MEGR3156

Junior design
Design report
Team 6
October 19, 2017

Abdulaziz Alrushayd, Benson Crooks,

Camden Carstens
Daniel Garver, Jason Banks, Muayed
Alhilal
Introduction:

Figure 1: Robot assembly Figure 2: Robot front view

The base, seen in blue, is responsible for holding the stepper motor (yellow) that actuates the 180
degree movement of the robot. It also holds the Arduino and motor shield, shown in gray. Our
control system consists of the Arduino Uno, motor shield, and all necessary wiring going to the
servo motor, two stepper motors, and two microswitches. The arm at the very top is the cable
strain relief, which swivels around the rod in a full circular motion while holding the welding
cable in place. Along with the stepper motor, Rotary Axis 1 contains the main driveshaft, collar,
pin, cam and microswitch, all shown in yellow. The collar directly below the stepper motor takes
the axial stress off of the stepper motor shaft, and the pin connects the collar with the stepper
motor shaft. Just under the base are the cam and microswitch. They are responsible for signaling
a “home” position to the Arduino. The bottom of the shaft (yellow) connects with Rotary Axis 2,
seen in green. This system contains the second stepper motor, two pulleys, a ribbed belt, a
second microswitch, and a long shaft connecting to the welding torch chassis(orange). At the
other end of the shaft is the cam and microswitch. As the welding torch chassis is rotated 45
degrees the cam will connect with the microswitch and sends a signal to the Arduino to provide a
second “home” position for the robot. The last subsystem, shown in orange, is responsible for
holding the welding torch in place. The welding torch chassis, servo motor, and servo motor
lever arm all make up one subsystem, as shown in orange above.

Subsystem calculations:
Base Chassis Overview
The base chassis has a multitude of functions for the robot. The criteria that the base chassis must
fulfill are providing support for the weight of the lower assembly, providing a platform to mount
the control assembly, providing a location for the cable strain relief assembly, providing a mount
for the rotary axis 1 drive, as well as providing a way to hold the robot in the collet of the CNC
machine. These criteria are met by the parts listed below
Collet Attachment
Starting from the simplest criteria of holding the robot to the CNC machine, a rod of one half
inch diameter was selected. This rod would need to support the entire weight of the robot as well
as providing a location to mount the strain relief. The calculations listed below describe the
process of selecting the material for the rod using failure criteria. With a safety factor of above
our specified value, aluminum was chosen for the material of the rod. This rod is affixed to the
chassis by a means of a press fit and a fastener system utilizing a threaded portion of the rod and
a washer and nut combination. This ensures that the force on the collet attachment rod will be
distributed across the chassis and keeps the rod inline with the chassis. Figure (1) below shows
the parts of the

Figure (3): collet attachment.

Control Support
The base also has to support the control assembly. The control board comes with a mount that
can be fastened to the base chassis using bolts. To incorporate the control board mount hole
positions and size were calculated to be machined into the side place of the chassis.
 Figure (4): provides a visual of where the control will be mounted.

Strain Relief
The next part of the criteria to meet was providing a strain relief that rotated with the lower
assembly to support the weight of the torch cable as it moved around the robot. To do this
common materials were used such as a cable clamp, threaded rod, and a common pipe t. The
cable will be supported by the clamp which is then attached to the chassis using a t shape adapter
that is free to move about the collet mounting rod. This provides 360 degrees of motion for the
cable strain relief. Figure (5) provides a visual for this mechanism. Figure (6) is a representation
of the clamp that is planned for in the design.
 Figure 5: Mechanism for strain relief

Figure 6: Representation of the clamp that is planned for in the design.

Mount for Motor

For the design, the motor for rotary axis 1 needed to be housed in the base and above the axis to
be rotated. To do this we also needed to provide a support for the axis. This was done by using
two dual race bearings separated by a bearing plate. Above this bearing plate the stepper motor
mount would be placed to provide a direct drive configuration. This stepper motor plate is
connected to the base of the chassis by means of four mount legs. Figure (7) contains a view of
the bearing setup and plate mounts. Figure (8) contains The plate for mounting the stepper
motor.
 Figure 7: Bearing and mounts Figure (8): Motor mount

