BACHELOR OF MECHANICAL ENGINEERING

WITH HONOURS

BEM4043 / BEM4053
INTEGRATED DESIGN PROJECT

TITLE OF THE PROJECT

GROUP NO 2
No Student Name Student ID
1 Nour Eldin Mahmoud Taher Beit 1001956307
2 Ali Ehmer Khimjee 1001956871
3 Saw Ying Hau 1001957305
4 Poon Yew Jun 1001957307
5 Amro Mohamed Mohamed Mansour 1001956793
6 Abdurahman Hisham Khogali Muhammad 1001955511

SUPERVISOR:
Associate Professor Dr Ezutah Udoncy Olugu

COURSE COORDINATOR:
Ms Ummi Zulaikha bt Abd Rahman

JAN 2023
 ACKNOWLEDGEMENT

We would like to sincerely thank Associate Professor Dr. Ezutah Udoncy Olugu for all
his help and assistance with this study. His knowledge and perceptions have been
crucial in determining the project's course and assuring its success. His dedication to
study and teaching has motivated us to pursue excellence. We would also like to take
this opportunity to extend our sincere thanks to UCSI University, where we have had
the privilege of pursuing our studies. The excellent facilities, resources, and support
provided by the university have been crucial in enabling us to achieve our academic
goals.

We would also like to express our gratitude to Ts Amar Ridzuan Bin Abd Hamid, who
served as the project's examiner and gave us helpful criticism. His constructive criticism
and enlightening remarks helped us improve our work and obtain a better understanding
of the subject.

Last but not least, we would like to express our gratitude to Ms Ummi Zulaikha bt Abd
Rahman for her crucial work as the project coordinator. Her nonstop coordination and
management of the project's activities and logistics have been crucial to its successful
completion. We appreciate her support throughout the project and are incredibly
appreciative of her dedication and expertise.

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 DECLARATION OF ORIGINALITY AND EXCLUSIVENESS

I hereby declare that the dissertation is based on my original work except for quotations
and citations which have been duly acknowledged. I also declare that it has not been
previously or concurrently submitted for any other degree at UCSI or other institutions.

Days
____________________________ _
Nour Eldin Mahmoud Taher Beit (1001956307)

As
____________________________ _
Ali Ehmer Khimjee (1001956871)

Yat Hal
____________________________ _
Saw Yong Hau (1001957305)

141
____________________________ _
Poon Yew Jun (1001957307)

As
____________________________ _
Amro Mohamed Mohamed Mansour (1001956793)

#
____________________________ _
Abdurahman Hisham Khogali Muhammad (1001955511)

Supervised by:

__________________________ ___
Associate Professor Dr Ezutah Udoncy Olugu

Date: 6/4/2023

ii
 ABSTRACT

High-rise buildings create difficulties for window cleaning due to the restricted access
to some places and the dangers of working at heights. According to an analysis report
by The Occupational Safety and Health Administration (OSHA), there are eighty-eight
window cleaning accidents over the past 15 years. In this study, these issues will be
addressed by developing a window cleaning mechanism to increase efficiency, decrease
labor costs, and improve safety of the process. Three conceptual designs for window
cleaning of high rise-buildings have been proposed and evaluated including window
cleaning drone, suction cup robot, and window cleaning robot arm. Wiper-Watt, the
window cleaning robot arm, was selected to be the best of the three designs based on a
matrix selection constructed in this project. It consists of the three main components
including 3 DOF robot arm, linear drive, and gantry crane. The cleaning efficiency of
Wiper-Watt was found to be 67.5 m2/hr considering a delay factor of 2. Upon
performing statics structural analysis for the gantry crane, stresses allocated at the
wheels of the crane were found to reach 6200 N/m2 which is five times the ones acting
on the pulley brackets. Topology optimization was performed for the robot arm to
reduce its mass and power consumption where 46% power consumption reduction was
obtained for the optimized design. The project's results show the possibility of using
Wiper-Watt for window cleaning of high-rise buildings and offer prospective directions
for additional research and development. A few suggestions are made to improve the
performance of Wiper-Watt including the mobility of its links, cleaning mechanism, and
developing a fully autonomous version of it.

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 TABLE OF CONTENT

Page
ACKNOWLEDGEMENT i
DECLARATION OF ORIGINALITY AND EXCLUSIVENESS ii
ABSTRACT iii
TABLE OF CONTENT iv

CHAPTER I INTRODUCTION 1

1.1 BACKGROUND INFORMATION 1

1.2 MARKET STUDY 2
1.2.1 Efficiency and Efficacy 2
1.2.2 Safety 3
1.2.3 Control 3
1.2.4 Building Compatibility 3
1.2.5 Cost 4
1.2.6 Sustainability and Environmental Friendliness 4
1.3 PROBLEM STATEMENT 4
1.4 OBJECTIVES 5
1.5 SCOPE & LIMITATIONS 5
1.5.1 Scope 5
1.5.1 Limitations 5

CHAPTER II` PROJECT-RELATED LITERATURES 7

2.1 CONVENTIONAL WINDOW CLEANING 7

2.2 AVAILABLE PRODUCTS IN THE MARKET 8
2.2.1 Biped Robot 8
2.2.2 SiriusC 9

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 2.2.3 Window-mate 10
2.2.4 Mantis 12
2.2.5 Mech-Clean Bot 12
2.2.6 Sky-Cleaner 3 14
2.2.7 TITO 500 15
2.2.8 Benchmark for the Available Products in the Market 16
2.3 PATENTS 17
2.3.1 Gas Driven Automatic Window Wiping Robot 17
2.3.2 Window Cleaning Apparatus 18
2.3.3 Cleaning Robot for Window of High-Rise Building 20
2.3.4 Window Wall Washing Device for High-Rise Building 21
2.3.5 Automatic Window Washer 22
2.3.6 Remote Control Valve for Water Meter Control 24
2.3.7 Surface Washing Drone 25
2.3.8 Suction Cup Robot with Wall Climbing Function 26
2.4 CONTROL 27
2.4.1 Internal Sensors 27
2.4.2 External Sensors 27
2.4.3 Control Unit 28
2.5 TOPOLOGY OPTIMIZATION 29

CHAPTER III CONCEPTUAL DESIGNS AND EVALUATION 31

3.0 INTRODUCTION 31
3.1 FLOW CHART 31
3.2 CONCEPTUAL DESIGNS 34
3.2.1 Conceptual Design 1: Window Cleaning Drone 34
3.2.1.1 Working Mechanism 34
3.2.1.2 Window Cleaning Drone Evaluation 35
3.2.2 Suction Cup Robot 40
3.2.2.1 Working Mechanism 41
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 2.3.2.2 Suction Cup Robot Evaluation 42
3.2.3 Window Cleaning Robot Arm 47
3.2.3.1 Working Mechanism 48
3.2.3.2 Window Cleaning Robot Arm Evaluation 49
3.3 FINAL DESIGN SELECTION 52

CHAPTER IV DETAILED DESIGN AND ANALYSIS 55

4.1 DESIGN OBJECTIVES 55

4.2 WINDOW CLEANING ROBOT ARM 55
4.2.1 Topology Optimization for Wiper-Watt 56
4.2.2 Material Selection for Wiper-Watt 60
4.3 CRANE DESIGN 62
4.3.1 Crane Design Concept 62
4.3.2 Pulley Brackets Calculations and Selection 63
4.3.3 Crane Material Selection 64
4.4 ENGINEERING CODES AND STANDARDS 65
4.4.1 Engineering Codes and Standards Deployed in Calculation 65
4.4.2 Engineering Codes and Standards Related to Environment 66
4.5 DESIGN CALCULATIONS 66
4.5.1 The Required Force to Hold the Nozzle During Operation 66
4.5.2 Servo Motor Torque Calculations 68
4.5.3 Forward Kinematics 70
4.5.4 Inverse Kinematics 74
4.6 BILL OF MATERIAL FOR THE FINAL DESIGN 75
4.7 FAILURE MODE AND EFFECTIVE ANALYSIS 76
4.8 STATIC STRUCTURE SIMULATIONS 82
4.9 ROI Analysis 84
4.10 MARKET STRATEGIES 85

CHAPTER V PROTOTYPE AND TESTING 90

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5.1 ROBOT ARM AND THE LINEAR DRIVE 90
5.2 CRANE CONSTRUCTION 91
5.3 CIRCUIT DIAGRAM 93
5.4 MIT APP INVENTER 96
5.5 BILL OF MATERIAL 97
5.6 DIFFICULTIES ENCOUNTERED 98

CHAPTER VI CONCLUSION AND FUTURE RECOMMENDATIONS 100

6.1 CONCLUSION 100

6.2 FUTURE RECOMMENDATIONS 100

REFERENCES 102

APPENDICES 107
APPENDIX 1 WIPER-WATT DIMENSIONS AND COMPONENTS 107
APPENDIX 2 MINUTES OF MEETINGS 108

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 CHAPTER I

INTRODUCTION

1.1 BACKGROUND INFORMATION

High-rise buildings are one of the miracles of the modern architecture.

Nowadays, there is an increase in the number of high rising buildings over the world
and many countries are trying to break a world record by building the highest building
in the world. According to Yang & Li, (2015), High rising building is defined as a
building more than 23 meters or 30 meters, measured from the lowest level of fire
department vehicle access to the floor of the highest occupiable story. It is roughly
estimated as seven floors.

With the increase of high rising buildings, a window cleaning mechanism for the
outside window was required. There are three main methods deployed for such a
process. First method is by suspending workers in the air by using a gondola or
abseiling techniques. The second method is ground cleaning by using mobile elevated
working platforms, using a ladder or scaffold. Due to the development in the technology
sector, a third method was introduced which is cleaning by using robots or automated
machines. Although the manual labour can be applied in different building types and
designs, but it is very unsafe to deploy and endangers the workers’ lives. In India, a
traditional way of using climbing equipment is deployed but the cost and time for this
process in very high.

Many accidents and near missed occurs during this process. According to an
analysis report by The Occupational Safety and Health Administration (OSHA), there
are eighty-eight window cleaning accidents over the past 15 years (Bula et al., 2021).
Sixty-two of them were causalities. A cleaning gondola in Shanghai lost control due to
heavy winds. Fifteen causalities during window cleaning were reported in South Korea
in 2016 (Li et al., 2021). Recently, a near miss occurred for two workers at the 48-storey
TS Law Tower, Kuala Lumpur Malaysia, while cleaning the window due to heavy
winds (Mishra, 2022).

Due to these accidents and the high risk in such a process, development of
automated machines became necessary. Engineers have developed several mechanisms
and robots to help in this process. These mechanisms can be categorized under two
main categories which are cleaner with vacuum chamber and cleaner with lifting cable.
This project is focusing on developing a system that combines these two mechanisms
for higher safety and performance (T. Seo et al., 2019).

1
1.2 MARKET STUDY

In this section, the rapidly growing market of facade cleaning services is

investigated. Estimates approximate the cleaning service market size to have reached
$74,299 million by 2022 (Li et al., 2021). In Europe, 20% of the annual cleaning market
(estimated at 100 billion euros) is attributed to non-human labour costs. Since 30% of
buildings towering over 12 stories tall have a facade, they are a perfect target for
cleaning services (Yoo et al., 2019). This section also comprises the reaction the market
has had thus far in terms of incorporating and fulfilling customer needs. This
information is crucial to the development of a functional high-rise window cleaning
mechanism that is applicable to the target market. It must therefore be noted that each
market has its own unique requirements that depend on a varying set of factors such as
environment, climate, building design, etc. Therefore, it is necessary to cater to the
difficulties and nuances of each factor.

Primarily, the criteria which requisite the development of this project are simple
from a client/customer priority perspective; to efficiently (speed) and effectively
(quality) clean the windows of a specific high-rise building while minimizing or
practically eliminating risks involved to personnel and bystanders (safety) (Yoo et al.,
2019). Hence, it is vital for mechanisms developed with this purpose to have features
and equipment enabling the reach of difficult access surfaces and angles (building
accessibility).

However, a plethora of questions arise with the reduction of personnel involved

in the actual cleaning process. Consequently, most data available is indicative of the
necessity to involve complex machinery. In fact, robots and automation are increasingly
being viewed as an outlet to fulfilling most of -if not all- these requirements at a time.
To achieve this, robots are equipped with a variety of tools for performing tasks such as
cleaning, locomotion and adhesion. Due to the resultant complexity, cost becomes a
constraint to both manufacturers and consumers. In fact, it raises the necessity of
viewing customer requirements from a perspective of not only priorities, but also factors
that constrain and limit them. Below are descriptions of the contextualised customer
requirements being defined as customer priorities as well as customer constraints.

1.2.1 Efficiency and Efficacy (Cleaning speed vs cleaning quality)

It is crucial for the presented project to be capable of higher cleaning efficiency

than manual window cleaning. Therefore, the mechanism must be able to clean
windows at no less than 30m2/h (Li et al., 2021). In addition, the mechanism must be
able to thoroughly clean the facade effectively using all methods it can employ within

2
its deployment duration such as contamination level sensors. It must also not leave
residue stains, nor trickling trails of water/solution (Y. S. Lee et al., 2016).

1.2.2 Safety

Safety is defined with two main parameters including, stability and adhesion,
and emergency protocol. For stability and adhesion, the mechanism design must be as
risk free as possible, with a high factor of safety. Vital factors to ensure this include
prioritizing mechanism stability during locomotion, especially while manoeuvring
obstacles, and in steady states. In turn, maximizing stability relies on the strength of
adhesion used, regardless of the adhesion mechanism (Li et al., 2021). Another factor of
safety necessary is the mechanism’s potential to withstand environmental risks. These
may include moderate to high wind speeds or sudden rains, amongst other natural
impacts, or a sudden electrical or mechanical failure. When unable to operate as per
norm, the mechanism must have an emergency protocol either implemented within its
body or using support paraphernalia to avoid damaging itself or its surroundings
(Houxiang Zhang et al., 2006).

1.2.3 Control

Control is concerned with three main parameters which are building

accessibility, feedback control, and level of autonomy. For the mechanism to be used to
its highest potential, its locomotion mechanism must be supportive of the client’s
building structure. It must be able to navigate in all directions to cross target obstacles
such as windowsills, metal frames, etc, and may be capable of reaching nearly
inaccessible locations (Nansai et al., 2018). For the feedback, the mechanism might
optionally have the capability to distinguish types of stains, therefore using an
appropriate cleaning solution. Otherwise, visual feedback could be sent to an operator
who would then select the optimal solution manually. This is because stains of differing
intensity and type react differently to solutions, some of which could stain the glass
further (Y. S. Lee et al., 2016). In addition, the mechanism may allow for a selectable
degree of control between complete autonomy and complete remote control (Houxiang
Zhang et al., 2006).

1.2.4 Building Compatibility

Certain mechanisms in the market are built into the building structure, whether
initially or following construction completion. However, certain buildings are not
compatible with this feature, and must employ a semi-remotely deployed system.
In addition, certain mechanisms are limited by the sheer dimensions of the building, and
hence become incompatible. For instance, the weight build-up of supply hoses becomes

3
increasingly difficult for the mechanism to cater for at extreme vertical distances
(Houxiang Zhang et al., 2006).

1.2.5 Cost

Cost is one of the main factors when it comes to any design. There are some
parameters to be considered including components cost, and complexity of the design.
The materials utilized in constructing the mechanism must be within achievable limits
regarding the context of deployment location. Aside from that, usage of expensive
material must be justified through increased functionality, safety or otherwise. In
addition, the mechanism can be as simple or complex in construction as need be,
provided the complexity does not result in liabilities. This includes handicapped
performance or an exorbitant price due to manufacturability (Bula et al., 2021).

1.2.6 Sustainability and Environmental Friendliness

Water circulation and energy efficiency are two main factor that must be
considered to chieve a sustainable design. The mechanism must not use excessive
amounts of water during cleaning to prevent waste, as well as pollution caused when
cleaning water sprays away. In addition, the mechanism must not be overbearing in
terms of power consumption, as it would invalidate the use of mechanisms over manual
labour.

1.3 PROBLEM STATEMENT

High-rise buildings are a common sight in contemporary cities, but when it

comes to window washing, they pose a special set of difficulties. In particular for
buildings with unusual shapes or difficult-to-reach regions, traditional methods, such as
employing ladders or scaffolding, can be risky and time-consuming. Employees are
exposed to perilous heights, hazardous weather, and possibly broken equipment.
Moreover, the cleaning quality produced by these procedures is frequently variable as
some places may be ignored or not sufficiently cleaned. Building owners and facility
managers must therefore overcome the issue of locating a safe, effective, and
economical window cleaning solution that can satisfy the requirements of contemporary
construction (Moritz, 2018).

Robotic window cleaners are one example of a product on the market that offers
some solutions, but they frequently have drawbacks that prohibit them from being
extensively used. For instance, installing and maintaining some models may be
prohibitively expensive or complicated. Others might not be able to adjust to various

4
building conditions or may only have limited movement. Furthermore, the size, form,
and location of the structure may have an impact on the efficiency and safety of these
items. In addition, the efficiency of manual cleaning is about 30 m2/hr (H. Zhang et al.,
2006). In economic aspect, the personnel costs for cleaning the building facades were as
high as 70% according to Fraunhofer IPA (Schraft, 2000). According to ARD cleaning
services, the total cost can go as high as $1250 for the complete process. In addition, the
available product in the market is too expensive.

In this project, three different conceptual designs for high-rise building window
cleaning will be proposed and evaluated in order to overcome these difficulties. These
systems may be controlled using a mobile application, making cleaning versatile and
effective. The project will be focusing on examining the systems’ cost-efficiency,
safety, and effectiveness as well as their viability and usability.

1.4 OBJECTIVES

The objectives of this project are:

1. To propose a window glass cleaning mechanism for high-rise buildings.

2. To evaluate the design using appropriate engineering software and mathematical

approach.

3. To construct a functional mini prototype of the window glass cleaning

mechanism.

