copper electrodes, making welding relatively easy. Low carbon steel is most suitable for spot welding. Higher carbon content or alloy steel tends to form hard welds that are brittle and could crack. Aluminium has an electrical resistivity and thermal conductivity that is closer to that of copper. However, aluminium's melting point is much lower than that of copper, making welding possible. Higher levels of current must be used for welding aluminium because of its low resistivity. Galvanized steel (i.e. steel coated with zinc to prevent corrosion) requires a different welding approach than uncoated steel. The zinc coating must first be melted off before the steel is joined. Zinc has a low melting point, so a pulse of current before welding will accomplish this. During the weld, the zinc can combine with the steel and lower its resistivity. Therefore, higher levels of current are required to weld galvanized steel.

Spot welding guns:

Spot welding guns are normally designed to fit the assembly. Many basic types of guns are available, the two most commonly used being the direct acting type, generally known as a "C"-type gun, where the operating cylinder is connected directly to the moving electrode, and the "X"-type (also known as "Scissors" or "Pinch") where the operating cylinder is remote from the moving electrode, the force being applied to it by means of a lever arm. C guns are generally the cheapest and the most commonly used. There are many variations available in each basic type with regard to the shape and style of the frame and arms, and also the duty for which the gun is designed with reference to welding pressure and current.

Figure 4: spot gun

Pneumatic guns are usually preferred because they are faster, and they apply a uniform electrode force. Hydraulic spot welding guns are normally used where space is limited or where high electrode forces are required

Figure 4.1: Types of spot guns

Welding Power Sources:

A welding power source must deliver controllable current at a voltage according to the requirements of the welding process. Normally, the power required is from 10 to 35V & from 5 to 500A. The various processes and procedures have specific arc characteristics that demand specific outputs of the welding machine. Automatic arc welding machines may require power sources more complex than those for semi-automated welding. An automatic welding machine usually electronically communicates with the power source to control the welding power program for optimum performance. A power source for arc welding is designed to provide electric power of the proper values and characteristics to maintain a stable arc suitable for welding.

There are three types of arc welding power sources, distinguished according to their characteristics output curve. The constant- power (CP) is the conventional type of power source that has been used for many years for shielded metal arc welding using stick electrodes. It can be used for sub merged and gas tungsten arc welding. The constant-voltage (CV) power source is the type normally used for gas metal arc and flux cored arc welding using small dia electrode wire. The constant-current(CC) power source is normally used for gas tungsten arc and plasma arc welding.

The selection of a welding power is based on:

The processes to be used. The amounts of current require. The power available at the job site. Economic factors and convenience.

CHAPTER 3
3.1 3.2 3.3 Types of welding robot 3.1.1 Specification of welding robot Spherical robot Material selection

Types of Welding Robot:

The hands and arms of early robots were pneumatically powered (air pressure) or hydraulically powered (fluid pressure). Flexible tubes carried the pressurized substances to the joints. Now, electrical motors located at the joint give the robot greater precision and control, but slow down its movements. Most robots are equipped with one hand and one arm of several articulated joints. Some of these joints swivel in smooth arcs mimicking the behavior of the human shoulder, wrist, and elbow. Other robots move in straight lines similar to a crane. Robots are grouped into classes according to the combination of joints used in their construction. There are five types of robot arms that are used today. Degrees of freedom are the axes around which it is free to move. The area a robot arm can reach is its work envelope. Rectangular arms are sometimes called "Cartesian" because the arms axes can be described by using the X, Y, and Z coordinate system. It is claimed that the Cartesian design will produce the most accurate movements.

A cylindrical arm also has three degrees of freedom, but it moves linearly only along the Y and Z axes. Its third degree of freedom is the rotation at its base around the two axes. The work envelope is in the shape of a cylinder.

The spherical arm, also known as polar coordinate robot arm, has one sliding motion and two rotational, around the vertical post and around a shoulder joint. The spherical arm's work envelope is a partial sphere which has various length radii.