Chassis Frame
Since there is no way to assemble the stepper motors and internal parts into the base chassis
without the chassis being modular, the main components were made to be assembled together for
the base using fasteners. The base chassis itself contains the main part which is made out of four
pieces being the top, the base plate, and the sides. Since the weight of these pieces are to be held
together with fasteners, calculations for the strain on these fasteners were calculated. Figure (2)
shows the fasteners location on the side of the chassis. The base main chassis is to be made out
of aluminum due to the fact of machinability, ease of access, and the materials relatively light
weight. The calculations for the base all use aluminum then for the calculations for weight and
stresses. Below are the calculations for the fasteners and the calculation of the overall weight.
Table 1 : Weight of all base components

Table 2: Key of table 1

Base calculations
Rotary Axis 1

Figure 7: Drive shaft with cam Figure 8: Shaft connection to Stepper Motor

Description:
Rotary axis 1 is made up of a stepper motor, main driveshaft, collar, two pins, set screw, cam,
and a microswitch. The driveshaft of the stepper motor is connected to the main shaft using a
pin. The pin goes through the collar, the main shaft, and the stepper motor shaft to connect all
three together. A set screw is used to keep both driveshafts aligned. Near the bottom of the main
shaft is the cam and microswitch. As the assembly turns, the cam will hit the microswitch and
send a signal to the Arduino. At the very bottom of the main shaft a large pin holds the chassis of
Rotary Axis 2.

Moment of Inertia:

Equation (1)
Where:
J is the total moment of Inertia
m is the mass of the object
r is the radius to the center of object

The calculated moment of inertia for our design was calculated to be 1.46 ∗ 10'( 𝑘𝑔 ∗ 𝑚, .

Motor Torque:
153 N-mm @300 RPM
Torque Required: 20.1 N-mm
Using a safety factor of three in our design of the rotary axis, our new torque required was 60.3
N-mm. This value was still well below the torque available from the motor.

Angular Speed and Resolution:

Resolution = 1.8 degrees/second
Angular Speed=300RPM
The rotary motion of a single step using this stepper motor was found using the equation

3456789:6;
𝑡 = 2𝜋𝑟 Equation (2)
(<=

Where:
r is the radius
t is the length of the step

Using this equation the calculated rotary motion of a single step was 2.83mm. The value refers to
the length the tip of the welding torch moves under one step from the stepper motor.

Plastic Failure:
Factor of Safety = 3
Steel pins were used to connect the stepper motor driveshaft to the main shaft as well as the main
shaft to the chassis containing rotary axis 2. The deflection in these two steel pins were
calculated using the equation

𝑌 = −𝐹𝐿( /48𝐸𝐼 Equation (3)

Where:
F is the force acting on the pin
L is the length of the pin
E is the modulus of elasticity
I is the moment of inertia

Deflection of Upper Pin: 9.2*10^-5mm

Deflection of Lower Pin: 3.2*10^-5mm
 Table #2 : Weight of all rotary axis components

Rotary Axis 2:

Figure 8: Rotary axis 2 Figure 9: Pulley 1 and 2 with the stepper motor

Figure 10: Driveshaft with the microswitch mounted on the side

Description:

Rotary axis 2 controls the vertical movement of the torch holder assembly. It is responsible for
articulating the assembly through 45 degrees of motion. The components comprising rotary axis
two are: stepper motor, stepper motor mounting bracket, microswitch, aluminum shaft, 15 tooth
pulley, 22 tooth pulley, 63 tooth cogged belt, 20 screws,2 bushings, 1 pin, and an aluminum
chassis (chassis #2). Chassis #2 rotates horizontally about rotary axis one and provides support
for all rotary axis two components. A two pulley drive system was selected in order to multiply
the torque from the stepper motor and improve resolution. A cam activated, normally open
microswitch is used to signal the “home” position to the Arduino during the homing sequence.
Total mass for the subsystem is 466.9 grams.

The moment of inertia for components actuated by the stepper motor is 3.11*10-3 kg*m2. The
moment of inertia for the torch holder assembly was calculated using Eq (1):

Eq. (1)
where:
J is total moment of inertia
m is mass of object
r is radius of center of mass

An initial calculation was performed to determine the motor torque necessary by using an
estimated angular acceleration value of 20 rad/s2. This returned a necessary motor torque of 62.3
N*mm. A NEMA style stepper motor was selected that produced 153 N*mm of torque at 300
rpm and 230 N*mm at stall speed. A belt driven step up pulley system was selected in order to
multiply torque, improve resolution, and increase acceleration. A final ratio was selected of .68:1
where the diameter of the drive pulley was .68 times the size of the driven pulley. The available
torque at the driven shaft is 224.4 N*mm. The reflected inertia for the motor was calculated and
found to be 1.44*10-3 kg*m2. The reflected inertia was calculated using Eq (3):

