Republic of Iraq

Ministry of Higher Education

& Scientific Research
AL-Nahrain University
Information Engineering College
Systems Engineering Department

Fix the failures and maintain the final

project system (Manipulator Robot)

4th year - Report

in
System Reliability

By
Haider Hashim Dkhikh

Supervised by
Dr. Hiba Zuhair

July 2020
 Abstract

The development of robotic studies and the importance of their applications in

practical life, led them to impose themselves in all fields of science. Because of this

importance, this project aims to position and path planning control, design and

assembling a Manipulator Robot with six degrees of freedom (6DOF's). Where this

project is very important and useful for use in all fields including industrial,

automation, medical and military fields. In this report, we will classify and fix the

failure according to what we have learned on a subject System Reliability.

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 List of contents
Abstract 2
List of Contents 3
List of Figures 3

Chapter 1: Introduction 4
1.1 Overview 4
1.2 Objective 5
1.3 Application 5

Chapter 2: System Reliability to Fix the failures 6

2.1 System Functional Block Diagram 6
2.2 Identify the mode of Probable Failures 7
2.3 Classify Failures by Failure Classification Hierarchy 7
2.4 Analyse Cause and Effects by FISHBONE for each failure 8
2.5 Evaluate Failures Likelihood, Severity, Detectability, Impacts, RPN 11
2.6 FMECA worksheet 13

Chapter 3: Discussion and Conclusions 14

3.1 Discussion 14
3.2 Conclusions 14
References 15

List of Figures
Figure Title Page
No. No.
1-1 Image of the final shape of 6DOF's Manipulator Robot 4
2-1 System Functional Block Diagram of Manipulator Robot 6
2-2 Analyse Cause and Effects by FISHBONE for each failure 10

List of Table
Table No. Title Page No.
2-1 Categorize the function of each component 6
2-1 Identify the mode of Probable Failures 7
2-4 Failure Severity Matrix 11
2-5 Failure Impact Matrix 12
2-6 Assessment Matrix 12
2-7 Risk Priority Number 13
2-8 FMECA worksheet 13

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 Chapter 1
Introduction

1.1 Overview

Multi-degree of freedom robot is playing very important role in different

application of automation. They are providing much more accuracy in carrying out a
typical procedure as compared to the manual work done by human. [1]

This project describes a mechanical system, design concept and prototype

implementation of a 6 DOF Manipulator Robot, which should perform industrial task
such as pick and place of fragile objects operation. [2] This 6DOF's Manipulator Robot
will be controlled by Arduino Mega 2560 microcontroller has base, shoulder, elbow,
wrist rotation and a functional gripper. Depending on the numbers of joints and links
as Figure (1-2), 6DOF's differs, but generally Manipulator Robots operate using 6
servo motors. The servo motors are popular for their desirable characteristics for
robotic application [3]. The microcontroller and designed interfacing circuits built for
position control of the robot Servo motors. [4] [5] [6]

Figure (1-1): Image of the final shape of 6DOF's Manipulator Robot

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1.2 Objective
Part.1: The aims of this report can be factorized in following:
classify and fix the failure according to what we have learned on a subject System

Reliability.

Part.2: The aims of the Manipulator Robot project can be factorized in following:
1. Implementation and Assembling the Robot Structure with Connecting the required
electronic components to control and actuate the Robot.
2. Deriving of forward kinematic Mathematical model, building a 3D Simulation.
3. Firstly, the researcher will use the Wire Position Control technique for control the
6DOF's Manipulator Robot (open-loop control system) using:
• By Joystick PS2 Controller with Record & Playback Trajectory
4. Secondly, the Wireless Position Control method for 6DOF's Manipulator Robot
(open-loop control system) will be developed using:
• By Smartphone Android Application with Record & Playback Trajectory
5. Thirdly, the Automatic Position Control of 6DOF's Manipulator Robot (closed-loop
control system) will be developed using:
• By Color sensor & Ultrasonic sensor, IR sensor and PIR sensor
6. Finally, the Forward Kinematics for the 6DOF's Manipulator Robot will derive
simulate and tested via tracking a specific root trajectory planning in 3D
representation using MATLAB program.