The SCARA (Selection Compliance Assembly Robot Arm) is also known as a horizontal articulated arm robot. Some SCARA robots rotate about all three axes, and some have sliding motion along one axis in combination with rotation about another. The last and most used design is the jointed-arm., also known as an articulated robot arm. The arm has a trunk, shoulder, upper arm, forearm, and wrist. All joints in the arm can rotate, creating six degrees of freedom. Three are the X, Y, and Z axes. The other three are pitch, yaw, and roll. Pitch is when you move your wrist up and down. Yaw is when you move your hand left and right. Rotate your entire forearm, this motion is called roll.

Spherical Robot:
The SPHERICAL arm, also known as polar coordinate robot arm, has one sliding motion and two rotational, around the vertical post and around the shoulder joint. The spherical arms work envelope is a partial sphere which has various length radii.

Configuration:
Configuration is a fundamental classification for industrial robots. Configuration refers to the geometry of the robot manipulator, i.e., the manner in which the links of the manipulator are connected at each joint.

. The spherical configuration consists of two revolute joints and one linear joint as shown in fig. 1. This results in a set of joint coordinates that matches with the spherical Coordinate system.

Spherical robots are typically heavy duty robots. They have the advantages of high speed due to the rotary base, and a large work volume, but are more kinematically complex than either Cartesian or cylindrical robots. Generally, they are used for heavy duty tasks in, for example, automobile manufacturing. They do not have the dexterity to reach around obstacles in the workspace. Spherical robots also do not have fixed resolution throughout the workspace.

Materials Selection:
Mild steel is a poor material for gears as it has poor resistance to surface loading. The carbon content for unhardened gears is generally 0.4 %( min) with 0.55 % ( min) carbon for the pinions. Dissimilar materials should be used for the meshing gears - this particularly applies to alloy steels. Alloy steels have superior fatigue properties compared to carbon steels for comparable strengths. For extremely high gear loading case hardened steels are used the surface hardening method employed should be such to provide sufficient case depth for the final grinding process used.

Notes applications Ferrous metals Low Cost easy to machine with Large moderate power, commercial Cast Iron high damping gears Power gears with medium rating to Cast Steels Low cost, reasonable strength commercial quality Good machining, can be heat Power gears with medium rating to Plain-Carbon Steels treated commercial/medium quality Heat Treatable to provide Highest power requirement. For Alloy Steels highest strength and durability precision and high precisiont Corrosion resistance with low Stainless Steels Good corrosion resistance. Nonpower ratings. Up to precision (Aust) magnetic quality Stainless Steels Hardenable, Reasonable Low to medium power ratings Up (Mart) corrosion resistance, magnetic to high precision levels of quality

Material

Non-Ferrous metals

Aluminium alloys
Brass alloys Bronze alloys Magnesium alloys Nickel alloys Titanium alloys Di-cast alloys Sintered powder alloys Acetal (Delrin Phenolic laminates Nylons PTFE

Light weight, non-corrosive Light duty instrument gears and good machinability up to high precision quality
Low cost, non-corrosive, low cost commercial quality gears. excellent machinability Quality up to medium precision Excellent machinability, low For use with steel power gears. friction and good compatibility Quality up to high precision with steel Light weight with poor Light weight low load gears. corrosion resistance Quality up to medium precision Low coefficient of thermal Special gears for thermal expansion. Poor machinability applications to commercial quality High strength, for low weight, Special light weight high strength good corrosion resistance gears to medium precision Low cost with low precision and High production, low quality gears strength to commercial quality Low cost, low quality, moderate High production, low quality to strength moderate commercial quality Non metals Wear resistant, low water Long life , low load bearings to absorption commercial quality Low cost, low quality, moderate High production, low quality to strength moderate commercial quality No lubrication, no lubricant, Long life at low loads to absorbs water commercial quality Special low friction gears to Low friction and no lubrication commercial quality

CHAPTER 4
4.1 4.2 4.3 Welding torch Electric Welding Accessories 4.2.1 Electrode Holders 4.2.2 Earthing Clamps Synchronous Electric Motor 4.3.1 Stepper Motor 4.3.2 Advantages

Welding torch:
A welding torch is used in an automatic welding system to direct the welding electrode into the arc, to conduct welding power to the electrode, and to provide shielding of the arc area. There are many types of welding torches, and the choice depends on the welding process, the welding process variation, welding current, electrode size and shielding medium. Welding torches can be categorized according to the way in which they are cooled. They may be water-cooled with circulating cooling water or air-cooled with ambient air. A torch can be used for a consumable electrode welding process such as gas metal arc or flux cored arc welding, and shielding gas may or may not be employed.