1.5 SCOPE & LIMITATIONS

1.5.1 Scope

High-rise structures can be cleaned effectively using the suggested designs

without endangering human life. Users may control every aspect of the system using the
mobile application, making it flexible and adaptable to their cleaning requirements. The
machine can clean the windows considerably more quickly than it would take a person
to do so, which increases productivity. Because they are not required to operate at risky
heights, the system's utilisation ensures the workers' safety and security.

1.5.2 Limitations

The limitations for the design can be summarised in these points:

5
1. Environmental Factors: The cleaning procedure may be hampered by
environmental variables like strong winds, a lot of rain, or snow.

2. Restricted Mobility: Because the robot arm is linked to a linear drive, it can only
move horizontally, which restricts the angles and positions at which it can clean
windows.

3. Maintenance: Regular maintenance and repairs are necessary for the robot arm,
which can be expensive and time-consuming.
4. Power Supply: The robot arm needs a constant power source, which might be
difficult when operating in isolated or difficult-to-reach locations.

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 CHAPTER II

PROJECT-RELATED LITERATURES

2.1 CONVENTIONAL WINDOW CLEANING METHODS

High-rise building window cleaning is a time-consuming, demanding, and

dangerous task that needs to be done sometimes. The four major techniques window
cleaners have historically employed for that job are the bosun's chair, the boom, the
carriage, and the portable davit (A. Zhang et al., 2022).

The bosun's chair is a practical piece of equipment for comfort and security. It is
a piece of equipment that allows someone to work while suspended from a height in its
most basic form. There will be rigging, a safety belt, and a seat on a bosun's chair.
Pulleys and ropes connected to the rigging are used to lift and lower the chair. It sounds
like a climbing harness, but it is not one. A climber's harness and a bosun's chair will
resemble one another in certain ways, and they may even have some features in
common. The hard seat of a bosun's chair does, however, alter the user's range of
motion. The user can work comfortably while suspended in a bosun's chair, but
climbing would be impossible due to the restricted range of motion. Although providing
the mobility needed for climbing, a climber's harness lacks a seat, making it difficult to
work from it (McManus, 2018).

The oldest and most often used approach is Boom. It has a structure that can
hold a lot of washers, allowing a crew to work together at once. Remember that this is a
permanent system that is used as required and is attached to the building's roof. A
Carriage, on the other hand, is a better choice that is currently gaining in popularity.
Since the carriage is mounted on a rail on the roof, it may move left and right across the
facade. It has a clear mobility advantage over a Boom and is similar to a Boom in that it
can handle multiple washers at once (Banks et al., 2018).

The davit system looks like a miniature crane or a portable window cleaning
tool. To move anything that is hanging in the davit's hanging area, a hoist is required.
Cleaning the windows of imposing structures is a difficult task. Everything might go
wrong if the wrong tools aren't used. Your building's window cleaning operation will be
made significantly easier by installing a davit facade cleaning system. The two
fundamental parts of a davit system in general are a base plate or pedestal and a moving
davit arm. There is no need to worry about any injury because the system is constructed
of materials like stainless steel and aluminium. The base of the davit, which supports the
davit arm, is a metal plate affixed to the roof (A. Zhang et al., 2022).

7
2.2 AVAILABLE PRODUCTS IN THE MARKET

2.2.1 Biped Robot

While it excels at reach and area coverage, this robot is not nearly as efficient in
cleaning speed as other available products are. However, it can flexibly manoeuvre
obstacles using a biped climbing mechanism. Each of the two feet is equipped with
cleaning brushes, suctions, vacuum pumps, amongst other components as shown in
Figure 2.1. This allows for heightened building compatibility, as it needs no prior
infrastructure. Remote controlled servo motors acting as joints in each leg serve to
provide further reach as required for window size. While there is a lack of information
about the pricing of this unit, it is worth mentioning that authors highlighted its low
maintenance value (Mohd Aris, 2020).

With a total weight of 5kg, the robot uses 2 motors, along with 4 suction cups.
The first motor is used to drive the robot up and down. While the other motor is used for
horizontal motion. Furthermore, the robot also uses two sliders placed on top of each
other. This provides the robot with a four-way directional movement. On top of that,
four sensors are also installed in the device in order to determine the location of the
robot once the cleaning process is finished. LEDS are also installed in the robot to
indicate the battery power (Mohd Aris, 2020).

FIGURE 2.1 Biped Cleaning Robot (Mohd Aris, 2020).

8
 In addition to two squeegees at either end of the device to remove extra water,
the gadget has two sponges at the bottom. The apparatus has a plastic container attached
for carrying cleaning fluid. Two trans-wheels are employed for movement, allowing the
machine to travel in any direction. On either side of the robot, two linear sliders are
utilised simultaneously. There are two linear actuators utilised to create movement. A
vacuum generator is also used to regulate the cup suctioning operation. The robot moves
by using its two suction cups, one on each side (Shamah, 2008).

2.2.2 Sirius

A bulky system is bound to have pros and cons that justify the weight and
resources mobilised. Sirius, developed by the Fraunhofer Institute for Factory Operation
and Automation, presents a suitable exhibit of this statement. To utilise this system, a
gantry crane must be installed on a railing on the rooftop, making it an incompatible
system for buildings with limited roof access. Four gantry cables provide hanging
support for the robot, bearing its weight so as to reduce load on the facade. Winding and
unwinding of the cabling via an actuated winch initiates vertical motion along a singular
panel plane, while an advanced sliding mechanism assists in upward and downward
climbing or walking (Saenz, 2001).

Consequently, a slightly sluggish cleaning speed of 80 m2/h is achieved.

Contrary to expectation, this begets a higher cleaning performance due to highly
optimised equipment gaining more time to clean any given windowpane, confirming
cleanliness of tough to reach corners (Elkmann et al., 2001).

The SIRIUS robot's key characteristics are as follows:

• The most extensive range of facade type adaptation.

• Move safely without using rails on the facade.

• Navigation of barriers, such as cover strips, lamellae for sun protection, and
ventilation grates.

• Sensors can recognise the structure and barriers on a façade on their own,
and an autonomous software can create robot behaviours based on sensor
data.

• Facade stress is less.

• Simple operation.
9
 • Dependable cleaning.

• Observance of safety standards (TÜV, BG).

Additionally, trickling water is filtered and recycled in a closed loop, increasing

sustainability of the device. Meanwhile, the advanced sliding mechanism consists of
two module pairs equipped with vacuum suckers, which provide the most remarkable
adhesion to the glass building surface which can be seen in Figure 2.2. Employing the
aforementioned safety components working in conjunction with a distinctly complex
human-interface, maximum safety is acquired. The sensors and actuators required in
producing the said human-interface are capable of constructing a frame for various
levels of automation and monitoring.

FIGURE 2.2 Modular Climbing Robot for Façade Cleaning (Elkmann et al., 2001).

2.2.3 Window-mate

Window-mate is another small-size glass-cleaning robot that utilises magnetism

and vortex suction for attachment to the surface and uses the fibre pads to clean the
surface. Window-mate is directed more towards domestic use with the main focus being
customers living in apartments or houses. Due to its ability to attach to both sides of the
glass as seen in Figure 2.3, Window-mate can simultaneously clean both sides of the
10
glass. This is possible due to Window-mate being equipped with magnets. Furthermore,
upon losing power, Window-mate is able to stay attached to the wall and not fall off
proving some level of safety (Prudour, 2022).

Window-mate is also equipped with a lithium-ion battery. This battery can last
for around 90 minutes on a full charge. On top of that, the robot can move at a speed of
6cm/sec. According to the product description, Window-mate is ideal for windows with
a thickness varying from 5cm to 15cm (David, 2022).

FIGURE 2.3 Window-mate Cleaning Robot (David, 2022).

When it comes to cleaning area, cleaning performance, and safety, Window-

mate lags certain products that already exist in the market. However, pertaining to the
ease of use and cost, Window-mate excels. One of the downsides of Window-mate is
that without being attached to both sides of the window, the robot is rendered useless.
Hence, there is no use for the robot on windows that do not open. On top of that, the
price point is also a point of concern. Coming in at $560, the robot is considered
expensive for the audience it is trying to cater (Park et al., 2019).

11
2.2.4 Mantis

The constant maintenance of modern skyscrapers and high-rise buildings

includes cleaning their glass facades. Robots may take the place of humans in this
scenario. Many studies on themes connected to glass façade cleaning robots have been
conducted in recent years, including climbing mechanics, human-robot interaction,
control strategies, and autonomy (K. Seo et al., 2013; Tomiyama et al., 2017).

Mantis, as shown in Figure 2.4, is a modular climbing robot that uses a strong
commercial impeller as the adhesion mechanism, as reported by (Vega-Heredia et al.,
2020). It is frequently required to separate the robot through one window panel and re-
join it to another, even with robotic façade cleaners. Mantis can recognise frames (or
any other obstructions besides glass) and, thanks to its modular nature, can move from
one window panel to the next while avoiding the frame. As a result, no human
intervention is needed. This is a part of the autonomy that was created for the façade
cleaning robot, which underwent thorough design, mobility, and control analysis.
Mantis's locomotion system allows it to move at a top speed of 15 cm/s. Mantis also
offers a high level of safety in addition to providing proper cleaning thanks to its crack
detection approach.

FIGURE 2.4 Mantis Robot (Vega-Heredia et al., 2020).

2.2.5 Mech-Clean Bot

Modern window cleaning robots, like the one created by Houxiang, Jianwei, and
Guanghua, are more automated, reducing the need for human interaction. The use of
pneumatic technology, which has the nonlinearity property that makes it difficult to
12
execute exact position control, was the design element that stood out the most (H.
Zhang et al., 2006).
It is obvious that these businesses lack the funding to invest in pricey robots
when you consider that the labour in the cleaning sector is often part-time, female-
dominated, and has a large share of migrant workers and employees from ethnic
minorities. Below are several cost-oriented robots that were made at incredibly cheap
costs to get around the need that robots be pricey. There haven't been many reports in
the literature about budget-conscious ways to construct robots out of leftover
mechatronics.

Then, a self-sustaining robot made from e-waste and powered by renewable

energy called Scrapino; may be utilised in a variety of ways, such as welcoming people,
handing out flyers, and serving as an information robot by providing details about
upcoming conferences, the schedule, workshops, etc. (Hoxha et al., 2018).

Reached by Bula et al., (2021), Mech-Clean Bot in Figure 2.5, a Cost-Oriented

Autonomous Window Cleaning Robot from Mechatronic Scrap, is a one-of-a-kind robot
that can be used not only in the home but also in skyscrapers. The Mech-Clean Bot
project was made with old parts found in the Mechatronic laboratory, including Arduino
Uno R3, Bluetooth HC-06, Gear motors, Motor Shield L298, Neobidium Magnet,
Resistor, Servo motor SG9, and Transistor IRFZ44N.The instant the robot is placed on
the window, it begins cleaning it using the Bluetooth RC Controller programme that has
been downloaded to the smartphone in preparation. Using the same application,
customers are able to direct the Mech-Clean Bot to clean the window without having to
move. With a nominal cost of around 16 euros due to it mainly being built from e-scrap
material, Mech-Clean Bot is one of the cheapest Autonomous window cleaning robots
on the market. However, because it is built from e-scrap, Mech-Clean Bot has a low
product life, and relatively low safety when compared to other window cleaning robots
on the market.

13
 FIGURE 2.5 Mech-Clean Bot (Bula et al., 2021).

2.2.6 Sky-Cleaner 3

Akira Nishi and Hiromori Miyagi developed a form of wall-mountain climbing

robotic the usage of the propulsive pressure of propellers (Nishi & Miyagi, 1993). The
robot could be very light however the noise generated with the aid of using propellers is
simply too loud to apply on glass walls. Even if the bad strain chamber isn't always
touchy to a leakage of air, the bad strain will now no longer be sufficient for the secure
and dependable attachment to the vertical floor while the robot crosses window frames.

A kind of pneumatic cleansing robot developed for cleaning the embassy of

Canada through a business enterprise in Japan (Nishigami & Mizushima, 1992).
However, it cannot stroll sideways. Since 1996 the organization of the Robotics Institute
of BeiHang University has been growing an own circle of relatives of sky cleanser self-
sustaining mountaineering robots with sliding frames for glass-wall cleansing.

Nowadays, it is not uncommon to find buildings of varying structures and

geometries, accommodating various themes. Shanghai Science and Technology
Museum is one such case, in which its complicated facade curvature becomes the basis
for the building and deployment of the SkyCleaner3 facade cleaning robot as shown in
14
Figure 2.6. Researched by (Houxiang Zhang et al., 2006). Sky-Cleaner 3 is an all-
around contender, meeting most stipulated criteria, yet coming up short at a minor
handful of setbacks. The climbing mechanism for Sky-Cleaner 3 uses suction cups and
the cleaning mechanism of this robot uses a brush. The cleaning efficiency is about 125
m2/ hour. An adaptive cleaning head is designed especially for effective, efficient and
safe cleaning, equipped with a drainage collecting device.

FIGURE 2.6 Sky-Cleaner 3 (Houxiang Zhang et al., 2006).

When the glass is being cleaned, the water is not allowed to drip down, it is
firstly drawn off the glass wall through a vacuum pump on the robot. Then the water
will flow down because of the gravity and be collected on the supporting vehicle on the
ground. At last, the drainage will be filtered, and then reused for cleaning. It is light and
consumes less energy. Even if the robots are very complex and intelligent, the suitable
working height is below 50 m because the weight of the hoses has to be taken into
account when the robot works in mid-air, and it is quite costly.

2.2.7 TITO 500

One of the most advanced solutions robots SiriusC. Elkmann et al., (2008) has
developed it at the Fraunhofer Institute for Factory Operation and Automation and is
primarily based totally on using suction cups collectively with a sliding body
mechanism. Robot SiriusC is a strolling system and is characterized through
extraordinarily complicated shape and occasional speed of movement. As a result, the
robot SiriusC is characterized through high fees and low productivity (2 m2 /min).
15
 According to Akinfiev et al., (2009), the cleaning efficiency for TITO 500 is
about 25 m2 /min. It has a mass of 200 kg and dimensions of 1.5m x 1.3m x 0.34 m. The
climbing mechanism of this robot uses a pulley system. For the cleaning mechanism,
there are 5 brushes which can rotate on the window. The cleaning robot moves vertical
surfaces, therefore increasing productivity. Then, the safety and control of this robot are
fully reliable. It is quite costly because the thruster needs to use a lot of power. It is not
sustainability based on energy efficiency on this robot. Figure 2.7 shows TITO 500
cleaning robot.

FIGURE 2.7 TITO 500 Cleaning Robot Akinfiev et al., (2009).

2.2.8 Benchmark for the Available Products in the Market

The window cleaning products available in the market have been evaluated
based on the criteria mentioned in Chapter I section 1.2. There was a weakness observed
in the job completion for most of the product as well as their building accessibility. In
addition, the cost of the products is expensive including the initial cost, maintenance
cost, and running cost. Table 2.1 shows the benchmark for the available window
cleaning robots in the market.

16
TABLE 2.1 Benchmark for the Available Window Cleaning Robots in the Market.

Model Biped SiriusC Window- Mantis Mech- Sky- TITO

Cleaning mate Clean Cleaner 500
Robot. Bot 3
Feature
Cleaning
Efficiency
(m2/h)
Accuracy

Stability &
Adhesion
Emergency
Protocol
Building
Accessibility
Feedback
Control
Level of
Autonomy
Compatibility

Cost

Complexity

Water
Circulation
Energy
Efficiency

2.3 PATENTS

2.3.1 Gas Driven Automatic Moving Steam Circulation Window Wiping Robot
(US20190038091A1)

A gas driven automatic moving steam circulation window wiping robot was
invented by Siu Tung Nam in 2019. It was introduced to solve some of the common
problems that exist in current products which are missing corners when wiping, bad
wiping results and circulation of water for wiping windows. The structure is reasonable,

17
with the advantages of being simple, convenient to use, saving water, being safe and
dependable, and having a high degree of automation, allowing it to successfully tackle
the problem of existing window wiping robots being unable to wipe the corners of
windows.

The present invention has the benefit of including a housing having an aperture
at the bottom, a driving mechanism, a wiping mechanism, and a steam circulation
system. The drive and steam circulation mechanisms are located inside the housing, and
the circular grooves on the housing allow safety ropes to be inserted, preventing the
ropes from binding together, thus improving the safety of window cleaning robots.

The wiping mechanism consists of a striped wiping cloth and a rotating brush
deployed inside the housing; the striped wiping cloth washes the middle region of the
window while the rotary brush wipes the edges and corners, ensuring that all areas of
the glass are covered, resulting in cleaner wiping. The driving mechanism provides
support for the housing via rolling wheels, connects the present invention to the window
by suction cups, and allows it to travel along windows using a suction cup walking
device, therefore improving safety. Figure 2.8 shows the patent details.

FIGURE 2.8 Gas Driven Automatic Moving Steam Circulation Window Wiping
Robot (US20190038091A1).

2.3.2 Window Cleaning Apparatus (US7231683B1)

Cruz, (2007) revealed a window-cleaning apparatus for a building. In

particular, a window cleaning apparatus placed on the outside of a window frame
18
within tracks attached to a building. The window washing apparatus can be operated
only in certain circumstances from within the building. Cleaning solution is released
from dispensing jets placed along the bottom edge of the equipment as it goes down
the tracks. The equipment has a brush element that extends between the distal ends
to clean the windowpanes of dirt. A sponge element placed vertically above the
brush element further cleans the display. The window is then dried after coming into
touch with a drying device.

By providing a window cleaning tool mounted to the outside of a window

opening, the window cleaning apparatus overcome the problems with the
patentability. The device has a cover piece that contains a window cleaning tool. By
using a motor attached to the window cleaning equipment, the cleaning apparatus
may be moved over the surface of the windowpane while being selectively operated
from the interior of the building. Moving along fixed guide tracks on opposite sides
of the window opening the apparatus follows the aperture's curve. Figure 2.9 shows
the patent details.

FIGURE 2.9 Window Cleaning Apparatus (US7231683B1).

