PROJECT - I MID SEM REVIEW

Design and analysis of a robotic tentacle arm

using a mechanical multiplexer and bowden cable

mechanism 

Group Members- 
Aditya Potnis 111810071
Rohit Khadilkar  111810109
Bhavika Chawla  111810014
Kaushik Kunale 111813024
Guide : Dr. N K Chougule

College of Engineering Pune

Department of Mechanical Engineering
Academic Year 2020-21
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AIM
We propose the design of a redundant multi degrees of freedom-
tendon actuated robotic tentacle arm using a Bowden cable assembly
for joint actuation with a mechanical multiplexer module to allow
actuation joint selection and motor count reduction. ​
The novelty of the design is the mechanical multiplexers which can
select joints and change the relative angle between the selected joints.
The joints preserve angles passively until a mechanical multiplexer
actuates them again. 
 SCOPE

Since our model is extremely light, sturdy, flexible and

maneuverable; it has the following applications:

1. It could be used along with a camera to get a visual

inspection of disaster-stricken areas like the aftermath of
earthquakes, which are inaccessible to human intervention.
These robots could help find humans and other life forms
trapped under debris. 
2. It has the potential to be used underwater to explore the
ocean and its various mysteries, or for biological research.
3. It could be used for mining applications, such as metal
detection, finding cracks and faults in metals.
4. If fitted with the appropriate equipment, it could be used in
the construction of tunnels and underground passageways.
 • Articulated robotic arms have
undergone considerable
developments in specific
manufacturing environments.
Yet, some significant
opportunity for research exists in
the development of highly
redundant obstacle-constrained
arm mechanisms. These arms
generally require lower accuracy
and much higher flexibility than
typical articulated arms, along
with the small size necessary to
travel in highly constrained
areas.

NEED FOR
MECHANISM
OBJECTIVES
1. Design of light components of arm with High
structural integrity.
2. Designing system with Bowden cable and pulley to
improve accuracy and reduce cable slack.
3. Using high tensile strength Kevlar cables with low
stretching.
4. Implementation of potentiometer/ optical encoder for
higher accuracy closed loop control.
5. Simulation of static, dynamic system performance and
simulation.
6. Test of system performance.
METHODOLOGY
i. Literature review of current technology.

ii. Identification of structural parameters.

iii. Design in CAD software.

iv. FEA static structural analysis.

v. FEA motion analysis.

vi. DH parameter arm calculation and forward kinematics for arm using ROS gazebo/ MoveIt simulation.

vii. Arm motion study in simulation.

viii. Mechanical multiplexer(gearbox) design for redundant arm.

ix. Control system design for closed loop control.

x. Motor selection & part selection.

xi. 3D printing parts and prototyping.

xii. Assembly and Functional testing.

 Initial Idea was developed with a different design in Mini project.
LEARNIN  AIM AND NECESSITY OF THE PROJECT:
GS FROM During natural disasters, early response is crucial to rescue

THE MINI survivors. Assistive devices which are compact and easy to

transport are valuable for rescue purpose.
PROJECT- This device can be used to inspect for survivors in a natural disaster
affected area.
PROBLEM Robotic arms with motors fixed on linkages tend to have higher

STATEME cost & size as the degree of freedom increases. 

The problem is two-fold:
NT TO BE 1. Motor, harmonic drive, pulley etc. are required to drive each
ADDRESS joint, each adding weight to the previous joint.

ED 
2. Arm must be designed to be larger to accommodate for
this greater weight.
This increases cost due to requirement of larger motors and
components. 7
 LEARNINGS FROM
THE MINI PROJECT
- SOLUTION
Using a modular 2 Degree of freedom
knuckle joint based system which is
driven by tendons (cables) which are
located remotely.
Design of knuckle joint is hollow,
allowing passage of additional
movement of tendons in the next
segments.
As motors and components are
remote, arm does not require
waterproofing and can be used in places
with risk of radiation as well.
Fig. Robotic Arm
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 1) The Universal joint restricts angular movement
to +/- 60 degrees due to forks restricting travel.