Eq. (3)
Where:
Jeq is reflected inertia
r1/r2 is gear ratio
J is moment of inertia

The available torque at the driven shaft was calculated using Eq (4):
 Eq. (4)

where
T2 is torque at driven shaft
T1 is motor output torque
R2 is driven pulley size
R1 is drive pulley size

The stepper motor has a resolution of 1.8 degrees per step. This was improved with the addition
of the pulley system to 1.23 degrees per step using a .68:1 ratio. The welding torch tip has as
estimated movement distance of 2.25 degrees per step. The rotary motion of a single step was
calculated using Eq (5):

Eq. (5)
Where
r is the distance to torch tip
c is the central angle in degrees

The angular acceleration of the torch holder is 49.12 rad/s2. The angular acceleration was
calculated using Eq(6):

Eq. (6)
where
T is available torque
J is moment of inertia
Alpha is angular acceleration

Failure calculations for the subsystem support chassis were completed using a safety factor of 3.
Aluminum was selected as the primary material for construction, and has a yield strength of 240
MPa. Considering the safety factor the allowable yield stress is 80 MPa. The Von Mises stress
for the chassis are .438 MPa with a deflection of -2.81*10-mm. The Von Mises stress for the
torch holder driveshaft are 12.75 MPa, with a deflection of -.046 mm.

Table 3: Rotary axis 2 cost.

Trigger actuator:

Figure 11: Trigger actuator with the torch

 Figure 12: Trigger actuator front view Figure 13: Trigger actuator with the
servo motor mounted in the bottom

Description:
The trigger actuator subsystem is comprised of the welding torch chassis, the servo motor, and
all necessary fasteners. The welding torch chassis is made up of two parts that fasten together to
hold the welding torch in place. Underneath the welding torch is a servo motor that rotates to
contact the torch trigger. The servo motor is attached in the torch chassis using four fasteners. At
the top of the assembly is a “D” shaped shaft that connects to the lower stepper motor. Two set
screws are used to fix the shaft with the torch chassis.

Servo Motor Torque:

The required force to depress the trigger on the welding torch was measured to be 8.5 N. The estimated length of our
servo lever arm was 10 mm. From these values the torque required to depress the trigger was 85N-mm.

Mass: 153.8 grams.

 . Table # : Weight of all torch holder components

Positioning performance:

Top Stepper Motor: 1.8 degrees/step

Lower Stepper Motor: 2.25 degrees/step

Budget:

Subsystem Components Manufacturability Price

Base base plate, bearing All components are $16.25

holder, sides, legs manufactured by
mount, stepper team members.
plate, top plate,
collet attach, strain
attach

Rotary axis 1 main shaft, upper Stepper motor and $22.09

collet, pin upper, micro switch are
cam upper, stepper purchased.
Cam is 3D printed.
motor, micro switch All other
components are
manufactured by
team members.
 Rotary axis 2 chassis, split shaft, Pulleys, stepper, $41.62
cut bushing, belt are purchased.
stepper mount, pin, Cam is 3D printed
cam, micro switch, All other
stepper motor, components are
pulleys, belt manufactured by
team members.

Control Arduino, motor All components are $51.89

shield, mount, purchased by team
power supply, wires members

Trigger actuator Trigger assembly, Trigger assembly $65.65

servo arm, servo and servo arm are
printed.
Servo motor is
purchased.

Total budget: $287.50

RP material: ABS

Setup fee: 20$

Model Material (in^3) Support Material (in^3) Total Material (in^3) Time Cost($)
(hr.min)

Torch 4.61 1.87 6.48 10.29 $37.4

Holder

Top Cam 0.06 0.02 0.08 0.14 $5.40

Lower 0.03 0.01 0.04 0.12 $5.20

Cam

Servo 0.04 0.02 0.06 0.10 $5.30

Tap
Table 1 : RP Material with budget
 Total Material (in^3) 6.66

Time Required (hr.min) 10.29

Total Cost ($) $53.30

Table 2: Total cost and time of RP parts

Labor :

Labor

Student Hours Rate (per hour) Total

Abdulaziz
Alrushayd 52 10 520

Daniel Garver 61 10 610

Benson Crooks 48 10 480

Camden
Carstens 47 10 470

Jason Banks 38 10 380

Muayad Alhilal 56 10 560

Outside Labor 0 100 0

302
Total Cost of
Labor
$3020
Manufacturing
Parts 43 10 430

Assembly 15 10 150
Testing 10 10 100

RP Labor Cost 20

Total $3720