19
2.3.3 Cleaning Robot for Window of High-Rise Building (KR101128526B1)

The present invention's window cleaning robot for high-rise buildings operates
the building's glass windows to improve uniform adherence on the glass window
cleaning surface while effectively overcoming obstacles. It was invented by US KR (US
KR, 2012). The cleaning robot is contained in the space section of the main body, which
is created with a space portion on the rear. In addition, the robot body has two sets of
driving wheels attached to its top and lower ends by suspension-link systems,
respectively, to help it manage obstacles. The main body also has thrusters on both sides
that help the main body move quickly toward the cleaning surface.

Moreover, the suspension-link device is a swing arm with one end attached to
the driving wheel's rotation axis, the lower end vertically connected to the other end of
the swing arm, and the higher end connected to the main body's rear. A link linked
buffer could be included in it. A propeller housing attached to both ends of the main
body, a rib inside the housing created radially, and a propeller attached to the rib to
produce thrust are possible components of the thrust device.

The cleaning equipment comprises of a sprinkler attached to the back of the

water supply pipe and horizontally mounted to the space, a detergent mixing device
connected to one side of the water supply pipe, and a water supply pipe mounted to the
upper end of the space. For cleaning the contact surface while rotating, it could come
with a brush. Besides, a cable for power supply, control communication, and towing
may also be added to the main body's top part. By maintaining a consistent contact force
on the cleaning surface while overcoming obstacles effectively and quickly without
inclining the body when overcoming obstacles, the existing invention has the effect of
enhancing the stability and efficiency of the cleaning operation. Figure 2.10 shows the
patent details.

20
 FIGURE 2.10 Cleaning Robot for Window of High-Rise Building
(KR101128526B1).

2.3.4 Window Wall Washing Device for High Rise Buildings (US3942213A)

Window wall washing device for high rise buildings was invented by (Hoener,
1976). The invention relates to window and wall washing devices enclosing a wall
washing sight in a curtain of fast-moving air. The device includes an air barrier around
the perimeter to keep washing liquids from leaking into the space between the unit and
the outsides of high-rise buildings' windows and walls. The device also contains
mechanisms that restrict considerable outflow of cleaning liquids from the wall washing
sight while guiding any cleaning liquids away from the buildings outside wall surface
back into the mobile cleaning equipment through the wall washing sight.

The implementation of this invention, the device has a hollow perimeter duct
that is partially defined by the housing’s boundary wall. The hollow perimeter duct has
a perimeter opening that is set back from the buildings outside wall and directs the
previously mentioned high-velocity air flow against it. Besides, the housing has a
forward edge that is set aside from the outside wall surface of the structure. The
mentioned air curtain's high velocity, inside rush is created by effectively pulling
ambient air inside at the wall washing site's edge. For collecting the cleaning solutions
and recovering some of the entrained air, the housing has an enclosed chamber that
extends backward from the wall washing sight. Through a liquid reservoir carried by the
mobile cleaning device, cleaning solutions are recirculated from the enclosed chamber
for reuse.
21
 Next, the housing has a linear opening that runs the full length of the chamber
and directs the in-rushing air curtain at the outer wall surface of the building. The
housing additionally has a compartment that spans the top of the chamber completely
and is partially delineated by spaced squeegees. The squeegees are placed in wiping
alignment with the outer wall surface of the structure while the washing cycle is in
progress. They are angled with respect to the horizontal. The pressure inside the
compartment is kept higher than inside the chamber. The design of the compartment
creates at least one high-velocity, rushing gas stream when the initial squeegee is
deformed by contact with a protrusion, such a horizontal muntin. The high-velocity in-
rushing gas stream travels across the whole width of the muntin because to the slope of
the squeegees, basically removing all the extra cleaning solution and returning it to the
chamber. Figure 2.11 shows the patent details.

FIGURE 2.11 Window Wall Washing Device for High Rise Buildings
(US3942213A).

2.3.5 Automatic Window Washer (US30805921)

A wall window device was invented by Charles in 1963. It provides an

extremely rapid, efficient, and reliable automatic window cleaning robot. The invention
is housed on a structure that can be lowered along a vertical row of windows at speeds
of up to 60 feet per minute while simultaneously cleaning all of the windows in the row.

22
A motor-driven rotational sponge assembly with methods for continually soaking the
sponges is part of the frame.

The invention has a built-in supply of cleaning water that is filtered and
circulated, recovered by sealing mechanisms below the rotational sponges, and does not
require supply hoses or any other external water source. The objective of the device is to
reduce the hose's weight, avoid the potential for fouling, and the issue of how to dispose
of wasted water. In addition, the rotating sponge assembly is positioned above the
mechanism carrying a squeegee wiper against the window surface so that the equipment
may carry out all of the typical window washing tasks.

Besides, durable material is used to create the components of the rotating sponge
assembly and the water recovery seals that extend from the frame toward the windows.
Such components will give way in the presence of a sash or other projection and recover
their usual shape and functionality after the projection has passed. Figure 2.12 shows
the patent details.

FIGURE 2.12 Automatic Window Washer (US30805921).

23
2.3.6 Remote Control Valve for Water Meters Control (EP 3 660 364 A1)

Remote control valve for water metre control was invented by Miraglia &
Giuseppe in 2020. The invention includes an electric motor-controlled shutter,
communication means for transmitting data to a remote server and receiving commands
from said remote server, at least one sensor for acquiring information about the position
of said shutter, supply means for said electric motor and said sensor, and electronic
means for controlling said electric motor to limit the water flow rate that can be
supplied to said shutter.

Remote control valve for water meters control is a motorized hydraulic valve for
usage at a water supply network user connection point means of transmitting data to a
distant server as well as receiving commands. The data supplied may include
information about the state of the same valve's operation, as detected by an appropriate
sensor, as well as information about the metre reading, if the valve is incorporated into
the metre.

Furthermore, the valve has conveniently local control mechanisms that allow it
to be controlled by an operator, either manually (through one or more buttons) or
electronically (for example an infrared remote control). The valve additionally has a
display that displays information about the valve's operational state to the operator.
Figure 2.13 shows the remote-control valve.

FIGURE 2.13 Remote Control Valve for Water Meters Control (EP 3 660 364 A1).

24
2.3.7 Surface Washing Drone (US20170305547A1)

In a nutshell, the embodiments of surface washing drones with a rotating,

pivoting modular cleaning head unit, or drone head, are described herein. Building
owners and property managers will be able to considerably cut costs and risk while
cleaning their windows thanks to surface washing drones (also referred to as drones
herein for simplicity). Some surface cleaning drones can fly up to 1,600 feet in the air,
enabling them to clean windows on some of the world's tallest buildings while being
controlled remotely, like from the ground.

The window washing drone, invented by Scott J. Tamkin, SR., consists of a

body, at least four propellers attached to the body, a central unit attached to the body,
the central unit including a processor, a parachute module, a connection for fluid supply,
and one or more sensors, and a drone head attached to the front of the body, the drone
head including a cleaning head and a squeegee, the drone head additionally including
one or more motors to control a number of spur gears that control the cleaning.

A camera may be included in the surface cleaning drone so that the user can
view both the area being cleaned and its surroundings. The camera may also be used to
set the surface cleaning drone's location in relation to its objective (Tamkin SR, 2016).
Figure 2.14 shows the surface washing drone.

FIGURE 2.14 Surface Washing Drone (US20170305547A1).

25
2.3.8 Suction Cup Robot with Wall Climbing Function (CN104149868A)

The suction cup robot, developed by a Chinese inventor, is a modular patent

with the main ability to climb walls, inclined surfaces as well as small obstacles. The
modularity of the robot is not implemented within the proposed embodiment of the
robot, but rather it is asserted as a suitable platform for various uses to combine with
wall climbing. Instead, the creators go into deep detail describing components of the
robot that allow it to crawl along either a flat surface or a sloped surface of varying
degrees.

The main body in the centre of the robot is composed of two smaller fused
bodies (8mm hard alloy casting between parts labelled 1 and 2) which house the
actuating components of the system such as the vacuum pump and the driving motor.
The motor is directly connected on either side to an axle drive shaft, which is then
connected to a driving wheel. This main driving wheel (labelled 4) consists of gear-like
protrusions that interface with a connecting latch (labelled 7) built into the crawler belt
(labelled 6). As the drive wheel rotates, the crawler belt engages with the two ‘flower
wheels’ (labelled 5) which in turn assists in the rotation of the crawler belt in order to
cause attachment of the suction modules onto the surface.

Meanwhile, there are a minimum of 16 suction modules attached (minimum 8

embedded into each crawler belt) which are actuated by the vacuum pump built into the
fuselage body. Finally, a ventilation pore for the vacuum pump is placed between the
suction module and the crawler belt, with airflow controlled by a manual valve. The
purpose of this is to control the consolidating drive force provided by the suction and
crawler belt module. Figure 2.15 shows the suction cup wall climbing robot.

FIGURE 2.15 Suction Cup Robot with Wall Climbing Function (CN104149868A).
26
2.4 CONTROL

Window-cleaning robots, as with most industrial robots, rely on a control system

to govern the operation of the robot mechanisms dynamically. The controller system
typically uses feedback from various sensors to result in desirable positioning and
actuation of the remaining system components. This provides a bridge between desired
control and its realisation in an intelligent system (Li et al., 2021).

It is important to note that the controller architecture is highly dependent on the

type and number of sensors, actuators, and desired controls. Thus, the complexity of the
controller is connected to the desired complexity of the system in terms of adhesion,
locomotion, and cleaning actuation requirements. Furthermore, additional complexity is
attributed to the level of autonomy employed by the robot, with some systems allowing
for multiple levels of control between full-automation and remote control (RC)
(Gambao et al., 2008).

2.4.1 Internal Sensors

A survey on window-cleaning robots and their techniques by (Li et al., 2021). It

categorises sensors into two main types, being internal and external sensors. As the
name implies, internal sensors assess the internal working state of components, relaying
them to the controller as feedback. For instance, (Sun et al., 2021) designed an
Unmanned Aerial Manipulator with three vacuum suctions for adhesion. In this case, a
simple sensor is used to monitor the pressure within the suction cup, ensuring the
stability of a pressure value which indicates safe robot adhesion. This is in fact a
barometer sensor embedded within the vacuum which reports the pressure inside its
respective cup in real time.

2.4.2 External Sensors

Meanwhile, external sensors scope and observe the surrounding work

environment for required parameters, such as distance between the robot’s end effector
and the glass. An example of this capability is demonstrated by the facade cleaning
robot SiriusC, which uses a novel eddy current sensor to detect oncoming obstacles
(Elkmann et al., 2005). Eddy current sensors, also known as inductive sensors, are non-
contacting position sensors used for measuring the change of position of a specified
target, which in this case is the robot position relative to the window borders.
Measurements made using this sensor are of high resolution.

27
2.4.3 Controller Unit

The data from sensors is transmitted to the control unit for processing and
combination with data input from other sensors before an action is decided. In the case
of SiriusC, the chosen controller is a Programmable Logic Controller (PLC) which was
modularly programmed to maximise compatibility of the robot with other facades. This
adaptive programming allows the various sensors on board the system to detect system
boundaries for new buildings given only a few parameters such as total building length
and maximum obstacle height. Figure 2.16 demonstrates the conceptual control system
of SiriusC. It is to be noted that this robot operates fully automatically.

FIGURE 2.16 Robot System (Gambao et al., 2008).

Meanwhile, robots that involve remote control and/or semi automation often
utilise multiple controllers in collaboration. CAFE, a semi-automatic window cleaning
robot was developed by (Gambao et al., 2008). It has three main controllers distributed
amongst its system components. The control module, responsible for kinematics and
cleaning mechanisms, consists of an embedded PC with Twin Cat-PLC core and

28
Windows CE. This allows for the combination of Windows based programming and
PLC programming.

The carrier module, responsible for vertical motion of the robot along the facade,
is equipped with the same microcontroller. Finally, the third controller is a PC or Laptop
used by an operator on the ground, providing a graphical user interface. This setup is
not only cost effective, but it also allows for manual operation, automatic operation,
amongst other advantages such as increased safety. The controllers are designed to be
able to control different parts of the robot in the case of a malfunction or error elsewhere
in the system. The control scheme for the CAFE robot is pictured below. Figure 2.17
shows the wireless connections.

FIGURE 2.17 Wireless Connections (Elkmann et al., 2005).

2.5 TOPOLOGY OPTIMIZATION

In the design process known as topology optimization, mathematical methods

are used to maximize the form and arrangement of a building or system while adhering
to a set of requirements (Yao et al., 2019). Finding the best material distribution in each
design space that maximizes system performance while decreasing the system's weight,
cost, or other design parameters is the goal of topology optimization (Zhu et al., 2016).
29
 Under the most difficult operating conditions, in both static and dynamic
working situations, Yao et al., (2019) employed ABAQUS to perform structural
topological optimization on an upper arm of an industrial welding robot to minimize
weight. The repeatability tests' outcomes showed that the optimized upper arm's overall
performance was better than the original one.

An investigation into topology optimisation was done on a multi-modal robot

with the ability to walk and fly. The study focused on lowering the weight of each robot
component while keeping the structural integrity and performance standards using the
Solid Isotropic Material with Penalization (SIMP) method. According to the findings,
the optimised design reduced weight by up to 54.4% when compared to the original
design (Natarajan et al., 2019).

30
 CHAPTER III

CONCEPTUAL DESIGNS AND EVALUATION

3.0 INTRODUCTION

In this chapter, the procedures taken to achieve the specified objectives are
thoroughly discussed. With the aid of SolidWorks and ANSYS softwares, three window
cleaning mechanisms have been developed and evaluated. A selection matrix is created
to select one of the designs to proceed with. After that, a prototype is constructed to test
out the functionality of the design.

3.1 FLOW CHART

Different window cleaning mechanisms for high-rise buildings are proposed and
discussed in terms of design concept, working mechanism, and modeling. Proceeding
with the next step, the designs have been evaluated from different perspectives and
criteria which is mentioned in chapter I section 1.2. Once done, a design selection
matrix is constructed to select the design to go with. Topology optimization was
conducted for the selected design to improve its efficiency and power consumption.
Other analysis such as stress, deformation, and safety factors are conducted. Moreover,
a prototype is constructed to prove the functionality of the design. MIT APP Inventor is
used to develop the application used to control the system. Figure 3.1 shows the
detailed flow chart for the project.

31
32
FIGURE 3.1 Detailed Flow Chart.

33
3.2 CONCEPTUAL DESIGNS

3.2.1 Conceptual Design 1: Window Cleaning Drone

Commercial window cleaning has developed in great part thanks to technology.

Reaching windows on towering buildings or large facilities has always been difficult.
Cleaning drones are a game-changer in this regard, enabling efficient and unobtrusive
remote cleaning. Cleaning drones can be set to target difficult-to-reach places and fly to
the desired height. By eliminating the need to do challenging and hazardous cleaning
tasks at great heights, technology has transformed the cleaning operative into more of a
cleaning programmer (Li et al., 2021).

Drones are a perfect fit for the agricultural industry, as farmers may have access
to real-time data about vast areas of land. Drones can assist in tracking nearly anything,
including soil analyses, crop health, heat signatures, and water use (Meola, 2021).
Drone inspection of existing infrastructure may be quicker, cheaper, and most
importantly, safer. As an illustration, the New York Power Authority tested deploying
drones to examine an ice boom close to Lake Erie recently. Normally, inspecting one of
these ice booms would cost $3,500 to send a helicopter or $3,300 to send a boat, but
deploying a drone only cost about $300 (Walker, 2019). This design has been greatly
inspired by the window cleaning drone invented by Scott J. Tamkin, SR in 2016
(US20170305547A1).

3.2.1.1 Working Mechanism

The robot's movements are managed by RF signals and have six modes. The
cleaning module begins operating when it contacts the wall, and the cleaning task is
finished by directing the UAVs up and down movement. Three actuated omnidirectional
wheels, an aerial manipulator, and a specially designed end effector make up the multi-
modal motion system. The UAV system provides the foundation for movement, carries
the manipulator to the intended location, and supplies the necessary normal force to
produce friction. The end-effector of the robot performs a cleaning motion.

Furthermore, metallic wires along with heavy weights are used to support the
drone as seen in Figure 3.2. This provides an added level of safety in case of a low
battery scenario. The drone is equipped with two hoses. The first one receives the water
and air from a separate tank installed on the roof. The other hose is used to inject
pressurized water or air to the glass window.

34
 FIGURE 3.2 Climbing Mechanism of the Window Cleaning Drone.

3.2.1.2 Window Cleaning Drone Evaluation

The Efficiency and Efficacy of the design can be evaluated in this section.
Figure 3.3 shows the window portion to be cleaned. The time required to clean 1 m2
area is obtained by the following method.

𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 0.15 𝑚𝑚/𝑠𝑠

𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 0.2(0.9) = 0.18𝑚𝑚2

Equation (3.1):

𝑠𝑠
𝑣𝑣 =
𝑡𝑡

0.9
𝑡𝑡 = = 0.0016 ℎ
0.15

0.18(1)
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑝𝑝𝑝𝑝𝑝𝑝 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = = 108𝑚𝑚2 /ℎ
0.0016

35
 As the window cleaning drone will be spraying a cleaning solution, a delay
factor of 2 is considered.

108
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑝𝑝𝑝𝑝𝑝𝑝 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = = 54𝑚𝑚2 /ℎ
2

FIGURE 3.3 Window Portion to be Cleaned.

As for the job competition, being small and lightweight, the drone can reach
certain small areas. Furthermore, due to its high cleaning speed, jobs can be completed
quickly. Further mor, the safety is evaluated based on the emergency protocol and
stability and adhesion. As for the emergency protocol, the drone would be attached with
a cable. This cable will not only supply water to the drone, but also act as a fail-safe in
case of any power loss. However, there may be loss of connection if the drone exceeds
the range limit. According to Zang, (2019), this range on average is around 160 ft
vertically which is approximately 14 floors. The stability and adhesions are evaluated
based on the following wind effect process. Figure 3.4 shows the Free Body Diagram of
the drone.