LEARNIN 2) Nylon tendons undergo large extension in

GS FROM tension leading to inaccurate angles.

MINI 3) Tendon is slack on one side reducing accuracy of

angles of joints and lead to oscillations.

PROJECT - 4) Each joint requires 1 stepper motor, thus

increasing overall cost of system.
SUMMAR 5) Open loop control system leads to low accuracy
Y of arm.

6) Average accuracy of +- 4 degrees

 a) Usage of bowden system to
ensure fixed length of cable
required

IMPROVE
MENTS b) Addition of encoder/
potentiometer for control system
POSSIBLE
c) Usage of Mechanical
Multiplexer to reduce motor count

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TITLE OF PAPER:SUPER DRAGON: A 10 M-LONG COUPLED TENDON-
DRIVEN ARTICULATED MANIPULATOR
Objective and need for mechanism : 
The decommissioning of the Fukushima Daiichi Nuclear Power Plants was a national urgent problem in Japan. The target task of
this study was to investigate inside the PCV(primary container vessel) using a 10 m-long articulated manipulator with a
measurement device weighing 10 kg

Significance : 
The primary objective was to design and develop a coupled tendon-driven mechanism that can mount all actuators on the base
structure. The mechanism permitted the design of a lightweight arm structure while achieving a large payload at the end while
attaining a high radiation resistance. 

Mechanism : 
The coupled-tendon driven mechanism shares the gravitational torque by multiple wires, resulting in a
lightweight and compact mechanism

Conclusion : 
They successfully introduced a coupled tendon-driven mechanism and a weight compensation mechanism using synthetic fiber
ropes to design a lightweight, compact, and high-payload manipulator and confirmed its feasibility through basic motion
experiments

Inspiration: 
1) Designing of lighter components of arm with same structural integrity
2) Exploring the possibility of using Bowden cables for actuation in place of the synthetic cables used by them.
 Title of Paper:M I N I M A L L Y A C T U AT E D S E R I A L R O B O T

Objective and need for mechanism : 

The paper proposed the design of a Minimally Actuated Serial Robot (MASR) which combined some characteristics and advantages from
both hyper redundant robots(Hyper redundant robots are robots with serially connected links that possess a large kinematic redundancy)
and compliant robots.

Significance :
The advantages of MASR are its simplicity, smaller weight, higher energy density (power/mass), low cost and modularity, as the number
of links and actuators can be easily and quickly changed.

Mechanism : 
The MASR is a serial robot consisting of multiple links connected by passive joints and of a small number of movable actuators. The
actuators translate over the links to any given joint and adjust it to the desired angular displacement. The joint passively preserves its
angle until it is actuated again. The number of degrees of reconfigurability(DOR) is equal to the number of joints. This enables the MASR
to achieve similar mobility (albeit slower) to regular hyper redundant robots.

Inspiration: 
(1) The designing of a robotic arm which is also very modular - the number of links and mobile actuators can be changed in a matter of
minutes.

(2) Designing of lighter components of arm with same structural integrity

(3) Utilising a closed loop control algorithm for higher accuracy.
 Title of Paper:DESIGN OF TENDON-DRIVEN MANIPULATORS

Objective and need for mechanism: 

The purpose of the paper was to make an overview on the state-of-the-art review in the design of tendon-driven
manipulators. Basic issues including structure characteristics, kinematics, statics, dynamics and control of tendon-driven
manipulators are reviewed.
 