A torch can be described according to whether it is a straight torch or has a bend in its barrel. A torch with a bend is often used for robotic arc welding applications to provide access for the weld. The major function of the torch is to deliver the welding current to the electrode. For consumable electrode process this means transferring the current to the electrode as the electrode moves through the torch. A second major task of the torch is to deliver the shielding gas, if one is used, to the arc area. Gas metal arc welding uses a shielding gas that may be an active gas usually carbon dioxide or a mixture of an inert gas, normally argon, with CO2 or oxygen. The welding torch is mounted to the robot flange with a matching mounting arm. Preferably an anti collision clutch is used to prevent damages on expensive weld equipment in case of sticking electrode and crashes during installation and start-up.

Electric Welding Accessories:

Impeccably designed to perfection, our premium quality electric welding accessories have carved a niche in domestic and overseas markets within a short span of time. These electric welding accessories are made using cutting edge technology in compliance with rigorous industrial standards. Use of high standard metal & other materials provide these accessories optimum durability. Easy to use, our electric welding accessories are known for their hassle free long life service.

Electrode Holders:
Our insulated electrode holders are made from finest raw materials to give superior performance and extended service life.

Features of Electrode Holders are:

The grip jaws of copper alloy can obtain stable arc under high current for superior welding Jaw covers are made of special fire retardant compound which are spatter proof and have Low profile leverage reduces welding fatigue. Insulated parts can withstand high arc resistance current effects. high impact strength.

Electrode Holders are available in the following range of models:

S. No 1

Model STD - 600 (Standard)

Description Semi insulated electrode holder 600 Amps Electrode Holder 600 Amps Jaws insulated with HOFR compound cover Fully insulated with HOFR compound cover Electrode Holder 600 Amp Jaws insulated with HOFR compound cover and having full copper base. semi insulated electrode holder 400 amps Fully forged One Piece Special Alloy electrode holder for guaranteed extra heavy duty performance.

2 3

E -600 (Export Quality) F-600 (Export Quality) Cu -600 (Export Quality)

Sleek - 400 Power -1000

Earthing Clamps
Earthing clamps are made from finest quality raw materials for uninterrupted service and longer life. All type of earthing clamps is galvanized / zinc plated for longer life. The cable connectors are with nut and bolt to ensure positive and tight cable connection. These are available in Crocodile Jawspring loaded type in current rating of 200, 300, 400 and 600 amps.

Specification :

Model No. SEC-201 SEC-301 SEC-401 SEC-601

Description 200 Amp EARTH CLAMP 300 Amp EARTH CLAMP 400 Amp EARTH CLAMP 600 Amp GROUND CLAMP

Recommended Cable 10-25 mm2 25-50 mm2 50-70 mm2 70-120 mm2

Synchronous Electric Motor:

A synchronous electric motor is an AC motor distinguished by a rotor spinning with coils passing magnets at the same rate as the alternating currents and resulting magnetic field which drives it. Another way of saying this is that it has zero slip under usual operating conditions. Contrast this with an induction motor, which must slip in order to produce torque. Sometimes a synchronous motor is used, not to drive a load, but to improver the power factor on the local grid its connected to. It does this by providing reactive power to, or consuming reactive power from the grid. In this case the synchronous motor is called a Synchronous condenser.

Stepper Motor:

A stepper is a brushless, synchronous electric motor that can divide a full rotation into a large number of steps. The motors position can be controlled precisely, without any feedback mechanism. Stepper motors are similar to switched reluctance motors, which are very large stepping motors with a reduced pole count, and generally are closed-loop commutated.