Assumptions (Mohandes et al., 2011):

• Wind speed at 100m, V = 9.8m/s.

• Fixed Parameter for wind load at 100m

• 𝐴𝐴𝐴𝐴𝐴𝐴 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑, ρ = 1.225 𝑘𝑘𝑘𝑘/𝑚𝑚3

36
 • 𝑇𝑇ℎ𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = 0.25𝑚𝑚2

• 𝑇𝑇ℎ𝑒𝑒 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 90°

Equation (3.2) (Smith et al., 1975):

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 0.5 × 𝐴𝐴𝐴𝐴𝐴𝐴 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 × 𝑉𝑉 2

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 0.5 × 1.225 × 9.82

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 58.82 𝑁𝑁

For Thrust Force:

• Mass of the Drone = 0.2kg

• Acceleration of the drone = 4.75 𝑚𝑚/𝑠𝑠 2

• Acceleration due to gravity = 9.81 𝑚𝑚/𝑠𝑠 2

Equation (3.3):

𝐹𝐹 𝑛𝑛𝑛𝑛𝑛𝑛 = 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 × 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

𝐹𝐹 = 0.2 × 4.75 = 0.94 𝑁𝑁

Equation (3.4) (Nguyen et al., 2020):

𝑇𝑇ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 + (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 × 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑑𝑑𝑑𝑑𝑑𝑑 𝑡𝑡𝑡𝑡 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔)

𝑇𝑇ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 0.94 + (0.2 × 9.81) = 2.9 𝑁𝑁

Calculating the Resultant Force:

Equation (3.5):

𝐹𝐹𝑅𝑅 = �(𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐿𝐿𝐿𝐿𝐿𝐿𝑑𝑑2 + 𝑇𝑇ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝑒𝑒 2 )

𝐹𝐹𝑅𝑅 = �(58.822 + 2.92 )

𝐹𝐹𝑅𝑅 = 58.89𝑁𝑁

Angle between the Thrust force and Resultant Force:

37
Equation (3.6):

𝐹𝐹𝑡𝑡ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
𝜃𝜃𝑡𝑡ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = cos −1
𝐹𝐹𝑅𝑅

2.9
𝜃𝜃𝑡𝑡ℎ𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = cos−1 = 87.2°.
58.89

FIGURE 3.4 Free Body Diagram of the Window Cleaning Drone.

As the angle between the thrust force and resultant force is very high, the drone
is not stable. Next category is the control. As stated by Guo, (2019), drones are mostly
suitable for building structures having less than 7 floors. Furthermore, due to the cable
attached, the drone would be prone to restricted movement. Overall, the window
cleaning drone has a low level of autonomy. Furthermore, it is subjected to spatial
limitations of the environment. As mentioned by Barzan, (2021), drones can remain in
the air without a pilot but must stay in the pilot’s Visual Line of Sight (VLOS). Also,
drones are usually toy drones with six-axis gyro sensors to aid in stabilization and
sometimes include a “return home” button on the controller, which returns the drone to
its launch point when pressed.

In terms of sustainability, the window cleaning drone would be attached to a

cable. This cable will provide both pressurized water and pressurized air. However,
there is no water recirculation method that is implemented. According to (Chan 2020), a
38
drone can consume 245.2815W with a standard deviation of 0.2540W. Furthermore, as
the window cleaning drone is not equipped with DC batteries, constant power supply is
a must. Lastly, cost estimation is conducted to evaluate the overall cost of the system.
Table 3.1 shows the cost estimation for the window cleaning drone.

TABLE 3.1 Cost Estimation for the Window Cleaning Drone.

Part Name Price (RM) Material

Drone Assembly 2500 Fiber Glass + ABS Plastic

Water Tank 500 Stainless Steel

Pulley 17 Stainless Steel

Metallic Wire 30 Aluminum

Water Nozzle 50 Plastic

Plastic Hose 1.5 PLA

Air Compressor 320 -

Water Pump 130 -

Electric Wire 0.77 -

Automatic Valve 18.5 -

Electric Motor 130 -

The advantages and disadvantages and disadvantages of the window cleaning

drone are summarised in Table 3.2.

39
 TABLE 3.2 Advantages and Disadvantages of the Window Cleaning Drone.

Advantages Disadvantages

Cleaning area New technology

Cost Not allowed in certain areas

Reusable Frequent maintenance

Cleaning Speed Safety

3.2.2 Conceptual Design 2: Suction Cup Robot

The cleaning module for this design concept consists of suction cups, timing
belt, guide rails, motor, pulley, and shaft. On the outside surface of the timing belt,
suction cups are inserted at equal intervals as the attachment mechanisms that revolve
with the timing belt. A guide rail is important to ensure the suction cup position and
distribute the force of the attached suction cups since the converge belt that is linked to
the suction cup is flexible. The guide rail should press the front suction cup against the
surface while pulling the rear connected suction cup away from it because the suction
cups follow the direction of the guide rail (Ge, 2015). Through the pulley, the motor is
used to drive the conveyor belt into rotation. The Figure below shows the concept
design for suction climbing window cleaning robot. Figure 3.5 shows the Suction Cup
Robot.

FIGURE 3.5 Suction Cup Robot.

40
3.2.2.1 Working Mechanism

By investigating the guide rail and conveyor belt assembly, it can be seen how
the mechanical valve and suction cups interact with the guide rails through guide pins.
The main goal is to use a mechanical valve to automatically open and close the vacuum
supply to the vacuum cups that are run along the guide rail. The mechanical valves in
the other portions of the guide rail may be left closed while the vacuum supply can be
pushed open since the bottom portion of the rail is thicker than the rest of it. This makes
it simpler to raise or remove the cup from the glass surface.

Mechanical valves are crucial in this portion of suction cups. The objective of
the mechanical valve is to switch the vacuum supply on or off for the specific vacuum
cup as needed by using a variety of components. A suction cup does not technically
attach itself to the window and cling to it. Instead, a vacuum generator (such as a
vacuum ejector, blower, or pump) is activated when a suction cup contacts the
workpiece surface and sucks air out of the cup's interior to generate a vacuum (Korane,
2017). The valve is forced to open and close as required by the guide rail's varying
thickness throughout the path.

A cylindrical spinning brush with a holder to keep the window cleaning

materials is attached in front of the cleaning module for use in the cleaning mechanism.
To carry the internal tank in optionally clean the small window area, the main body is
further divided into two portions with acrylic boards: one for the electrical component
and the other for the tank. The cleaning solution is fed to the cleaning module using a
water hose and spray nozzle with a 40° angle. The wiper is assembled in the cleaning
module to wipe the water residue and ensure that no water drops remain that could stain
when dried. Figure 3.6 shows the cleaning module.

41
 FIGURE 3.6 Cleaning Module of Suction Cup Robot.

2.3.2.2 Suction Cup Robot Evaluation

The Efficiency and Efficacy of the design can be evaluated in this section.
Figure 3.7 shows the window portion to be cleaned and the brush size. The time
required to clean 1 m2 area is obtained by the following method. The average maximum
speed using the suction cup modules may achieve 0.05 m/s, according to the robot
invented by Dong Sun, Jian Zhu, and Shiu Kit Tso (Sun et al., 2007). With a brush
cleaning area of 0.1m, the cleaning efficiency is predicted to be 18 m/h. In addition, the
suction climbing robot only moves in one direction, thus this leads to low efficacy.

Figure 3.7 Window Portion to be Cleaned and the Brush Size.

42
Calculations:

𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 𝑜𝑜𝑜𝑜 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 = 0.05 𝑚𝑚⁄𝑠𝑠

𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑜𝑜𝑜𝑜 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏ℎ 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐, 𝐴𝐴𝑏𝑏 = 0.9 𝑥𝑥 0.05 = 0.045𝑚𝑚2

0.05
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏ℎ 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐, 𝑆𝑆 = 2𝜋𝜋 𝑥𝑥 � � = 0.157𝑚𝑚
2

Time taken for cleaning,

𝑆𝑆 0.157𝑚𝑚
𝑡𝑡 = =
𝑉𝑉 0.05 𝑚𝑚⁄𝑠𝑠

Cleaning area in 1 hour:

3600
𝐴𝐴 = 𝑥𝑥 0.045 = 51.59𝑚𝑚2
3.14

A delay factor of 2 is considered:

51.59
𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 = = 25.795 𝑚𝑚2 /ℎ𝑟𝑟
2

The vacuum suction cups themselves may have adhesion restrictions on the
curved and sharply inclined surface. These surfaces might make it difficult to provide
consistent and steady suction. Furthermore, a filthy surface may jam a valve or vacuum
supply (Bouchard, 2014). Thus, the time taken to clean the window will be longer.

As for safety evaluations, suction wall climbing is fundamentally weak to

contact pattern with the surface, as well as the center of mass position, and sliding due
to gravity. As a result, it is critical to measure the harmful impacts of such external force
robot stability, such as the drastic change in wind velocity and center of mass position
caused by variable contact patterns with the surface, as well as the changes of the
adhesive force.

Assuming Parameter to develop in Suction Climbing Robot:

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀, 𝑚𝑚 = 7𝑘𝑘𝑘𝑘 (𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝑑𝑑𝑑𝑑 𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇)

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑜𝑜𝑜𝑜 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐, 𝑑𝑑 = 6𝑐𝑐𝑐𝑐 = 0.06𝑚𝑚

43
Safety factor, 𝑛𝑛 = 4

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑓𝑓𝑓𝑓𝑓𝑓 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔, µ = 0.5

𝑇𝑇ℎ𝑒𝑒 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎ℎ𝑒𝑒𝑒𝑒 𝑖𝑖𝑖𝑖 𝑡𝑡ℎ𝑒𝑒 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 , 𝑆𝑆 = 12

Equation (3.7) (Follador et al., 2014):

𝑚𝑚 𝑥𝑥 𝑆𝑆
𝑑𝑑 = 1.12�� �
𝑃𝑃𝑢𝑢 𝑥𝑥 𝑛𝑛 𝑥𝑥 µ

7 𝑥𝑥 12
0.06 = 1.12�� �
𝑃𝑃𝑢𝑢 𝑥𝑥 4 𝑥𝑥 0.5

Equation (3.8):

𝑃𝑃𝑢𝑢 = 14634.67 𝑃𝑃𝑃𝑃

Equation (3.9):

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑥𝑥 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 14634.67 𝑥𝑥 𝜋𝜋 (0.03)2

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 41.4 𝑁𝑁

(100𝑚𝑚 − 2𝑚𝑚) 2𝑚𝑚

𝑉𝑉 = � � 𝑥𝑥 10% 𝑥𝑥
2 𝑠𝑠

𝑉𝑉 = 9.8 𝑚𝑚/𝑠𝑠

The same fixed parameters for wind load at 100 m used for Window Cleaning
Drone will be applied for The Suction Cup Robot.

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 0.5 𝑥𝑥 𝐴𝐴𝐴𝐴𝐴𝐴 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑥𝑥 𝑉𝑉² = 0.5 𝑥𝑥 1.225 𝑥𝑥 9.8²

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 58.8245 𝑁𝑁

𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑥𝑥 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑥𝑥 sin(𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎)

44
𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 58.8245 𝑥𝑥 0.5 𝑥𝑥 sin 90°

𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 29.41 𝑁𝑁

For gravitational force:

𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑑𝑑𝑑𝑑𝑑𝑑 𝑡𝑡𝑡𝑡 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔, 𝑔𝑔 = 9.81 𝑚𝑚⁄𝑠𝑠

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑜𝑜𝑜𝑜 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅, 𝑚𝑚 = 7 𝑘𝑘𝑘𝑘

𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = 7 𝑥𝑥 9.81 = 68.67 𝑁𝑁

Resultant Force:

𝐹𝐹𝑅𝑅 = �(𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)2 + (𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹)2 + (𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹)2

𝐹𝐹𝑅𝑅 = �(29.41)2 + (68.67)2 + (41.4)2 = 85.41𝑁𝑁

Angle between Suction Force and Resultant Force

𝐹𝐹𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 41.4
𝜃𝜃𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 𝑐𝑐𝑐𝑐𝑐𝑐 −1 = 𝑐𝑐𝑐𝑐𝑐𝑐 −1 = 61°
𝐹𝐹𝑅𝑅 85.41

As the angle between the Suction force and Resultant force is very high, the
suction climbing is not stable. For the control evaluation, the suction-climbing robot
relies on a one directional rotation of the timing belts to induce motion. This is perhaps
its most detrimental feature, as the robot consequently cannot make turns. This forces it
to only move in upwards and downwards directions, unless moved using a harness or
human assistance. This substantially decreases its accessibility to different areas of a
building, essentially forcing it to depend entirely on the size of its cleaning equipment.

For the optimum utilization of the nozzles attached for cleaning, a pre-set
pressure of 8 bar needs to be maintained. To do so, a water flow sensor might be
attached and connected with the control method, being an Arduino or otherwise. The
machine would be mostly remote-controlled (semi-automated) so that it would climb in
either up or down directions. Control would be fulfilled through an Arduino, with the
capability to climb either up or down, the capability to stop for water retrieval from the
roof and storage in its internal tank, and finally an emergency protocol in which it
would climb to the nearest shelter-like location from winds and rains. This would all be

45
completely operator controlled, and therefore there exists no level of autonomy further
than the combination of processes required for one task at a time.

For sustainability, this robot was not designed with an incorporated water
recirculation method. However, the use of a pressure nozzle with parameters optimal for
cleaning is a strategy towards reducing the amount of water necessary to clean
contamination from building facades. Finally, cost estimation has been conducted to
evaluate the cost of this design. Table 3.3 shows the cost estimation for the Suction Cup
Robot.

TABLE 3.3 Cost Estimation for the Suction Cup Robot.

Parts Name Price (RM) Quantity Total Amount

(RM)

Suction Cup 25 12 300

DC Motor 100 1 100

Water Pump Motor 25 1 25

Shaft 15 2 30

Timing Belt (15mm) 50 2 100

Motor Coupling 3 2 6

Roller Brush 95 1 95

Water Holes (1200mm) 10 1 10

Spray Nozzle - 40° angle 20 2 40

Wiper Blade 5 1 5

Hollow Aluminum Bar 20 2 40

(600mm)

46
 Acrylic Board (200mm x 47.5 4 190
200mm x5mm)

Total Cost 941

In addition, the advantages and disadvantages of the suction cup robot have been
summarized in Table 3.4.

TABLE 3.4 Advantages and Disadvantages of the Suction Cup Robot.

Advantages Disadvantages

Low Complexity Low efficiency

Safe Consume a lot of Power supplies

Low Initial Cost Can properly clean only rectangular

surfaces

Recyclable and Reusable Noise

Low weight -

Easy to operate -

Running Cost -

Maintenance -

3.2.3 Conceptual Design 3: Window Cleaning Robot Arm

A robotic arm, also known as a mechanical arm, is a device that operates in a

similar way to a human arm, with certain degrees of freedom that can be determined
based on the number of joints that either move along an axis or can rotate in certain
47
directions (Mecharithm, 2021). In fact, some robotic arms are anthropomorphic and try
and imitate the exact movements of human arms. They are, in most cases,
programmable and used to perform specific tasks, most commonly for manufacturing,
fabrication, and industrial applications. In this section, a window cleaning robot arm is
proposed to replace human labor in a crucial yet dangerous task which is window
cleaning for high-rise buildings.

3.2.3.1 Working Mechanism

A simple 3 DOF robot arm fixed in a ball and screw linear actuator is proposed.
This system is highly inspired by the conventional window cleaning methods as
discussed in the literature review. Powered by servo motors, the robot arm can be
positioned precisely to cover the whole window including the corners. A camera will be
fixed on the arm so that the robot arm can be controlled remotely using an application
with a friendly user interface. The end effector will carry a rotating brush and a nozzle
for cleaning. A hose will be attached to the nozzle during the setup and the water will be
supplied to the nozzle from a roof tank. Moreover, an automatic water valve will be
installed for sustainable usage and water rationalization. The valve is inspired from the
automatic water valve patent discussed earlier. Figure 3.8 shows the robot arm with the
linear actuator.

FIGURE 3.8 Window Cleaning Robot Arm.

A roof car system is recommended to be used for this application. It provides

great flexibility for buildings with varying setbacks, parapet walls, or any other complex

48
forms. The roof car arm allows for greater extension compared to other systems and can
be easily adjusted without much setup time. In addition, the roof car is permanently
fixed to the roof and moves on rails or concrete pads, and the window washing staging
where the robot arm is fixed will be suspended by the roof car arm. Figure 3.9 shows
the initial roof car suspension system design.

FIGURE 3.9 Initial Design of Roof Car Suspension System.

3.2.3.2 Window Cleaning Robot Arm Evaluation

The efficiency and Efficacy of the design is evaluated in this section based on
the following assumptions and calculations.

Assumptions:

• The velocity of the linear actuator v=0.15 m/s

• Wiper length =25 cm

• Cleaned area=0.9×0.25=0.225 m2

Time required to clean 0.225 m2:

𝑆𝑆 0.9 1
T0.225=𝑉𝑉 = 0.15 = 6 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 600 ℎ𝑜𝑜𝑜𝑜𝑜𝑜

49
Cleaned area per hour:

Ahour=0.225 × 1 × 600 = 135 𝑚𝑚2 /ℎ𝑟𝑟

Considering a delay factor of 2 in the cleaning operation:

135
Ahour= 2
= 67.5 𝑚𝑚2 /ℎ𝑟𝑟

According to Li et al., (2021), the product is considered efficient if the cleaning

efficiency is higher than 30 𝑚𝑚2 /ℎ𝑟𝑟. Being suspended in air, the proposed mechanism
will have the ability to reach each corner of the windows and clean it with no problems.
This will result in higher cleaning quality in comparison with the other designs
according to (Y. S. Lee et al., 2016). Furthermore, the safety of the design is evaluated.
The surface is at the contact surface between the system and the building minimised to
provide stability in case of heavy winds. This should provide more stability and safety
to the system while operating. The wind effect is evaluated based on the same
assumptions for the other two designs.