Significance:
Tendon drives have the advantages of being lightweight, low backlash, low friction, small size, and being able to absorb
shock. Two features of tendon drives are: (1) actuators can be installed on the base and (2) a properly pretensioned tendon-
driven system has little backlash
Mechanism:
To reduce the size and inertia of a manipulator, tendon driven mechanical power transmission systems can be utilized. A
properly designed transmission system permits the actuators to be installed nearby or at the base. Hence, lightweight and
compact size manipulators can be produced

Inspiration: 
1) Making appropriate choice of transmission system such as gear trains, bar linkages, and tendon drives (cables, belts,
tapes, chains, or ropes).The choice of a transmission mechanism depends on the application and other design
considerations( the power-to-weight ratio optimized, backlash and vibration minimized, and friction reduced)
2) Implementation of potentiometer/ optical encoder for higher accuracy closed loop control.
DESIGN OF SYSTEM
Following are main components of the system:
1. Mechanical Multiplexer
2. Bowden cables
3. Arm assembly
4. CNC motor controller for servo motors
5. Encoder/ Potentiometer for precision control
The Mechanical Multiplexer is used to select the pulley that requires to be driven. The bowden cable pair
attached to the corresponding selected pulley is actuated to the required angle.
The spring-loaded lock is used to lock it when motor is disengaged. 
The Bowden cable pair is attached on the other end to the arm joint pulley which is to be actuated.
The diameter of driving pulley on multiplexer to the driven pulley at joint is kept in a ratio of around 1:10 to
increase torque.
CNC controller is used to interface motors to the software.
Encoder/ Potentiometer are used for closed control loop to increase accuracy.
 STAGE 1 - MECHANICAL
MULTIPLEXER
Multiple iterations were reviewed for simplicity and
utility and circular layout was selected.
Design analysis and FEA of parts related to mechanism
will be done
Following parts/ assemblies are needed for Multiplexer:
1. Tooth lock and clutching module for locking pulley
at fixed angle deviations when motor is disconnected.
2. Selector assembly for selecting and driving lock/
clutch module by rotating motor to required position.
3. Engagement mechanism to connect and disconnect
from clutch module using linear actuation
4. Circular housing frame for holding clutching Fig. 1 Mechanical Multiplexer Layout
mechanism
5. Pulley to be attached to bowden cable system.
 Locking Mechanism
Reciprocates (currently in
TOOTHED LOCKING AND locked state )
CLUTCHING MODULE

Current locking mechanism is in process Toothed feature to engage

driving selector on.
of design which uses spring loaded
locking. When required to be unlocked,
the selector will actuate and push lock to
disengage, thus allowing it to be rotated.
When selector retracts, spring loaded lock Fig. 2 Section view Locking
will reengage. assembly

Fig. 4 Section view Locking Fig. 3 Locking assembly design

assembly without shaft
STAGE 2 - ARM DESIGN
•Stage 2 is the design of Arm Assembly
•Arm Assembly consists of Bowden cable and the
Joint pulley.
•Initial tests using simulations for multibody analysis
•FEA and Design analysis of arm members.
Fig. 5 Bowden cables
Stage 3 – Prototyping & Tests
• Components to be Fabricated using 3D printing and CNC acrylic cutting.

• Testing to be done for various loading conditions, positions, angles, accuracy etc.

Stage 4 – Forward/ Inverse Kinematics

control algorithms
• Mathematical model of Forward and Inverse Kinematics to be developed for
simulations and autonomous control.
• Optimization of control algorithm and automatic operation development.
 1. As an improvement to our previous design, we have
started working on the design of a mechanical
SUMMAR multiplexer as a limb selector for our arm. We aim to
finish the design and FEA analysis of the multiplexer
Y OF 2.
by the end of this semester
We went through different iterations of models of the
PROGRES mechanical multiplexer involving components like a
sliding linear mechanism, a geared reducer
S IN mechanism, but finally decided on using a tooth clutch
with a circular layout for the required reduction as it
SEM VII offers the most simple and manageable design with
good accuracy.

TILL MID- 3. We will be using a Bowden cable mechanism to

actuate the limbs with satisfactory precision.
SEM 4. We have decided to replace the hollow universal joint
with a simple joint actuated with a pulley mechanism.

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THANK YOU

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