1.3 Application
Application of 6DOF's Manipulator Robot are very wide, among them [7] [8]:
• Industrial Application for replay back operation in assembly process.
• Medical Application in robotic surgery.
• Military Application in bomb dismantling and rescue operations.
• Laboratory Application in Epidemiology analysis.
• Chemical Application in acids and harsh chemicals.
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 Chapter 2
System Reliability to Fix the failures

2.1 System Functional Block Diagram

Figure (2-1): System Functional Block Diagram of Manipulator Robot

Categorize the function of each component:
Ref. no. component Function
1 Arduino Essential
2 Servo Driver Auxiliary
3 Servos X6 Auxiliary
4 LCD 2x16 Information/ Auxiliary
5 Battery Auxiliary
6 Joystick Interface / Auxiliary
7 Bluetooth Information/ Auxiliary
8 App. smartphone Interface / Auxiliary
9 Sensors Interface / Auxiliary
10 Gripper Auxiliary
11 Laptop Information / Auxiliary
Table (2-1): Categorize the function of each component
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2.2 Identify the mode of Probable Failures
failure mode
Fail to open (on demand) the Gripper Failure to cease operation at a
prescribed time
Fail to close (on demand) the Gripper Failure to cease operation at a
prescribed time
High temperature Servo motor Premature (spurious) operation
Cannot fully control of Servo motor Premature (spurious) operation
Crash gearbox of Servo motor Failure during operation
Fail to regulate voltage Failure during operation
Table (2-2): Identify the mode of Probable Failures

2.3 Classify Failures by Failure Classification Hierarchy

Failure Type Degree Time Detectability
Fail to open Extended Partial failure Sudden _____
(on demand) failure failure
the Gripper
Fail to close Extended Partial failure Sudden _____
(on demand) failure failure
the Gripper
High Extended Partial failure Gradual Degraded
temperature failure failure failure
Servo motor
Cannot fully Extended Complete Sudden Catastrophic
control of failure failure failure failure
Servo motors
Crash Extended Partial failure Sudden _____
gearbox of failure failure
Servo motor
Fail to Intermittent _____ _____ _____
regulate failure
voltage
Table (2-3): Classify Failures by Failure Classification Hierarchy

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2.4 Analyse Cause and Effects by FISHBONE for each failure

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Figure (2-1): Analyse Cause and Effects by FISHBONE for each failure

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 2.5 Evaluate Failures Likelihood, Severity, Detectability,
Impacts, RPN
F1 = Fail to open (on demand) the Gripper
F2 = Fail to close (on demand) the Gripper
F3 = High temperature Servo motor
F4 = Cannot fully control of Servo motor
F5 = Crash gearbox of Servo motor
F6 = Fail to regulate voltage

A. Failure Severity Matrix:

Failure Likelihood (or Occurrence)

Frequency/ 1 2 3 4 5
consequence Very unlikely Remote Occasional Probable Frequent
Failure Mode

Catastrophic
10
Critical
7-9
Major F6
4-6
Minor F4, F5 F1, F2, F3
1-3
Table (2-4): Failure Severity Matrix

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B. Failure Impact Matrix:
Failure Mode
Catastrophic Critical Major Minor
(10) (8) (5) (2)
Very Unlikely 1 x 10 = 10 1x8=8 1x5=5 1x2=2
Failure likelihood
(or Occurrence)

(1)
Remote 2 x 10 = 20 2 x 8 = 16 2 x 5 = 10 2 x 2= 4
(2)
Occasional 3 x 10 = 30 3 x 8 = 24 3 x 5 = 15 3x2=6
(3)
Probable 4 x 10 = 40 4 x 8 = 32 4 x 5 = 20 4 x 2= 8
(4) F6 F3,F4
Frequent 5 x 10 = 50 5 x 8 = 40 5 x 5 = 25 5 x 2= 10
(5) F1, F2, F3
Table (2-5): Failure Impact Matrix