Dynamic Pressure=0.5 × 𝐴𝐴𝐴𝐴𝐴𝐴 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 × 𝑉𝑉 2

Dynamic Pressure=0.5 × 1.225 × 9.82 = 58.82 𝑃𝑃𝑃𝑃

Wind load=Dynamic Pressure × The surface area = 58.82 × 1

Wind load=58.82 N

For suction Force

• Mass of the system with the suspended platform=40 Kg

• Diameter of suction cup d=0.115 m

• 𝑛𝑛 = 4 (Safety Factor)

• 𝜇𝜇 = 0.5 (For window)

• S=4 (Number of suction cups attached)

𝑚𝑚 × 𝑠𝑠
𝑑𝑑 = 1.12�( )
𝑃𝑃𝑢𝑢 × 𝑛𝑛 × 𝜇𝜇

50
 40 × 4
0.115 = 1.12�( )
𝑃𝑃𝑢𝑢 × 4 × 0.5

𝑃𝑃𝑢𝑢 = 7588.053 𝑃𝑃𝑃𝑃

𝐹𝐹 = 𝑃𝑃𝑢𝑢 × 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 = 7588.05 × 𝜋𝜋(0.0575)2

𝐹𝐹𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 78.82𝑁𝑁

Calculating the Resultant Force:

𝐹𝐹𝑅𝑅 = �𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 2 + 𝐹𝐹𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 2

𝐹𝐹𝑅𝑅 = �58.822 + 78.822 = 98.3 𝑁𝑁

Angle between the suction force and resultant force:

𝐹𝐹𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 78.82
𝜃𝜃𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 𝑐𝑐𝑐𝑐𝑐𝑐 −1 � � = 𝑐𝑐𝑐𝑐𝑐𝑐 −1 � �
𝐹𝐹𝑅𝑅 98.3

𝜃𝜃𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 36.6°

Since the resultant force is closer to the suction force, the system is considered
stable and safe. In addition, the system will be suspended from the top roof using a roof
car suspension system. In case the main system fails, which is the robot arm and the
linear actuator, the system will still suspend in air via cables causing no damage to the
system nor the surroundings. Also, in cases of high wind speed, the system was proved
to be stable as shown above.

For the control evaluation, being suspended from the roof with no adhesion
between the building and the cleaning module, the system can move and clean in all
directions and level up to its potential. The system depends on visual feedback sent to
an operator enabling them to control and monitor the cleaning process from their
phones. The connection will be implemented using wireless module HC-12 that allows
for a 1000m connection range. The system depends on visual feedback sent to an
operator enabling them to control and monitor the cleaning process from their phones.
Yet, pattern saving feature is introduced to make the cleaning process much easier. The
operator can save specific patterns from a specific point and press run. The robot arm
will automatically repeat the saved pattern making the cleaning process much easier.
51
 Regarding sustainability, although the system does not allow for water
circulation, a water control valve that can be controlled remotely will be used to control
the water flow and rationalize the water consumption. This will result in a more
sufficient and sustainable system. The energy consumption of the mechanism was
estimated to be 1.5kW/h with each unit costing RM0.50 (Wang, 2016). Further analysis
to compare the running cost of the design with the manual labor cleaning is to be
performed in chapter 4. Finally, cost estimation was performed for the window cleaning
robot arm as shown in Table 3.5.

TABLE 3.5 Cost Estimation for Window Cleaning Robot Arm.

Component Cost (RM)

Wrist Servo Motor (60 kg-cm) 83
Elbow Servo Motor (300 kg-cm) 375
Shoulder Servo Motor (400 Kg-cm) 452
Arduino 103
Wireless Module (HC-12) 19
Linear Actuator 786
Automatic Water Timer Valve 40
Visual Sensor (Mini Camera) 28
Window Cleaning Wiper 5
Aluminium Alloy 100
Total 1991

3.3 Final Design Selection

A pairwise table is constructed to compare and analyze the products and

prototypes detailed in the literature review. The models are evaluated in a point-based
system dependent on the criteria listed in chapter 1. Each criterion is evaluated based on
the number of sub-criteria that govern it. For instance, while safety of the mechanism is
a vital priority, each model registered up to two points, one for stability and one for
emergency protocol.

52
 Meanwhile, models could score up to three points for control, as it discerns the
compatibility of the model with each building, and therefore each client. On the other
hand, if a model does not include any data concerning the necessary criteria, it will be
marked with a dash, ‘-’. This point-based system will provide a numerical value to the
feasibility of these products within the context of this project. Prototypes will be
credited to the author or research institution, while products on the market will be
credited to the manufacturer, seller, or distributor. Table 3.6 shows the selection Matrix.

TABLE 3.6 Design Selection Matrix.

Feature Weight Drone Drone SCR SCR Robot Robot

Score weighted Score Weighted Arm Arm
(0.0-
score (1.0- Score Score Weighted
1.0) (1.0-
10.0) (1.0- Score
10.0)
10.0)
Safety 1.0 4.0 4.0 7.0 7.0 10.0 10
Cost 0.9 3.0 2.7 6.0 5.4 2.0 1.8
Efficiency 0.8 9.0 7.2 4.0 3.2 8.0 6.4
and Efficacy
Compatibility 0.7 4.0 2.8 8.0 5.6 4.0 2.8
Control 0.6 8.0 4.8 7.0 4.2 9.0 5.4
Sustainability 0.5 2.0 1.0 4.0 2.0 4.0 2.0
Total - 30.0 22.5 36 27.4 37.0 28.4

After the weightages and the scores of each criterion have been determined, the
overall score of each design can be calculated by applying the formula below.

𝑚𝑚

𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = �(𝑤𝑤𝑛𝑛 × 𝑠𝑠𝑛𝑛 )

𝑛𝑛=1

m: total number of criteria

𝑤𝑤𝑛𝑛 : weightage of n-th criterion

𝑠𝑠𝑛𝑛 : score of n-th criterion

53
 Being the highest in the overall score, the robot arm is selected to be the design
of interest for this particular project.

54
 CHAPTER IV

DETAILED DESIGN AND ANALYSIS

4.1 DESIGN OBJECTIVES

A set of design objectives have been stated to meet at the end of the project.
These objectives were adopted based on the market requirement to address the safety,
sustainability, health, and environment. Figure 4.1 shows the objectives of the design.

FIGURE 4.1 Design Objectives.

4.2 WINDOW CLEANING ROBOT ARM (WIPER-WATT)

The final design will be a 3 Degree of Freedom window cleaning robot arm
fixed to a linear actuator for horizontal movement based on the selection matrix and
evaluation performed earlier. The name of the robot will be Wiper-Watt which is
inspired by its purpose and functionality. Wiper-Watt is influenced by the traditional
window washing technique, which suspends workers manually in the air using a
gondola. One of the earlier discussed patents served as an inspiration for the water flow

55
control valve (EP 3 660 364 A1). Before completing the design, a number of
calculations must be made, including momentum analysis for the solution flow, inverse
kinematics, and forward kinematics to estimate the force applied to the end effector.

4.2.1 Topology Optimization for Wiper-Watt

Topology Optimization has been deployed for Wiper-Watt to reduce the overall
mass of the design and improve the efficiency and power consumption using Fusion 360.
The process starts by defining the design problem, choosing the material, and number of
axes needed to manufacture the design. After that, the program will start to do iterations
for the generated design until it reaches acceptable results. Figure 4.2 shows the
working are definition for topology optimization.

FIGURE 4.2 Defining the Working Area for Topology Optimization for Wiper-
Watt Link.

In Figure 4.2, there are three main colors, and each one serves a specific
function. The green color delineates the design boundaries, the red color delineates the
computer's limitations (i.e., the computer won't modify anything in this area and is
typically used for holes), and the yellow color delineates the working area for the
computer to enhance the design. Figure 4.3 shows the optimization process for Wiper-
Watt link structure to obtain lesser mass without affecting the structural integrity.

56
 FIGURE 4.3 Optimization Process for Wiper-Watt Link.

Upon using topology optimization, 90.4% reduction of link mass was achieved
as it went from 4.321 kg to 0.417 kg. This analysis's objective was to apply topology
optimisation to make a robot lighter, which it accomplished by significantly lightening
Wiper-Watt. Consequently, it is crucial to investigate how mass reduction affects the
energy consumption of servo motors to move the robot arm. Figure 4.4 shows the
power consumption of Wiper-Watt at full load conditions before and after mass
reduction, assuming the load to be 57.8 N and various velocities, to show how mass
reduction influences energy consumption. The graph is obtained by considering
identical motion scenarios for the design before and after topology optimization.

57
Following the mass reduction, the graph shows a discernible decline in power
consumption, which suggests a decrease in energy consumption as well.

Power Consumption (Old Design Vs New Design)

16
14
12
Power (W)

10
8
6
4
2
0
0 2 4 6 8 10 12 14 16

Time (s)
Befor weight reduction After weight reduction

FIGURE 4.4 Power Consumption for the Old and the New Design.

It can be observed that a reduction of 7.19 W in power consumption is obtained

after conducting topology optimization. It is necessary to take into account the force
necessary to move Wiper-Watt's links, which is proportional to its mass in accordance
with Newton's second law, in order to comprehend how reducing its mass affects its
energy consumption. As a result, lowering Wiper-Watt's mass will result in less force
being needed to move the robot. Moreover, as the mass of the links decreases, the
frictional force acting on the connections between them will likewise decrease. The
frictional force can be overcome with less energy as a result. In addition, the total force
used to move the Wiper-Watt arm must be greater than the product of the tractive force
needed to move the robot arm plus the force needed to overcome friction. The robot will
move with less overall force thanks to its reduced mass, which will result in less energy
being used. As a result, the relationship between the mass and the power is linear. The
following equations were used to do the analysis (Crenganis et al., 2021).

Equation (4.1)

𝐹𝐹𝑖𝑖 = 𝑀𝑀𝑀𝑀

Equation (4.2)
58
 𝐹𝐹𝑓𝑓 = 𝜇𝜇𝜇𝜇

Equation (4.3)

𝐹𝐹𝜏𝜏 > 𝐹𝐹𝑖𝑖 + 𝐹𝐹𝑓𝑓

Equation (4.4)

𝑇𝑇
𝐹𝐹𝜏𝜏 =
𝑟𝑟

Equation (4.5)

𝑣𝑣
𝜔𝜔 =
𝑟𝑟

Equation (4.6):

𝑃𝑃 = 𝜏𝜏 × 𝜔𝜔

Where:

𝐹𝐹𝑖𝑖 – Force Inertia

a – Desired Acceleration

𝐹𝐹𝑓𝑓 - Friction Force

𝜇𝜇 – Friction Coefficient

N – Normal Force

𝐹𝐹𝜏𝜏 – Torque Force

r – Radius of curvature

𝜔𝜔 – Angular Velocity

P – Power

59
 The mass reduction has led to energy and material saving, making the design
more sustainable and practical to use, which achieves the design objectives intended.
Figure 4.5 shows Wiper-Watt after performing topology optimization.

FIGURE 4.5 Optimized Design for Wiper-Watt.

4.2.2 Material Selection for Wiper-Watt

A material selection matrix is constructed to select material for Wiper-Watt

Links. In this material selection matrix, each criterion is given a weight from 1 to 5,
with 5 indicating the highest importance of that criteria in this specific application.
Following that, each material is evaluated based on its performance/attributes that
govern that criterion. Finally, the score of the material for each criterion will be
multiplied by that criterion’s weight, and the scores will be added up. The material with
the highest score will finally be selected.

For the robot arm linkage material, a comparison was drawn between the
mechanical properties of two attainable varieties of aluminum and stainless steel.
Aluminum alloy 3003 was chosen for its light weight and high strength to weight ratio.
SAE304 Stainless steel on the other hand is the most used stainless steel, being a
relatively more affordable variety. However, when compared with aluminum, it was
assessed that 304 stainless steel is considerably denser. While this is usefully attributed
to the higher strength stainless steel provides, it must be highlighted that the use of
lighter material is more prioritized than strength. This is chosen to be wary of the weight
limit that the motors of the robot arm can handle. A higher weight would require motors
that can provide higher torque, which is a limitation.
60
 Additionally, as a requirement for the robot arm, a material that is resistant to
corrosion is required for long term use of the robot arm in the harsh conditions
surrounding high-rise buildings. 304 Stainless-steel has a remarkable resistance to
corrosion that is superior to aluminum 3003. However, at the lowered cost that
aluminum 3003 is valued, its corrosion resistance qualities are sufficient to withstand
the contextual environment. Afterall, the robot arm will be protected by a plastic cover,
whose material will be selected using a similar selection matrix. Table 4.1 shows the
selection matrix.

TABLE 4.1 Material Selection Matrix for the Robot Arm Links.

Aluminium
Criteria Weight 304 Stainless Steel Source
3003
Density 5 5 2 ASM International
Tensile
4 3 5 ASM International
Strength
Corrosion
3 3 5 ASM International
Resistance
East Asia Metal
Cost 4 5 2
Limited
Total 66 53 -

Similarly, another material selection matrix is created to select a suitable

material for the robot arm cover. Table 4.2 shows the selection matrix for Wiper-Watt
links’ covers.

TABLE 4.2 Material Selection Matrix for Wiper-Watt Links’ Covers.

Criteria Weight PLA ABS PPSU Source

Density 4 4 5 4 Matweb (n.d)

Tensile 5
5 1 4 Matweb (n.d)
Strength
Corrosion 4
5 1 3 Matweb (n.d)
Resistance
61
 2 East Asia Metal
Cost 4 5 4
Limited
Total 46 66 69 -

4.3 CRANE DESIGN

4.3.1 Crane Design Concept

To reach every window, Wiper-Watt must be lifted and suspended. The robot is
frequently lifted and suspended in order to accomplish this using a crane. Rails, a crane
arm, and pulleys are some of the components that make up the crane design. The crane
arm can move along a track made of rails that are put around the outside of the structure.
The crane arm is a substantial, horizontal beam that protrudes from the structure and can
be moved around it on rails. The window cleaning robot is raised and lowered using a
hoist that is attached to the arm.

A rope connects the hoist to the robot. Four pulleys are utilised to hold the rope
in order to guarantee security and stability. The pulleys' purpose is to lessen friction
while uniformly distributing the robot's weight along the rope. Also, they aid in
directing the rope as the robot manoeuvres around the structure. Several pulleys are also
used, which boosts the system's mechanical advantage and makes it simpler to raise the
heavy robot. Figure 4.6 shows the crane design.

FIGURE 4.6 Crane Design.

62
4.3.2 Pulley Brackets Calculations and Selection

With four fixed pulleys and an 800 N load, calculating the radius and width of
the pulley bracket can be done using Equation 4.7.

Equation (4.7):

𝑊𝑊
𝐹𝐹 = × (2 + cos(𝜃𝜃))
𝑛𝑛

Where F, W, n, and 𝜃𝜃 are defined as the force required to lift the load, applied
load, number of pulleys (which is four), and the angle of the rope (which is 90° since the
rope is perpendicular to the pulleys) respectively.

800
𝐹𝐹 = × (2 + cos(90))
4

𝐹𝐹 = 400 𝑁𝑁

The Mechanical Advantage formula is applied to get the relationship between

the radius and the width of the pulley required to lift the load.

Equation (4.8):

2 × 𝑟𝑟
𝑀𝑀𝑀𝑀 =
𝑤𝑤

Where MA, r, w are the mechanical advantage (which is 4 since 4 pulleys are
used, radius of the pulley, and width of the pulley respectively.

2 × 𝑟𝑟
4=
𝑤𝑤

𝑟𝑟 = 2 × 𝑤𝑤

From the corelation above, it appears that the radius of the pulley should be
twice the size of the width. Based on this, Pulley Type ETT-160 -120 Galvanised Cast
Iron Pulley with pressed steel bracket is selected. The radius is 60 mm, and the width is
40 mm. It is acceptable since usually the width is two-third of the pulley radius.

63
4.3.3 Crane Material Selection

Similar to the robot arm, the materials considered for the gantry crane installed
onto the roof railing were an accessible aluminum alloy and a stainless steel of
appropriate mechanical properties for this application. It can be seen from the table
above that the contrast between Aluminum 6061 and 316 stainless steel is very
reminiscent of the comparison between Al 3003 and 304 stainless-steel. However, in
this context, the 316 stainless steel receives a higher score, proving to be the superior
material in this context. The result of the variation on the similar evaluations is the
different weights of each factor. These weights were assigned by the authors of the
study, indicating the necessity of steel’s higher load carrying capacity, despite its higher
cost.

Aside from this, in this context the density of the material is a property of less
significance than the strength of the material. Afterall, the gantry crane would be
supported upon installation, requiring no further transport that would require a lighter
weight. Meanwhile, it needs to support the load inflicted upon the railing by the robot
arm and its supporting structure, as well as the weight of the water amongst other
components. This makes tensile strength a more deciding factor on the material
selected. Additionally, the increased chemical resistance of 316 stainless steel also
proves essential, as the gantry crane will be exposed to the harsh conditions inflicted at
the top of a high-rise building. This is attributed to the higher score that makes 316
stainless steel the choice of material for gantry crane. Table 4.3 shows the material
selection matrix for the crane.

TABLE 4.3 Material Selection Matrix for the Crane.

Criteria Weight AL 6061 316 Stainless Steel Source

Density 2 5 3 ASM International

Tensile
5 3 5 ASM International
Strength
Corrosion
4 3 5 ASM International
Resistance
East Asia Metal
Cost 3 4 2
Limited
Total 49 57 -

64
4.4 ENGINEERING CODES AND STANDARDS

A code is a set of guidelines and requirements for the appropriate techniques and
components to be utilised in a certain good, structure, or process. Governments at the
municipal, state, and federal levels may pass codes, which have legal effect. The basic
goal of codes is to safeguard the public by establishing the minimal degree of safety that
is allowed for structures, goods, and procedures. A technical standard is a rule or
condition that has been set. Typically, standardised engineering or technical standards,
methodologies, procedures, and practises are established in a formal document.
Standards provide quality, dependability, and safety while enabling the
interchangeability of parts and system interoperability (Biondini & Frangopol, 2016).