Advantages:
Synchronous motors have the following advantages over Stepper motors: Speed is independent of the load Accurate control in speed and position using open loop controls They will hold their position when a DC current is applied to both the stator and the rotor windings. Their power factor can be adjusted to unity by using a proper field current relative to the load.

CHAPTER 5
5.1 5.2 5.3 5.4 5.5 5.6 What is Degree of Freedom? Robot workspace Force calculations Forward Kinematics Inverse kinematics kinematics equation for robot motion 5.6.1 Motion calculation of two joint

Degree of freedom:
The degree of freedom, or DOF, is a very important term. Each degree of freedom is a joint on the arm, a place where it can bend or rotate or translate. We can typically identify the number of degrees of freedom by the number of actuators on the robot arm. When building a robot arm you want as few degrees of freedom allowed for our application, because each degree requires a motor, often an encoder, and exponentially complicated algorithms and cost. In general, a rigid body in d dimensions has d(d + 1)/2 degrees of freedom (d translations and d(d 1)/2 rotations). One line of reasoning for the number of rotations goes that rotational freedom is the same as fixing a coordinate frame. Now, the first axis of the new frame is unrestricted, except that it has to have the same scale as the original so it has (d-1) DOFs. The second axis has to be orthogonal to the first, so it has (d-2) DOFs. Proceeding in this way, we get d(d-1)/2 rotational DOFs in d dimensions. In 1-, 2and 3- dimensions then, we have one, three, and six degrees of freedom. A non-rigid or deformable body may be thought of as a collection of many minute particles (infinite number of DOFs); this is often approximated by a finite DOF system. When motion involving large displacements is the main objective of study (e.g. for analyzing the motion of satellites), a deformable body may be approximated as a rigid body (or even a particle) in order to simplify the analysis. In three dimensions, the six DOFs of a rigid body are sometimes described using these nautical names: 1. 2. 3. 4. 5. 6. Moving up and down (heaving) Moving left and right (swaying) Moving forward and backward (surging) Tilting forward and backward (pitching) Turning left and right (yawing) Tilting side to side (rolling).

Systems of Bodies:
A system with several bodies would have a combined DOF that is the sum of the DOFs of the bodies, less the internal constraints they may have on relative motion. A mechanism or linkage containing a number of connected rigid bodies may have more than the degrees of freedom for a single rigid body. Here the term degrees of freedom are used to describe the number of parameters needed to specify the spatial pose of a linkage.

A specific type of linkage is the open kinematic chain, where a set of rigid links are connected at joints; a joint may provide one DOF (hinge/sliding), or two (cylindrical). Such chains occur commonly in robotics, biomechanics and for satellites and other space structures. A human arm is considered to have seven DOFs. A shoulder gives pitch, yaw and roll, an elbow allows for pitch, and a wrist allows for pitch, yaw and roll. Only 3 of those movements would be necessary to move the hand to any point in space, but people would lack the ability to grasp things from different angles or directions. A robot (or object) that has mechanisms to control all 6 physical DOF is said to be holonomic. An object with fewer controllable DOF than total DOF is said to be non-holonomic, and an object with more controllable DOF than total DOF (such as the human arm) is said to be redundant.

Robot Workspace:
The robot workspace (sometimes known as reachable space) is all places that the end effecter (gripper) can reach. The workspace is dependent on the DOF angle/translation limitations, the arm link lengths, the angle at which something must be picked up at, etc. The workspace is highly dependent on the robot configuration. Since there are many possible configurations for your robot arm, from now on we will only talk about the one shown below. I chose this 3 DOF configuration because it is simple, yet isnt limiting in ability.

Force Calculations of Joints:

The point of doing force calculations is for motor selection. We must make sure that the motor we choose can not only support the weight of the robot arm, but also what the robot arm will carry (the blue ball in the image below). The first step is to label our FBD, with the robot arm stretched out to its maximum length.

Parameters:

weight of each linkage weight of each joint weight of object to lift length of each linkage

Next we do a moment arm calculation, multiplying downward force times the linkage lengths. This calculation must be done for each lifting actuator. This particular design has just two DOF that requires lifting, and the center of mass of each linkage is assumed to be Length/2.