C. Risk Assessment Matrix:

Failure Likelihood Impact Detection When
Difficulty
Fail to open (on demand) the 5 10 1 Start-up
Gripper
Fail to close (on demand) the 5 10 1 Start-up
Gripper
High temperature Servo motor 5 10 2 movement
Cannot fully control of Servo 4 8 1 Overload
motors on
controller
Crash gearbox of Servo motor 4 8 2 Overload
on Servo
motor
Fail to regulate voltage 4 20 2 Start-up
Table (2-6): Assessment Matrix

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D. Risk Priority Number:

O = the rank of the occurrence (Likelihood) of the failure mode

S = the rank of the severity of the failure mode
D = the rank of the likelihood the failure will be detected before the system reaches
the end-user/customer.
All ranks are given on a scale from 1 to 10. The risk priority number (RPN) is
defined as:
RPN = S * O * D
The smaller the RPN the better - and - the larger the worse. [9]
Failure S O D RPN = S * O * D
Fail to open (on demand) the Gripper 2 5 1 10
Fail to close (on demand) the Gripper 2 5 1 10
High temperature Servo motor 2 5 2 20
Cannot fully control of Servo motors 2 4 1 8
Crash gearbox of Servo motor 2 4 2 16
Fail to regulate voltage 5 4 2 40
Table (2-7): Risk Priority Number

2.6 FMECA worksheet

Table (2-8): FMECA worksheet

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 Chapter 3

Result, Discussion and Conclusions

3.1 Discussion
Through what learned in subject System Reliability and from the all presented
tests and results; one can have concluded and fix or reduce failure that the 6DOF's
Manipulator Robot can be useful in executing tasks from faraway places. With
continues human interaction in order to save the human body from an effect of
chemicals, radiation waves and biological dissipation. Therefore, the designed robot
can be used in industrial automation processes and production lines in the factories
specially with wireless connection property to connect with distance range greater than
37 meters as appeared with physical tests.

3.2 Conclusions and Result

A complete hardware and software System with learned in subject System
Reliability was designed, fix failure and implemented for the 6DOF's Manipulator
Robot, the following points were concluded:

1. The artificial 6DOF's Manipulator Robot designed to approximate the manipulation

abilities of the human arm in efficient way.
2. This project reduces human efforts at places or situations where human
interventions are difficult.
3. The robot mechanical structure was made of lightweight aluminum to avoid putting
extra load on the robot links.
4. The Joystick controller interface and Android Application Smartphone with HC-
05 Bluetooth module was controlled the robot motion in real time.
5. The forward kinematics was simulated in Matlab to simulate the robot motion.

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References
[1] Lin, I. H., Liu, C. Y., Chen, L. C., "Evaluation of Human-Robot Arm Movement
Imitation", Proceedings of Asian Control Conference (ASCC), pp.287 292, 2011.

[2] Nikku, S., “Introduction to Robotics” USA: John Wiley & Sons, 2014.

[3] Muir, F. P., Neuman, P. C., "Pulsewidth Modulation Control of Brushless DC

Motors for Robotic Applications", IEEE Transactions on Industrial Electronics, Issue
3, Vol. 32, pp.222-229, 2012.

[5] Merlet, J-P. "Solving the forward kinematics of a Gough-type parallel

manipulator with interval analysis." The International Journal of robotics research 23.3
(2013): 221-235.

[6] Nehmzow, U.,” Mobile Robotics: a practical introduction”, UK: Springer, 2013.

[7] N. Pinckney. 2012. Pulse-width modulation for microcontroller servo control.

IEEE Potentials, vol. 25, no. 1, pp. 27–29.

[8] R. Ross. 2014. Investigation into soft-start techniques for driving servos.
Mechatronics, vol. 24, no. 2, pp. 79–86.

[9] System reliability theory: models, statistical methods, and applications / Marvin
Rausand, Arnljot Hoyland. - 2nd ed. pp. 66–28.

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