4.4.1 Engineering Codes and Standards Deployed in Calculations

The International Plumbing Code (IPC) is a set of rules that establishes

minimum requirements for the design and operation of plumbing systems. It is
employed to guarantee the security, dependability, and effectiveness of plumbing
systems. New plumbing-related technologies are approved using the code to make sure
they adhere to basic requirements and standards. In this project, the ideal water flow rate
and water pressure in a hose were determined using the IPC. This was done in order to
determine the force that was applied to the end effector while the system was in use.
The portion of the robotic arm that makes touch with the object being moved is called
the end effector. To ensure that the end effector can complete its mission without
harming the manipulable object or the system itself, the applied force must be calculated
(Fleming, 2016).

The ASTM International is a well-known standards body that develops and

disseminates voluntary consensus technical standards for many different kinds of
products, systems, and services. The American Society for Testing and Materials
(ASTM), which it was formerly known as, was established in 1898. There are numerous
technical committees within the organisation that create and uphold standards for
various applications and industries (J.-Y. Lee et al., 2021). The ASTM standards were
used in the context of this project to choose the material for the design. The material
selection is essential for ensuring that the product's design serves its intended purpose
and functions dependably under the anticipated operating circumstances. Materials that
met the necessary performance requirements, such as strength, durability, and resistance
to environmental conditions, were chosen using ASTM standards. The ASTM standards
are created by specialists in the industry and are founded on in-depth investigation and
testing, ensuring that the materials adhere to the necessary requirements and function
dependably in practical applications.

65
4.4.2 Engineering Codes and Standards Related to Environment and
Sustainability

One of the Codes that must be mentioned is the International Green Building
Code (IgCC). The IgCC sets minimum standards for both new and existing structures in
order to improve their energy efficiency, cut waste, protect natural resources, and
provide healthier interior environments. It emphasises building design and construction,
as well as building operation and maintenance (Eberhardt, 2022). A good example of
compliance with the IgCC standards is the use of recyclable materials in Wiper-Watt.
Using recyclable materials minimises the waste produced during the creation, usage,
and disposal of the design, lessening the impact on the environment. Another important
factor taken into account by the IgCC is the amount of energy needed to operate the
system. This can be done by using lightweight materials.

In addition, OSHA (Occupational Safety and Health Administration) regulations

should also be followed in this design. OSHA is in charge of making sure that
workplaces are secure and healthy for employees. For Wiper-Watt, workers can operate
the system from a safe distance using a smartphone application, reducing their chance of
getting hurt from falls or other incidents related to working at heights. The installation
of a controlled valve to reduce water waste complies with OSHA's requirement that
equipment be built and maintained to eliminate dangers (Michaels & Wagner, 2020).

4.5 DESIGN CALCULATIONS

4.5.1 The Required Force to Hold the Nozzle During Operation

According to the International Plumbing Code, the pressure inside a watering

hose should be 208.6 KPa, and the volume flow rate should be 0.32 L/s (PLUMBING,
2015). These values are used to calculate the required force to hold the nozzle to define
the force applied on the end effector. Figure 4.7 shows the free body diagram of the
nozzle.

66
 FIGURE 4.7 Free Body Diagram of the Nozzle.

𝑃𝑃1 = 208.6 𝐾𝐾𝐾𝐾𝐾𝐾

𝑄𝑄̇ = 0.32 𝐿𝐿/𝑠𝑠

Converting L/s to m3/s

𝐿𝐿 1 𝑚𝑚3
𝑄𝑄̇ = 0.32 × = 0.00032 𝑚𝑚3 /𝑠𝑠
𝑠𝑠 1000 𝐿𝐿

Applying the continuity equation to the find V1 and V2

Equation (4.9):

𝑄𝑄̇ = 𝐴𝐴1 𝑉𝑉1 = 𝐴𝐴2 𝑉𝑉2

𝜋𝜋 2 𝜋𝜋
𝐴𝐴1 = 𝐷𝐷 = × (19 × 10−3 )2 = 2.835 × 10−4
4 1 4

𝜋𝜋 2 𝜋𝜋
𝐴𝐴2 = 𝐷𝐷 = × (10 × 10−3 )2 = 7.854 × 10−5
4 2 4

𝑄𝑄̇ 0.00032
𝑉𝑉1 = = = 1.129 𝑚𝑚/𝑠𝑠
𝐴𝐴1 2.835 × 10−4

67
 𝑄𝑄̇ 0.00032
𝑉𝑉2 = = = 4.07 𝑚𝑚/𝑠𝑠
𝐴𝐴2 7.854 × 10−5

Applying Momentum Equation in x-direction.

Equation (4.10):

� 𝐹𝐹𝑥𝑥 = � 𝑢𝑢(𝜌𝜌𝑽𝑽. 𝑨𝑨)

𝐶𝐶𝐶𝐶

� 𝐹𝐹𝑥𝑥 = +𝑉𝑉1 (−𝜌𝜌𝜌𝜌. 𝐴𝐴)1 + 𝑉𝑉2 (+𝜌𝜌𝜌𝜌. 𝐴𝐴)2

𝑃𝑃1 𝐴𝐴1 − 𝐹𝐹 = −𝑉𝑉1𝑚𝑚̇ + 𝑉𝑉2 𝑚𝑚̇

𝐹𝐹 = 𝑃𝑃1 𝐴𝐴1 + (𝑉𝑉1 − 𝑉𝑉2 )𝑚𝑚̇

𝑚𝑚̇ = 𝜌𝜌𝐴𝐴1 𝑉𝑉1 = 1000 × 2.835 × 10−4 × 1.129

𝑚𝑚̇ = 0.32 𝐾𝐾𝐾𝐾/𝑠𝑠

𝐹𝐹 = 206800 × 2.835 × 10−4 + (1.129 − 4.07) × 0.32

𝐹𝐹 = 57.68 𝑁𝑁

From the calculations above, the force applied on the end effector due to water
flow in the hose is 57.68 N. This force can be used later to calculate the torque required
from the servo motors and helps in the servo motor selection.

4.5.2 Servo Motor Torque Calculations

Servo motors’ torque is crucial in order to select the servo motors for the design.
The torque is calculated in the worst-case scenario considering the robot arm is fully
extended. The required torque at any point can be found using this equation (Farman et
al., 2018).

Equation (4.11)

𝑇𝑇 = 𝐹𝐹𝑒𝑒𝑒𝑒𝑒𝑒 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 × 𝑑𝑑1 + 𝑀𝑀𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 1 × 𝑔𝑔 × 𝑑𝑑2 + 𝑀𝑀𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 2 × 𝑔𝑔 × 𝑑𝑑3 + ⋯

Required Torque for the wrist:

68
 𝑇𝑇𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 57.68(0) + 0.2 × 9.81 × 0.1

𝑇𝑇𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 0.1962 𝑁𝑁. 𝑚𝑚

By considering a safety factor of 1.5:

𝑇𝑇𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 0.1962 × 1.5 = 0.2943 𝑁𝑁. 𝑚𝑚

Convert the torque unit from Nm. to Kg-cm.

𝑇𝑇𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 0.2943 × 10.197 = 3 𝐾𝐾𝐾𝐾. 𝑐𝑐𝑐𝑐

Required Torque for the elbow:

𝑇𝑇𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 57.68 × 0.5cos (45) + 0.417 × 9.81 × 0.25sin (45)

𝑇𝑇𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 21.116 𝑁𝑁. 𝑚𝑚

By considering a safety factor of 1.5

𝑇𝑇𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 21.116 × 1.5 = 31.67 𝑁𝑁. 𝑚𝑚

Convert the torque unit from Nm. to Kg-cm.

𝑇𝑇𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 31.15 × 10.197 = 322.94 𝐾𝐾𝐾𝐾. 𝑐𝑐𝑐𝑐

Required Torque for the shoulder:

𝑇𝑇𝑠𝑠ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 57.68 cos(45) × (0.5 − 0.5 cos(45))

+57.68sin(45)(0.5 sin(45) + 0.417 × 9.81 × 0.25sin (45)

𝑇𝑇𝑠𝑠ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 24.1 𝑁𝑁. 𝑚𝑚

By considering a safety factor of 1.5

𝑇𝑇𝑠𝑠ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 24.1 × 1.5 = 36.15 𝑁𝑁. 𝑚𝑚

Convert the torque unit from Nm. to Kg-cm.

69
 𝑇𝑇𝑠𝑠ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 36.15 × 10. 𝑐𝑐𝑐𝑐. .7 = 368.622 𝐾𝐾𝐾𝐾. 𝑐𝑐𝑐𝑐

By considering the torques required for each joint, BLS-HV60MG, SUPER300,

and DDTS 380 servo motors are selected for the wrist, elbow, and shoulder joints,
respectively. Being waterproof with high torque, they are suitable for this design. They
will be controlled using Raspberry Pi 4 Model B. It is a quad-core ARM Cortex-A72
CPU running at 1.5GHz, up to 8GB of LPDDR4 RAM, dual-band 802.11ac wireless
networking, Bluetooth 5.0, Gigabit Ethernet, two USB 3.0 and two USB 2.0 ports, two
micro-HDMI ports (supporting resolutions up to 4Kp60), and a 40-pin GPIO header.
Moreover, it has two DSI display connections and two CSI camera ports which is
suitable since there is visual feedback in this design.

4.5.3 Forward Kinematics

As shown in Figure 4.8, five frames were assigned to the robotic arm. The
procedure of the frame assignment can be summarized in the following steps:

• Zi axis is assigned to point along the i-th joint axis.

• Z0 and Zn+1 are parallel to Z1 and Zn.

• Xi axis is assigned to point along the common perpendicular from Zi to Zi+1.

• Yi is assigned according to the right-hand rule.

70
 FIGURE 4.8 Frame Assignments for Kinematics.

The non-rotating reference frame {0} was attached to a fixed point at the center
of the base. Frame {1} corresponding to link (1) was attached at its upper end. Frame
{2} is located at the intersection between link (1) and link (2) where it rotates with link
(2). Frame {3} rotates with link (3) and it is attached at its intersection with link (2)
while frame {4} which is the end effector is located midway in the center of the
cleaning wiper. Denavit-Hartenberg (D-H) parameters were determined based on the
defined frame as shown in Table 4.5.

TABLE 4.4 The Denavit-Hartenberg (D-H) Parameters

i 𝛼𝛼𝑖𝑖−1 𝑎𝑎𝑖𝑖−1 𝑑𝑑𝑖𝑖 𝜃𝜃𝑖𝑖

1 0° 0 L1 𝜃𝜃1
2 90° 0 0 𝜃𝜃2
3 0° L2 0 𝜃𝜃3
4 0° L2 0 0°

71
Where:

𝛼𝛼𝑖𝑖 : Link twist which is the angle between (Zi, Zi+1) about Xi.

𝑎𝑎𝑖𝑖 : Link Length is the distance between (Zi, Zi+1) along Xi.

𝑑𝑑𝑖𝑖 : Link offset is the distance between (Xi-1, Xi) along Zi.

𝜃𝜃𝑖𝑖 : Joint angle is the angle between (Xi-1, Xi) about Zi.

The homogenous transform matrices ( 01𝑇𝑇, 12𝑇𝑇, 23𝑇𝑇, 34𝑇𝑇) are computed using the D-
H parameters by substituting in the general formula for 𝑖𝑖−1𝑖𝑖𝑇𝑇 (Farman et al., 2018).

cos (𝜃𝜃𝑖𝑖 ) −sin (𝜃𝜃𝑖𝑖 ) 0 𝛼𝛼𝑖𝑖−1

𝑖𝑖−1 sin (𝜃𝜃𝑖𝑖 )cos (𝛼𝛼𝑖𝑖−1 ) cos (𝜃𝜃𝑖𝑖 )cos (𝛼𝛼𝑖𝑖−1 ) −sin (𝛼𝛼𝑖𝑖−1 ) −sin (𝛼𝛼𝑖𝑖−1 )𝑑𝑑𝑖𝑖
𝑖𝑖𝑇𝑇 = � �
sin (𝜃𝜃𝑖𝑖 )sin (𝛼𝛼𝑖𝑖−1 ) cos (𝜃𝜃𝑖𝑖 )sin (𝛼𝛼𝑖𝑖−1 ) cos (𝛼𝛼𝑖𝑖−1 ) cos (𝛼𝛼𝑖𝑖−1 )𝑑𝑑𝑖𝑖
0 0 0 1

0 −1 0 0
0 1 0 0 0
1𝑇𝑇 = � �
0 0 1 𝐿𝐿1
0 0 0 1

cos (𝜃𝜃2 ) −sin (𝜃𝜃2 ) 0 0

1 0 0 −1 0
2𝑇𝑇 = � �
sin (𝜃𝜃2 ) cos (𝜃𝜃2 ) 0 0
0 0 0 1

cos (𝜃𝜃3 ) −sin (𝜃𝜃3 ) 0 𝐿𝐿2

2 sin (𝜃𝜃3 ) cos (𝜃𝜃3 ) −1 0
3𝑇𝑇 = � �
0 0 1 0
0 0 0 1

1 0 0 𝐿𝐿3
3 0 1 0 0
4𝑇𝑇 = � �
0 0 1 0
0 0 0 1

The end-effector frame with the reference frame ( 04𝑇𝑇) is obtained by multiplying
the homogenous matrices in the right order.

0
4𝑇𝑇 = 01𝑇𝑇 12𝑇𝑇 23𝑇𝑇 43𝑇𝑇

72
 0 0 1 0
0 C2 C3 − S2 S3 C2 C3 − C2 S3 − S2 S3 − S2 C3 S2 (C2 C3 − S2 S3 )L3 + C2 L2
4𝑇𝑇 = � �
S2 C3 + C2 S3 C2 S 3 + C2 C3 + S 2 C3 − S 2 S 3 −C2 (S2 C3 + C2 S3 )𝐿𝐿3 + S2 L2 + L1
0 0 0 1

Where C𝑖𝑖 is the cosine of the angle 𝜃𝜃𝑖𝑖 and 𝑆𝑆𝑖𝑖 is the sine of the sine if the angle 𝜃𝜃𝑖𝑖 .
The first three entries of the last column in 04𝑇𝑇 represent the Cartesian coordinates of the
position of the origin of the end effector frame {4} with respect to reference frame {0}.

𝑥𝑥 = 0 (Since there is no rotation around Z0)

𝑦𝑦 = (cos(𝜃𝜃2 ) cos(𝜃𝜃3 ) − sin(𝜃𝜃2 ) sin(𝜃𝜃3 ))L3 + cos(𝜃𝜃2 ) L2

𝑧𝑧 = (sin(𝜃𝜃2 ) cos(𝜃𝜃3 ) + cos(𝜃𝜃2 ) sin(𝜃𝜃3 )) L3 + sin(𝜃𝜃2 ) L2 + L1

The position and orientation of the robot arm's end-effector in relation to the
base frame are represented by this matrix. The end-position effector's is represented by
the fourth column of the matrix, while its orientation is represented by the matrix's first
three columns.

73
4.5.4 Inverse Kinematics

For inverse Kinematics, the position coordinates equations obtained above were
used to find the analytical expression of the rotational angles for the shoulder, elbow,
and waist servo motors as a function of the required x, y, and z coordinates.

For the base:

𝜃𝜃1 = 0 (Since is no rotation around Zo)

To obtain an explicit expression for cos(𝜃𝜃3 ), summation of forward the square

of position equations were performed (Farman et al., 2018).

Equation (4.12):

𝑥𝑥 2 + 𝑦𝑦 2 + 𝑧𝑧 2 − �𝐿𝐿1 2 + 𝐿𝐿2 2 +𝐿𝐿3 2 � − 2𝐿𝐿1 (𝑧𝑧 − 𝐿𝐿1 )

𝑐𝑐𝑐𝑐𝑐𝑐(𝜃𝜃3 ) =
2𝐿𝐿2 𝐿𝐿3

From the identity of Pythagorean trigonometric identity

Equation (4.13):

𝑠𝑠𝑠𝑠𝑠𝑠(𝜃𝜃3 ) = ±�1 − 𝑐𝑐𝑐𝑐𝑐𝑐(𝜃𝜃3 )

Equation (4.14):

𝑠𝑠𝑠𝑠𝑠𝑠(𝜃𝜃3 )
𝜃𝜃3 = 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎2( )
𝑐𝑐𝑐𝑐𝑐𝑐(𝜃𝜃3 )

The (atan2) function generates the arctangent of the argument and the proper
quadrant based on the signs of both the denominator and the numerator. By Considering
𝑧𝑧 = (sin(𝜃𝜃2 ) cos(𝜃𝜃3 ) + cos(𝜃𝜃2 ) sin(𝜃𝜃3 )) L3 + sin(𝜃𝜃2 ) L2 + L1 and applying the angle
addition trigonometric identity and defining the following variables.

𝑘𝑘1 = cos(𝜃𝜃3 ) L3 + L2

𝑘𝑘2 = sin(𝜃𝜃3 ) L3

𝑧𝑧 − L1 = 𝑘𝑘1 sin(𝜃𝜃2 ) + 𝑘𝑘2 cos(𝜃𝜃2 )

After rearranging and squaring both sides of the equation:

74
(𝑧𝑧 − L1 − 𝑘𝑘1 sin(𝜃𝜃2 ))2 = (𝑘𝑘2 cos(𝜃𝜃2 ))2

�𝑘𝑘1 2 + 𝑘𝑘2 2 � sin(𝜃𝜃2 )2 + 2𝑘𝑘1 (L1 − 𝑧𝑧) sin(𝜃𝜃2 ) + (𝑧𝑧 2 + 𝐿𝐿1 2 − 𝑘𝑘2 2 − 2𝑧𝑧𝐿𝐿1 = 0

By applying the quadratic formula, 𝜃𝜃2 can be expressed in terms of the robotic
arm geometry, z-coordinates, and the value of 𝜃𝜃3 .