As we can see, for each DOF we add the calculations get more complicated, and the joint weights get heavier. We can see that shorter arm lengths allow for smaller torque requirements.

Forward Kinematics:
Forward kinematics is the method for determining the orientation and position of the end effecter, given the joint angles and link lengths of the robot arm. For our robot arm example, here we calculate end effecter location with given joint angles and link lengths.

Assume that the base is located at x=0 and y=0. The first step would be to locate x and y of each joint.

Inverse Kinematics:
Inverse kinematics is the opposite of forward kinematics. This is when you have a desired end effecter position, but need to know the joint angles required to achieve it. Although inverse kinematics is much more useful than forward kinematics, but the calculations involved are much more complicated too. So what makes inverse kinematics so hard? Well, other than the fact that it involves non-linear simultaneous equations, there are other reasons too. First, there is the very likely possibility of multiple, sometimes infinite number of solutions (as shown below). How would arm choose which is optimal, based on torques, previous arm position, gripping angle, etc.

There is the possibility of zero solutions. Maybe the location is outside the workspace, or maybe the point within the workspace must be gripped at an impossible angle. Singularities, a place of infinite acceleration, can blow up equations and/or leave motors lagging behind (motors cant achieve infinite acceleration). And lastly, exponential equations take forever to calculate on a microcontroller.

ROBOTICS ARC WELDING THE COMPONENTS AND POSITION FOR WELDING

CHARATERSTICS

RANGE

1) Tool load 2) Torque 3) Displacement speeda) linear b) angular 4) Accuracy 5) Repeatability

10-20 kg 58-80 Nm -

ROBOT ARM CONFIGURATION

VARYING DEGREE OF FREEDOM & CONFIGURATION

MAJOR APPLICATION AND CAPABILITIES OF ROBOTS

Kinematic equation for robot motion:

The effecter position and orientation can be described in terms of the position and orientation of a co-ordinate frame embedded in the last link of the manipulator. Now [Total motion] = [arm motion] [wrist motion] Ot = Ota * Otw

Where Ot describe the end effecter position and orientation with respect to the base coordinate frame. The superscript designate the reference frame, O-represents the base frame and a represents the tip of the arm. The subscripts designate the new frames reached by the transformers, a is again the tip of the arm and w is the position centre as by the wrist. Using D and H method, one can have Ot = [A1 A2 A3] * [A4 A5 A6]

The above two suspect which represents the ARM and WRIST have been obtained by using the associative law regarding the product of matrices.

Motion calculation of two joint:

As per consideration the calculation been joint manipulator with the two robotic Arm motion. Considering: L1 = 20 cm L2 = 30 cm A1 (angle) = 30 deg. A2 (angle) = 45 deg. We know that, the motion equation b/w joint X = L1cos (A1) + L2cos (A1+A2) Y = L1sin (A1) + L2sin (A1+A2)

Substituting the value of the L1, L2 and A1, A2 in the above equation we get, X = L1cos (A1) + L2cos (A1+A2) X = 20 cos (30) + 30 cos (30+45) X = 20 cos (30) + 30 cos (75) X = 20 * 0.866 + 30 * 0.258 X = 17.32 + 7.74 X = 25.06 And Y = L1sin (A1) + L2sin (A1+A2) Y = 20 sin (30) + 30 sin (30+45) Y = 20 sin (30) + 30 sin (75) Y = 20 * 0.5 + 30 * 0.966 Y = 10 + 28.98 y = 38.98

P(X, Y) = 25.06, 38.98

This equation shows that the co-ordinate position for the end of the ARM. By this equation position of the Arm calculated at any position or any angle where the robot capability works.