Equation (4.15):

𝐴𝐴 ± √𝐵𝐵
𝜃𝜃2 = 𝑠𝑠𝑠𝑠𝑠𝑠−1 � �
2�𝑘𝑘1 2 + 𝑘𝑘2 2 �

Where:

𝐴𝐴 = −𝑘𝑘1 (𝐿𝐿1 − 𝑧𝑧)

𝐵𝐵 = (2𝑘𝑘1 (𝐿𝐿1 − 𝑧𝑧))2 − 4(𝑘𝑘1 2 + 𝑘𝑘2 2 )( 𝑧𝑧 2 + 𝐿𝐿1 2 − 𝑘𝑘2 2 − 2𝑧𝑧𝐿𝐿1 )

The set of joint angles that will lead to the required location and orientation of
the end-effector are represented by the inverse kinematics solution for a robot arm. This
solution is significant because it enables us to describe the desired position and
orientation of the end-effector, which allows us to control the movement of the robot
arm.

4.6 BILL OF MATERIAL FOR THE FINAL DESIGN

A bill of materials, or BOM, is a list of every material, part, and component

needed to make a product. The names, descriptions, quantities, and suppliers of the parts
are frequently included. BOMs are employed in manufacturing and production planning
to make sure that all required components are on hand and that the production process
goes without a hitch. Table 4.6 shows the bill of Material for this Project.

TABLE 4.6 Bill of Material for Wiper Watt.

Part Number Description QTY Price (RM)

BLS- Wrist Servo
1 83
HV60MG Motor
Robot Arm
Elbow
SUPER300 1 375
Servo Motor

75
 Shoulder
DDTS380 1 452
Servo Motor
Aluminium
P314 1 35
Base
Aluminium
P314 3 100
Link
Link’s
ABS 2 30
Cover
Mini
G4 PTZ 1 35
Camera
Raspberry Pi 4 Raspberry
1 600
Model B Pi
23HS30- Stepper
1 165
2804S1 Motor
C-Beam
05-LP 1 75
Linear Rail
C-Beam
Linear Drive HW1206PC 1 80
Gantry Plate
EN AW-6082 Aluminium
2 35
T6 6MM Rod
Aluminium
P314 1 35
Base
DS-1533 Wiper 1 5
Cleaning
SUS303 Nozzle 1 30
Module
- Valve 1 70
Pulley
ETT-160 -120 4 80
Brackets
Crane - Rail 2 2500*
Aluminium
FB6061 12 2500*
Bars
Total Cost 2385

4.7 FAILURE MODE AND EFFECTIVE ANALYSIS

Failure Mode and Effective Analysis, FMEA, is a useful tool for averting
possible issues and enhancing system safety and reliability. It is widely employed in a
variety of sectors, including the automotive, aerospace, and medical fields. FMEA
assists in identifying potential issues and prioritizing remedial measures that can be
taken to prevent or lessen the chance of failure by examining failure modes, their

76
causes, and the impacts they can have. By avoiding pricey repairs, recalls, or legal
action, this can save time and money. It can also improve product quality, customer
happiness, and reputation. There are 18 parameters to be considered while performing
FMEA as follows.

1. Items: Item (component, part, assembly) of the product/part to be analysed. An

Item has one or many functions.

2. Function: Functions of an item. A function has one or many requirements.

3. Requirement: Requirements of a function. A requirement has one or many

potential failure modes.

4. Failure Mode: The way that an item potentially fails to meet the requirement. A
failure mode has one or many potential effects.

5. Effects: Potential effects of the potential failure mode on the function and
customers.

6. Severity (SEV): a ranking number reflects the most severe potential effect of a
failure mode. Severity ranks on a 1 to 10 scale, 10 is the most severe risk.

7. Cause: The reason why failure happens. A failure mode has one or many
potential causes.

8. Prevention Control (in Control Method): Design action to prevent potential

cause to occur.

9. Occurrence (OCC): a ranking number reflects the possibility of occurrence of

the Failure. Occurrence ranks on a 1 to 10 scale, 10 means the highest possibility
of occurrence.

10. Detection Control (in Control Method) Design action to detect the failure or the
cause of the failure if it happens.

11. Detection (DET): a ranking number reflects the best detection control method.
Detection ranks on a 1 to 10 scale, 10 means worst detection capability.

12. RPN: (stands for Risk Priority Number) An indication number to evaluate the
risk of the process based on Severity, Occurrence, and Detection. Depend
on RPN and S, O, D indexes, the responsible team/individual has to decide

77
 corrective action needed for each failure mode. RPN formula is: RPN = S x O x
D.

13. Action: Recommended action to eliminate or reduce the chance of the causes of
failure mode.
14. Responsibility: Individual person or team/department who has to complete the
recommended action.

15. Severity: re-evaluate severity of failure mode after corrective action.

16. Occurrence: re-evaluate occurrence possibility after corrective action.

17. Detection: re-evaluate detection capability after corrective action.

18. RPN: re-calculate Risk Priority Number after corrective action.

All these parameters have been considered while performing FMEA analysis for
Wiper-Watt. Table 4.6 shows FMEA for Wiper-Watt.

78
 TABLE 4.5 FMEA for Wiper-Watt.

Item / Function Requirements Potential Failure Potential Effects of SEV

Mode Failure

Climb Functioning System stuck in a Delay in operation

Windows Gantry position
4

Spray Spray strong Stream velocity too Windows are not 7

Windows stream of water/ low being cleaned
cleaning fluid effectively; Water
Stream velocity too
wasted. 6
hig
Water is wasted.
No stream
Windows are not 6
being cleaned

Wipe Windows Water wiped Wipers do not wipe The window 4

away with water away remains wet after
sufficient washing.
The wiper does not
strength 7
move Window remains
wet after washing.

Provide Visual Functioning Loss of visual Inability to

Feedback Camera and feedback navigate/clean
7
active network visually.
connection

79
 " TABLE 4.6 - Continued."

Item / Potential Causes / Current Design OCC Current Design DET

Function Mechanisms of Controls Controls
Failure Prevention Detection

Climb Cable Rust Anti-Rust 2 Observing 4

Windows Coating motion of system

Spray Water pump Preventive 3 Observing 7

Windows malfunction Maintenance cleaning
quality/stream
strength

Water pump Preventive 3 5

malfunction Maintenance Observing water
tank levels
Water tank empty Regularly 5 5
filling tank Regularly
Water pump observing tank
malfunction Preventive 3 level 7
Maintenance Observing
cleaning
quality/stream
strength

Wiper blades worn Change blades 4 Observe quality 5

Wipe out. every set of cleaning
Windows interval.
Servo Motor 3 Observing 6
Malfunction Preventive motion of joints
Maintenance

Camera Insulate from 3 Observing 2

Provide malfunction water. feedback through
Visual controller
Feedback Network Monitoring 4 2
disconnection Bluetooth Observing
Module Status feedback through
controller

80
 " TABLE 4.6 - Continued."

Action Results
Item / RP Recommended
Function N Actions SE OC DE RP
Actions Taken V C T N
Will be covered in future
Climb iterations of the design
Windows 32 Non, RPN is low

Spray 147 Configure pump Will be covered in future

Windows malfunction iterations of the design.
detection feature.

Will be covered in future

90 Install water iterations.
circulation
system. Refilling Opening
125 Installed into the 2 2 5 25
Install water prototype.
filling feature
126 into tank. Configure pump
malfunction detection
feature.
Configure pump
malfunction
detection feature.

80 Durable Wiper The actions taken will be

Wipe Material. covered in future
Windows iterations.
126
Configure pump Future Iterations.
malfunction
detection feature.

Provide 42 Install Camera selection was

Visual waterproof, revised.
Feedback durable camera
56

81
4.8 STATIC STRUCTURE SIMULATIONS

Static Structural analysis was conducted to investigate the performance of the

crane while operating and allocate the stresses while lifting Wiper-Watt. For this
investigation, remote moment simulation was performed to model a moment or torque
imparted to the crane from a distance away from the measurement location. Moment of
2000 Nm is applied to the crane structure. It is observed that the wheels are the most
critical part of the system where the stress is mostly located. Stresses range between
3200 N/m2 and 6200 N/m2 can be observed at the wheels. This is due to the fact that the
crane's whole weight, as well as the weight of the robot it lifts, are mainly supported by
these wheels. Figure 4.9 shows the stresses allocated at the wheels.

FIGURE 4.9 Stresses Allocated at the Wheels of the Crane.

Since the load is distributed over four pulleys, the simulation shows a slight
stress on the pulleys which can barely be noticed. The only stresses that can be observed
for the pulley are located near the edges where they are fixed with the crane structure. It
can be seen that the highest stress at the pulleys is 1220 N/m2 which is around 20% of
the stresses allocated at the wheels. Other than that, the crane has passed the simulation
and proved to be suitable for the application. Figure 4.10 shows stresses at the pulleys.

82
 FIGURE 4.10 Stresses at the Pulley.

A slight deformation of 3.155×10-4 mm has been observed in the upper arms of

the crane. That is due to the length of the upper arms that hang the robot in the air. It is
noticed that the deformation keeps decreasing until it reaches zero at the base of the
crane. Yet, the deformation is negligible as it is in micron and the safety factor is
maintained at 15. Figure 4.11 shows the crane deformation.

FIGURE 4.11 Crane Deformation.

83
4.9 ROI ANALYSIS

According to a survey conducted by the Salary Expert 2021, the average salary
of a window cleaner is approximately RM23/hr (Salary Expert, 2021). Furthermore,
according to the data by ARD cleaning services (n.d), the total cost can go as high as
$1250 for the complete process. The analysis is done based on the following.

1. Cost of Wiper-Watt: RM3000.

2. According to a survey done by Engineering 360 in 2017, it was found that the
maintenance cost for running a robot arm can go as high as RM750 per year,
with servo motor being the main part that often needs replacement and can cost
up to RM500 (Engineering 360, 2017).

3. Furthermore, the electricity consumption can go up to 1.5kW/h with each unit

costing RM0.50 (Wang, 2016).

4. Clients are charged RM500 for each cleaning process.

5. A total of 6 orders are received each month.

6. The total process takes 5 hours.

7. Total electricity cost for one cleaning service = 1.5(0.50) (5) = RM3.75

8. Running cost for 6 services done each month = 3.75(6) = RM22.5

9. Total running cost per year = 22.5(12) = RM270.

10. Total cost of running the robot per year=RM270+RM750=RM1020

11. Gross profit each year=RM36,000

Benefit-Cost ration is used in this cost analysis. B-C Ratio Provides a measure
of the net benefits (or savings) of the project relative to its net cost. The project is
considered economically viable relative to the base case when the B-C Ratio is greater
than 1.0 (B-C Ratio > 1.0) (Sciencedirect, 2018). Figure 4.12 shows the cash flow
diagram.

84
 RM3000 RM1020 RM1020 RM1020 RM1020 RM1020

FIGURE 4.12 Cash Flow Diagram.

Assuming MARR= 5%

Project duration = 5 years (N=5)

Equation (4.16):

𝑃𝑃𝑃𝑃(𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵)
𝑃𝑃𝑃𝑃 𝐵𝐵 − 𝐶𝐶 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 =
𝑃𝑃𝑃𝑃(𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶)

𝑃𝑃
36,000� ,5%,5� 36,000(0.952)
𝐹𝐹
𝑃𝑃 = = 1.34
3000+1020( ,5,5) 3000+1020(0.952)
𝐹𝐹

As the B-C ratio is >1, our project is acceptable.

4.10 MARKET STRATEGIES

A marketing strategy is a comprehensive plan developed expressly to achieve

the organization's marketing objectives. It provides a plan of action for accomplishing
these marketing objectives. It acts as the cornerstone of a marketing plan. It was
developed following thorough market research. To increase sales, a business might
concentrate its limited resources on the most lucrative prospects by using a marketing
plan (Marketing Strategy - Meaning and Its Importance, 2018).

Setting the direction for the entire organisation, not just the marketing-related
operations, requires a marketing strategy. The marketing strategy aids in maintaining
communication with the clientele, creating the ideal items for customers, and deciding
how to convey information about those things. Without a clear plan, we won't be able to
identify our target market, create the appropriate products, or effectively market
products. In other words, having a clear marketing strategy increases success. A
85
Schedule survey found that businesses with a documented marketing plan are 313
percent more likely to succeed than those without one (What Is Marketing Strategy?
2017).

The worldwide window cleaning robots’ market is estimated to exceed USD 150
million by 2027, expanding at a CAGR of more than 15% during the forecast period.
Notably, the Window Cleaning Robots Market is divided into three segments: product
type, application, and geographical distribution. The market is classified into two
categories: vacuum suction and fan adsorption, and the applications include commercial,
residential, and industrial. Asia-Pacific, North America, South America, the Middle
East and Africa, and Europe comprise the market. North America has the largest market
share of Global Window Cleaning Robots due to advancements in AI technology for
usage in cleaning robots. Furthermore, the Asia Pacific region is predicted to be the
fastest growing market because of the considerable presence of important corporate
players such as Ecovacs Robotics Co. Ltd., Hobot Technology, Inc., and others
(TechsciResearch pvt ltd, 2018). Figure below illustrates the predicted market share of
window cleaning robot. Figure 4.13 shows the market for window cleaning for robots.

FIGURE 4.13 Global Window Cleaning Market for Robots (TechsciResearch pvt
ltd, 2018).

For the purpose of creating a high-quality product, understanding the design is

essential. In this stage, the customer's requirements for the window cleaning robot are

86
determined and translated into a technical description of what needs to be created. This
process consists of three phases as shown in the diagram.

T
1. Identify the 2. Determine the 3. Physical promoting
customer. customer requirement our product by
by research conducting survey

Step 1: Identify the customer and targeting market.

Robots are being produced more and more often nowadays to help or replace
humans in a variety of hazardous and demanding activities, including manufacturing,
security inspection, construction, and other fields. The ability of the robots to adapt to
various settings and circumstances is predicted. As having clean windows contributes
significantly to a person's quality of life, window cleaning work has been done to
provide a better living and working environment. Human employees do the standard
cleaning tasks. Thus, our focus of the project is the window cleaning robot.

The robot that cleans windows may be employed in residences as well. These
machines are designed to scale walls and clean both sides of windows. Such a robot
may be used in both residential and commercial structures, particularly those with large
glass-panelled windows or tall skyscrapers that can be challenging to access using
ladders or scaffolding (Dataintelo, 2021).

In additional, office buildings, hotels, and shopping centres all require regular
maintenance to keep them looking excellent. These kinds of structures frequently have
several windows that need to be cleaned frequently. Because it takes time and requires
specialised tools and technology, cleaning the outside glass window panel is a
challenging task for human resources. Consequence, the main focus was targeted for
building managers, tenants and resident.

Step 2: Determine the customer requirement by research.

In consideration of the growth in modern architecture, it is crucial to evaluate the

need for an automatic cleaning system for outside building surfaces like window glass.
A few specialised window cleaning tools have previously been put into use in the
building maintenance sector. However, most of them were incorporated into the design
of the building from the beginning and need significant expenditures. As a result, the
demand in the building maintenance sector is rising for small, lightweight, and portable
window cleaning robots. According to research of the requirements for the device, the

87
following elements are crucial for providing the window cleaning robot for use in
practise (H. Zhang et al., 2004).

1. Lightweight: It should be reasonable size and lightweight for potability.

Estimated the weight should not more than 5kg.

2. Movement: The robots should be able to move in both the up-down and
right-left directions in order to reach every location on the glass.

3. The ability of crossing window obstruction: In order to complete the

cleaning task, the robots must face all obstructions and cross them efficiently
and safely.

4. Intelligence to distinguish between various barrier situations: Several sensing

and control systems are integrated to deal with environmental uncertainties.
Software should be skilful enough to recognise the different wall geometries
and clever enough to independently recreate the surroundings.

5. Explore the environment with the correspondingly effective approach: After

the user enters the global task commands, the robot should maintain its
attachment to and movement on the glass while carrying out the cleaning
tasks.

6. Motion control function: Accurate motion control is necessary to fulfil the

demands of all types of movement functions, particularly while navigating
window obstructions. As soon as impediments are identified on the surface,
the movement will automatically start to be controlled in a precise location.

7. Efficient cleaning: For cleaning robots, efficiency is the primary objective.

Step 3: Physical promoting our product by conducting survey.

In this study, surveys were conducted to enhance the survey's completeness. The
questionnaire was distributed to building owners, managers, and residents. Those who
have expertise cleaning windows or are interested in the window cleaning device were
given questionnaires.

The survey question of demand and demand technology of automated equipment

for window cleaning was divided into four parts as follows:

88
 1. General Information: Respondent status, type of building and experience of
window cleaning.

2. Potential demand owing the window cleaning robot: Cleaning Frequency

and necessity for window cleaning equipment.

3. The intention device’s purpose: Intention to owing, possible of investment

cost and expected price range.

4. Introduce device and suggestions: Other aspects, such as the cleaning

device's desired purpose.

In contrast, physical promotion through surveying is a direct and useful

technique to begin the business chain to reach the public. Furthermore, by carrying out
the same strategy to reach the targeted audience, we might introduce our automated
cleaning device.

89
 CHAPTER V

PROTOTYPE AND TESTING

5.1 ROBOT ARM AND THE LINEAR DRIVE

A thermoplastic material called PLA was used to 3D print the robot arm. Due to
its low toxicity, low melting point, and simplicity of usage, PLA is a preferred material
for 3D printing. In addition, PLA is simple to print using a 3D printer and is stiff
enough to handle the weight of the robot arm. An STL file for the design was prepared
to get the CAD file ready for printing. One of the problems faced was that the size of
the 3D printer wasn’t big enough to print the base and rods for the linear drive. The base
was split into three segments to get it ready for printing while the rods were split into
two sections. Figure 5.1 shows the 3D printed parts.

FIGURE 5.1 3D Printed Components.

The different parts of the robot arm are assembled using screws and nuts once it
has been produced. To control the movement of the arm, the joints are attached to servo
motors, while the lead screw is under stepper motor control. MG996R Servo Motor and
SG90 servo motor are used to control the robot arm. These two servo motors are
commonly used for robot arms’ project due to their compatibility with most of
controllers, price, and high torque. A 5V pump is used to feed water to the wiper. The
pumping pressure is required to be low so no water wastage will occur. A 17HS4401
stepper motor was selected for the linear drive. It is a bipolar stepper motor that has
a 1.8º step angle (200 steps/revolution) with 40N.cm holding torque which is more than
enough for the prototype. A hand phone will be used as a camera to test out its
functionality.

90
 All electronic components will be controlled by Arduino UNO R3 with HC-05
Bluetooth module for the connection. It has a 10 m diameter range and allows for more
than one device to be connected. Figure 5.2 shows the assembly of the Robot Arm and
the Linear Drive.

FIGURE 5.2 Assembly of the Robot Arm and the Linear Drive.

5.2 CRANE CONSTRUCTION

The principal structural material was determined to be aluminum profile bars.

Due to its durability and corrosion resistance, aluminum is a lightweight and robust
metal that is frequently employed in construction. Four pulleys were to be mounted to
each side of the aluminum profile bars when they were obtained from the supplier. It is
simpler to lift and transport big objects when the force being applied to the crane is
changed by the use of pulleys. The crane was put up by first cutting the aluminum
profile bars to the right length, then joining them together using brackets and screws.
Then, using screws or bolts, the pulleys were fastened to each side of the bars. Figure
5.3 shows the crane structure.

91
 FIGURE 5.3 Crane Structure.

A cable or rope would be passed through the pulleys once the basic frame and
pulley system were put together to construct the lifting mechanism. In order to produce
a lifting mechanism that might be used to lift and move the robot, the cable or rope is
commonly fastened to a hook of a hand winch. Having a self-locked mechanism, a hand
winch is selected to be used as a lifting mechanism for Wiper Watt prototype. Figure
5.4 shows the hand winch used for lifting.

92
 FIGURE 5.4 Hand Winch used for Lifting Mechanism.

5.3 CIRCUIT DIAGRAM

The Arduino UNO Rev3 is a well-known microcontroller board that may be

utilised in a variety of electronic projects. It contains several digital and analogue
input/output pins for connecting and controlling other electrical components. The circuit
has been divided into four sub-circuits to distribute different voltage levels to each of
the components. The benefit of dividing the circuit into four sub-circuits is that it allows
each component to receive the appropriate voltage level needed to operate effectively,
which helps to ensure that the circuit operates reliably and safely. This can prevent
potential damage to the components and improve the overall performance of the circuit.
Additionally, it can make the circuit easier to troubleshoot and modify, as each sub-
circuit can be isolated and tested individually.

For the first circuit, the student is connecting the HC05 module and 5V relay
module to the Arduino UNO board with the power supplied by the board for the first
circuit provides a convenient and easy way to power the components and simplify the
circuit design. However, it's important to ensure that the power supplied by the Arduino
board is sufficient to power all the components and that the total current draw does not
exceed the maximum allowable limit of the board. The HC05 module should be
connected to the Arduino board using the serial communication pins (RX and TX) of the
board. The RX pin of the HC05 module should be connected to the TX pin of the
Arduino board (pin D0), and the TX pin of the HC05 module should be connected to the
93
RX pin of the Arduino board (pin D1). Additionally, the VCC and GND pins of the
HC05 module should connected to the breadboard and 5V and GND pins of the Arduino
board, respectively, to provide power to the module. Meanwhile, to connect the relay
module, the VCC/DC+ pin is connected to the breadboard in the same line with to the
Arduino's 5V pin and the GND/DC- pin to the Arduino's GND pin. Next, IN pin of relay
module is connect to pin D6 on the Arduino board.

For second circuit, the student is connecting a submersible pump to the relay
module, the power supply for the pump should be connected to the Normally Close (NO)
and Common (COM) contacts of the relay module. The submersible pump's power
supply positive wire should be connected to the NC contact and the negative wire
should be connected to the COM contact of the relay module. Apart of that, the circuit
includes a battery that powers the submersible pump, then the positive wire of the
battery should be connected to the side by side of Normally Close (NC). While the
negative wire of the battery be connected to the Common (COM) contact of the relay
module and the negative wire of the submersible pump side by side.

For third circuit, the student connects three servo motors, an Arduino board, and
a DC 5V power source. The positive and negative wires of the power supply should first
be connected to the power and ground, respectively, of the breadboard. Next, connect
the signal wire of each servo motor to a separate digital pin on the Arduino board (D9,
D10 and D11). Ground wires (Brown colour) for each servo motor should be connected
to the breadboard's ground, and power wires (Red colour) should be corresponding
connected to the 5V DC power source.

For fourth circuit, the student is connecting an Arduino, a stepper motor, and a
stepper motor driver. Initially, to connect the stepper motor driver's power supply to a
power source. Most stepper motor drivers require a 12V or 24V power supply, so to
ensure the power supply of stepper motor is sufficient the student is supplying the
power by using power bank source to make the stepper motor is working effectively.
Hence, the connection of +24V and GND is attach to positive and negative of power
bank source, respectively. Next, connect the stepper motor to the stepper motor driver.
Stepper motors have four wires, which must be connected to the corresponding
terminals on the driver (A+, A-, B+, B-). Following by the connection of the stepper
motor driver to the Arduino board. The stepper motor driver will have several pins,
including STEP (CLK+), DIR (CW+), ENABLE (EN+), and GND (CLK-, CW-, EN-).
Thus, the STEP, DIR and EN are connecting to Arduino digital signal of pins 5, 2 and 8
separately. Figure 5.5 illustrate the full circuit diagram of the project. Figure 5.5 shows
the circuit diagram.

94
FIGURE 5.5 Circuit Diagram for all Components.

95
5.4 MIT APP INVENTOR

Without extensive programming experience, the group was able to design

mobile applications for Android smartphones using MIT App Inventor, a web-based
visual development environment. In this instance, an application was developed using
MIT App Inventor to operate the robot arm, the linear drive system, water pump and
other elements of the cleaning process. Three servo motors that move the robot arm's
various joints will be under the control of the application. The stepper motor that
controls the linear drive system, which propels the robot arm back and forth along a
linear axis, will also be controlled by it. Also, the app will have the ability to turn on
and off a pump that is probably used for cleaning.

Creating a live video feed that can be displayed in the application is one of the
primary aspects of the MIT App Inventor. In this instance, a real-time view of the
cleaning procedure will be provided via the live video feed. This might be very helpful
for keeping an eye on the cleaning procedure and making sure it is being done
appropriately. The team started by designing the user interface and choosing the
relevant components for managing the various motors and turning the pump on and off
while building the application using MIT App Inventor. Then, they use the
programming language with visual blocks to develop the logic necessary to control each
of these elements.

Once done, the program can be installed on an Android device and used to
operate the robot arm, linear drive system, and other cleaning-related devices. Based on
user input and testing, the program may be further improved and modified to increase
usability and efficiency. Figure 5.6 shows the User Interface for the Application.

96
 FIGURE 5.5 User Interface.

5.5 BILL OF MATERIAL

In this section, the materials, components, and cost will be discussed for the
prototype. As the prototype is scaled down from the actual design and different
materials are used to test the functionality of the concept design, the specifications for
the motors will be different. Table 5.1 shows the Bill of Material for the prototype.

TABLE 5.1 Bill of Material for the Prototype.

Part Number Description QTY Price (RM)

Wrist Servo
SG90 1 6.5
Motor
Elbow and
Robot Arm MG996R Shoulder 2 13.52
Servo Motors
Robot Arm/
PLA - 500
Base of Drive

97
 Bluetooth
HC-05 1 12
Module
UNO R3 Arduino 1 35
Hand Phone Camera 1 0
Stepper
17HS4401 1 44.80
Motor
Linear Drive Relay
TB6560 3A 1 28.60
Module
T8 SUS304 Lead Screw 1 25

Cleaning DS-1533 Wiper 1 5

Module MK8 Nozzle 1 10
Pulley
- 4 40
Brackets
Crane H1200 Hand Winch 1 180
Aluminium
2020 12 180
Bars

Cost 1080.42

5.6 DIFFICULTIES ENCOUNTERED

During the process of building the prototype, coding errors, unstable voltage
across the circuit, connection wire issues and design can pose challenges and affect the
functionality and performance of the prototype. Coding errors can result in incorrect
behaviour or unexpected outcomes in the prototype's software. Unstable voltage across
the circuit can cause erratic performance, component damage, or system failure.
Connection wire issues, such as loose or faulty connections, can disrupt data transfer,
signal integrity, and overall system reliability. Lastly, the design didn’t include a
housing to place the electrical component during the design process.

To solve these issues in Wiper Watt, testing and debugging of the software code
are crucial to identify and fix coding errors. Next, for unstable voltage across the circuit,
the power supply was changed from battery to power adapter by ensuring a stable power
supply. Then, connection wire issues, careful inspection and testing of the physical
connections, such as soldering, crimping and connector integrity are necessary.
Replacing faulty wires or connectors, ensuring proper routing and grounding of wires,
and using shielded cables can help improve the stability and reliability of connections.

98
Finally, to solve the design of housing for the electrical component, replace it with a
plastic container.

99
 CHAPTER VI

CONCLUSION AND FUTURE RECOMMENDATIONS

6.1 CONCLUSION

The project's major objective was to develop a window cleaning system for high
rise buildings. Three conceptual designs including a window cleaning drone, a suction
cup robot, and a window cleaning robot arm were proposed by the team. The window
cleaning robot arm was chosen by the team as the best design after scoring the highest
in the matrix selection procedure. The selection process was based on a number of
factors, including cost, practicality, effectiveness, and safety achieving the first
objective.

The team selected the design and then tested it for efficacy using structural and
power consumption evaluations. The robot arm's safety factor, stress, and deformation
levels were all examined as part of the structural analysis. Although there were some
stresses allocated at the wheels for crane, the structure was safe to operate without any
failure with a safety factor of 15. To decrease the robot arm's mass and thus its power
consumption, the team also applied topology optimization which resulted in 46% power
consumption reduction. These studies gave insightful information that enhanced the
design and increased its efficacy achieving the second objective.

The group built a prototype after the design was decided upon and developed an
application to control it. The window cleaning robot arm's ability to successfully clean
the windows of high-rise buildings was demonstrated during testing of the prototype
under actual conditions. The application made it simple to observe and operate the robot
arm while it was cleaning which achieves the third objective.

By suggesting a feasible window cleaning mechanism design, evaluating it using

simulations, and building and testing a prototype that proved its usefulness and
effectiveness, the project ultimately succeeded in achieving its objectives. The project's
accomplishments demonstrate the value of thorough design and analysis procedures in
producing successful and safe solutions.

6.2 FUTURE RECOMMENDATIONS

Although the Wiper-Watt has proved to be efficient in window cleaning for

high-rise buildings, there is still room for improvements. Some of the future

100
considerations and suggestions to improve the Wiper-Watt are enhancing the mobility
of the robot, improving the cleaning mechanism, making it fully autonomous.

The robot arm's current design allows it to move both vertically and horizontally,
although it might not be able to reach some difficult locations of high-rise structures. As
a result, one suggestion is to increase the robot arm's mobility so that it may travel in
many directions to access every part of the structure. This can entail utilizing a new kind
of movement mechanism or including more joints. Although the robot arm's current
design is efficient, there may be ways to improve its cleaning system. For instance,
adding sensors and sophisticated algorithms can make it easier for the robot arm to find
and get rid of various detritus, such dirt, filth, or even bird droppings.

One of the suggestions is to make the window cleaning robot arm fully
autonomous. This technology might let the robot arm see and recognize various items in
its surroundings, such as windows, dirt, and debris. With the use of deep learning
algorithms, the robot arm might learn to categorize various surface types and create
cleaning tactics that are appropriate for the amount of filth or grime on each surface. In
addition, the robot arm might have sensors and mapping capabilities that let it negotiate
intricate construction settings and avoid obstructions. The robot arm's ability to function
totally autonomously would be made possible by these cutting-edge features, which
would also increase efficiency and safety while lowering the need for human
involvement.

101
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 APPENDICES

APPENDIX 1

WIPER-WATT DIMENSIONS AND COMPONENTS

107
 APPENDIX 2

MINUTES OF MEETINGS

UCSI University
st
1 Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 16 May 2022 Time: 5:00 PM

Meeting Nour Eldin Mahmoud Location: Discussion Room 5 /

Facilitator: Taher Beit UCSI Library

1. Meeting Objective(s)

- Finding the necessary references related to the project.

- Brief discussion regarding the topic

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad
108
109
3. Meeting Agenda
Topic
1. Discussing regarding the project topic and familiarizing amongst each other.

2. Creating a WhatsApp Group for all the group members for easier communication.

4. Next Meeting (if applicable)

Date: 23 May Time: 2:30 PM Location Block A

(MM/DD/YYYY) 2022 Level 3
Objective: Discussing the Problem Statement of the Project with the supervisor.

110
 UCSI University
nd
2 Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 23 May 2022 Time: 2:30 PM

Meeting Associate Professor Dr Location: Block A Level 3

Facilitator: Ezutah Udoncy
Olugu

1. Meeting Objective(s)
- Talking to the project supervisor.
- Brainstorming to create conceptual Designs.
- Discuss to build a timeline to complete the project.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

111
112
MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 30 May 2022 Time: 3:00 PM

Meeting Nour Eldin Mahmoud Location: MS Teams

Facilitator: Taher Beit

1. Meeting Objective(s)
- Assigning tasks regarding the preparations for the research phase of the project.
- Finding resources to propose components.
- Discussing ideas for the conceptual designs.
- Dividing the reports and discussing the chapters.

2. Attendees

Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering
Poon Yew Jun 1001957307 Mechanical Engineering
Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

113
114
 UCSI University
th
4 Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 26th June 2022 Time: 07:00 PM

Meeting Nour Eldin Mahmoud Location: MS Teams

Facilitator: Taher Beit

1. Meeting Objective(s)
- Rehearsal for the progress presentation.

2. Attendees

Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering
Poon Yew Jun 1001957307 Mechanical Engineering
Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

115
116
 UCSI University
5th Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 10th July 2022 Time: 8:30 AM

Meeting Nour Eldin Mahmoud Location: MS Teams

Facilitator: Taher Beit

1. Meeting Objective(s)
- Discuss the materials and components to be selected.
- Finalize the design.
- Check on the report progress.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

117
118
 UCSI University
6th Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 1st Aug 2022 Time: 4:00 PM

Meeting Nour Eldin Mahmoud Location: Discussion Room 8 /

Facilitator: Taher Beit UCSI Library

1. Meeting Objective(s)
- Prepare for the final presentation.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering
Poon Yew Jun 1001957307 Mechanical Engineering
Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

119
 UCSI University
7th Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 11 Jan 2023 Time: 5:00 PM

Meeting Nour Eldin Mahmoud Location: Discussion Room 6 /

Facilitator: Taher Beit UCSI Library

1. Meeting Objective(s)
- Review and discuss the design by using SOLIDWORKS.
- Review progress of the selecting components.
- Ordering components

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

120
 UCSI University
8th Meeting minutes
for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”.
Date of Meeting: 9 February 2023 Time: 4:00 PM

Meeting Nour Eldin Mahmoud Location: A-09-06, Riana South

Facilitator: Taher Beit

1. Meeting Objective(s)

- Started on robot arm assembly.

- Started working on the code and circuit part.
- Discuss any matters any group member arises.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

3. Meeting Agenda
Topic
1. Showed the final Robot built (3D Drawings).

2. Started working on the robot arm assembly, code, and circuit

121
 UCSI University
th
9 Meeting minutes for Group #2
MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 23rd February Time: 2:30 PM
2023
Meeting Nour Eldin Location: A-09-06, Riana South
Facilitator: Mahmoud Taher Beit

1. Meeting Objective(s)
- Continuation of building the prototype.
- Discuss to build a timeline to complete the project.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering
Poon Yew Jun 1001957307 Mechanical Engineering
Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

3. Meeting Agenda
Topic
1. The robot arm assembly work progress

122
 UCSI University
th
10 Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 9th March 2023 Time: 2:30 PM

Meeting Nour Eldin Location: A-09-06, Riana

Facilitator: Mahmoud Taher Beit South

1. Meeting Objective(s)
- Review the BOM.
- Work on the prototype
- Start work on the crane assembly

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering
Poon Yew Jun 1001957307 Mechanical Engineering
Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

3. Meeting Agenda
Topic
1. The meeting began with a review of the Bill of Materials (BOM) to ensure that all
necessary components had been included. The team discussed any concerns or
questions they had about the BOM.
2. The team then discussed the current progress and issues faced regarding the robot
arm code and assembly.

123
 UCSI University
th
11 Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 23rd March 2023 Time: 2:30 PM

Meeting Nour Eldin Mahmoud Location: A-09-06, Riana South

Facilitator: Taher Beit

1. Meeting Objective(s)
- Finalize the robot arm assembly.
- Finalize the crane design.
- Test out the stepper and servo motor code.

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

3. Meeting Agenda
Topic
1. The meeting began with completing the robot arm assembly.

124
 UCSI University
12th Meeting minutes for Group #2

MEETING AGENDA

Meeting/Project Integrated Design Project A “Window Cleaning Mechanism

Name: for High-Rise Buildings”
Date of Meeting: 5th April 2023 Time: 2:30 PM

Meeting Nour Eldin Mahmoud Location: A-09-06, Riana South

Facilitator: Taher Beit

1. Meeting Objective(s)
- Review the final prototype.
- Test out the prototype.
- Finalize the report

2. Attendees
Name ID Department/Division
Nour Eldin Mahmoud Taher 1001956307 Mechanical Engineering
Beit
Ali Ehmer Khimjee 1001956871 Mechanical Engineering
Saw Yong Hau 1001957305 Mechanical Engineering

Poon Yew Jun 1001957307 Mechanical Engineering

Amro Mohamed Mohamed 1001956793 Mechanical Engineering
Mansour
Abdurahman Hisham Khogali 1001955511 Mechanical Engineering
Muhammad

3. Meeting Agenda
Topic
1. Final touches on the prototype.

2. Testing out the prototype and fixing any issues.

125