CHAPTER 6
6.1 Screw Jack System 6.2 Electrode 6.2.1 Welding Electrode 6.2.2 Uses of electrodes 6.3 Gear system
6.3.1 Advantages & Disadvantages of Gear 6.3.2 Gear ratio 6.3.3 Spur gear

Screw jack system:

A jackscrew is a type of jack which is operated by turning a lead screw. It is also known as a screw jack, and are commonly used as car-jacks. A jackscrew's compressive force is obtained through the tension force applied by its lead screw. An Acme thread is most often used, as this thread is very strong and can resist the large loads imposed on most jackscrews while not being dramatically weakened by wear over many rotations. These types are self-locking, which makes them more intrinsically safe than other jack technologies like hydraulic actuators which require continual pressure to remain in a locked position. Most jackscrews are lubricated with grease.

Fig.6.1 Screw jack system with thread & car jack

Advanced screw mechanisms may use a recirculation-ball nut to minimize friction and prolong the life of the screw threads, but such jackscrews are usually not selflocking. The thread profile of such screws is semicircular, not trapezoidal as in an Acme thread.

Electrode:
An electrode is an electrical conductor used to make contact with a nonmetallic part of a circuit (e.g. a semiconductor, an electrolyte or a vacuum). The word was coined by the scientist Michael Faraday from the Greek words electron (meaning amber, from which the word electricity is derived) and hodos.

Welding electrodes:
In arc welding an electrode is used to conduct current through a work piece to fuse two pieces together. Depending upon the process, the electrode is either consumable, in the case of gas metal arc welding or shielded metal arc welding, or non-consumable, such as in gas tungsten arc welding. For a direct current system the weld rod or stick may be a cathode for a filling type weld or an anode for other welding processes. For an alternating current arc welder the welding electrode would not be considered an anode or cathode.

Alternating current electrodes:

For electrical systems which use alternating current the electrodes are the connections from the circuitry to the object to be acted upon by the electrical current but are not designated anode or cathode since the direction of flow of the electrons changes periodically, usually many times per second.

Uses of electrodes:
Electric currents are run through nonmetal objects to alter them in numerous ways and to measure conductivity for numerous purposes. Examples include:

Electrodes for medical purposes, such as EEG, ECG, ECT, defibrillator Electrodes for electrophysiology techniques in biomedical research Electrodes for execution by the electric chair Electrodes for electroplating

Electrodes for arc welding

Electrodes for cathodic protection Electrodes for grounding Electrodes for chemical analysis using electrochemical methods Inert electrodes for electrolysis (made of platinum) Membrane electrode assembly

Gear System:
A Gear is a component within a transmission device that transmits power to another gear or device. A gear is different from a pulley in that a gear is a round wheel which has linkages that mesh with other gear teeth, allowing force to be fully transmitted without slippage. Depending on their construction and arrangement, gear devices can transmit forces at different speeds, torques, or in a different directions from the power source. Gears are very useful simple machine. The most common situation is for a gear to mesh with another gear, but a gear can mesh with any device having compatible teeth, such as linear moving racks. A gears most important feature is that gear of unequal sizes can be combined to produce a mechanical advantage, so that the rotational speed and torque of the second gear are different from the first. A gear ratio refers to the ratio of driver shaft speed to driven shaft speed..

Point of contact

Line of contact

Line of action

Plane of action

Zone of action (contact zone)

Length of action

Advantages and disadvantages of gear drives:

The following are the advantages and disadvantages of the gear drive as compared to other drives, i.e. belt, rope and chain drives

Advantages:
It transmits exact velocity ratio. It may be used to transmit large power. It may be used for small centre distance of shafts. It has high efficiency. It has reliable service.

Disadvantages:
Since the manufacture of gears requires special tools and equipments, therefore it is costlier than other drives. The error in cutting teeth may cause vibration and noise during operation. It requires suitable lubricant and reliable method of applying it, for the proper operation of gear drives.

Gear ratio:
The gear ratio is the relationship between the numbers of teeth on two gears that are meshed or two sprockets connected with a common roller chain, or the circumferences of two pulleys connected with a drive belt.

The gear ratio is also given by the relation:

(Speed of gear A * No of teeth on gear A) = (Speed of gear B * No of teeth on gear B)

(NA * TA ) = (NB * TB ) Spur gear:

Spur gears are the simplest and most common type of gears. Their general form is a cylinder or disc. The teeth project radially, with this straight-cut gears, the leading edge of the teeth are aligned parallel to the axis of rotation. These gears can only mesh correctly if they are fitted to parallel axles.

CHAPTER 7
7.1 Specifications of Parts 7.1.1 Base 7.1.2 Gear 7.1.3 Synchronous Motor 7.1.4 Lower arm 7.1.5 Upper arm 7.1.6 Screw jack 7.2 Step of construction

Specifications of Parts:

1. BASE:
L shape clamp: 14.5 inch Height of the base: 7 inch Outer diameter of base: 7inch Diameter of circle cut on centre of base: 2.5 inch Dimension of the four metal plate: 45.5 inch

2. Synchronous Motor:

Providing 360 degree motion to the lower arm. Operates at 12 volt. With speed of 10 rpm. Current capacity 100vto 250 mA.

3. Gear:

No. of teeth in driver gear: 16 No. of teeth in driven gear: 60 Gear ratio: 60:16 Time taken for 1 revolution of driver gear: 6 sec Time taken for 1 revolution of driven gear: 1.6 sec.

Gear meshing diagram:

Lower Arm:
Square shape 2.52.5 Height from the base: 7 inch With 360 degree motion by motor

Upper Arm:
Square shape 2.52.5 Height: 7 inch Connected with lower arm by U-clip

2-D motion by screw jack system

Screw jack:
thread screw jack system Height: 9 inch Connected with synchronous motor With 360 degree motion by motor

Step of construction:

Preparation of base of robotic welding machine:

First of all we have taken flat metal sheet of 18 gauge. Round it in circular form like a hollow cylinder and welding is done on joint of it to make it like a hollow cylinder. After welding its diameter becomes 7 inch. To cover hollow cylinder from top and bottom we provide 16 gauge thick metal plate of 7 inch dia. In the top metal plate there is a hole of 2.5 inch diameter.

Some construction is also done inside the hollow cylinder, such as:
L Shape clamp of 14.5 inch. One hub (cycle wheel hub) use for giving smooth rotation. Two spur gears are used having gear ratio 16:60. Synchronous motor of 10 rpm is attached inside the hollow cylinder for providing 360 degree rotation. Most important thing is to balance the base properly with or without any load on it.

Preparation of Lower Arm of robotic welding machine:

First of all we have taken Aluminum metal sheet of square shape. Square metal sheet is cut into 7 inch. After that it connected with the U- clip. To making an adjusting hole in U-clip to fit the 7 inch as called lower arm with the base thread. In the top of arm also fitting the U-clip for further construction.

Preparation of upper Arm of robotic welding machine:

First of all we have taken Aluminum metal sheet of square shape. Square metal sheet is cut into 7 inch. After that it connected with the U- clip. To making an adjustment with the lower arm then it connected with u-clip. This upper arm is connected with the screw jack at 5 inch of upper arm & this screw jack system is proving an motion through to arm.

CHAPTER 8
8.1 DESIGN CONSTRUCTION OF THE
ROBOTIC WELDING PARTS

DESIGN CONSTRUCTION OF THE ROBOTIC WELDING PARTS: Design of base:

Design of hub-ring:

Design of hub:

Design of nut:

Design of u-clip:

Design of upper-arm:

Design of Screw jack system:

Design of upper plate:

Design of robotic welding m/c:

Design of robotic welding m/c:

CHAPTER 9
9.1 9.2 Conclusion Bibliography

Conclusion:
As per an adage each and everything on this universe has a specific designation of performance thus our efforts is to make a machine compatible with the big robotic industrial robots performing welding by the applications of electricity via joystick exactly on the same bases with the multidiode.

Bibliography:
A textbook of Machine Design by R.S Khurmi & J.K Gupta, S.Chand publication. Manufacturing process by V.D Shrivastava, S.Chand publication. A text book on Robotics by Lee & Fu. www.societyofrobots.com www.robotworx.com http://en.wikipedia.org/wiki/robot http://en.wikipedia.org/wiki/electrod http://en.wikipedia.org/wiki/arc_welding http://en.wikipedia.org/wiki/gear http://en.wikipedia.org/wiki/synchronous_motor