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Rotary Axis One

Figure 17: Rotary Axis 1

Rotary Axis is 3D-printed ABS plastic and connects directly to the base. One of the main reasons that
Team 2 went with an I-Beam made of out ABS plastic was to reduce the weight of it. Although the
deflection of it will be higher than if it was aluminum, it is cheaper and weighs less which puts less of a
load on our base. The supported side of the beam has a housing above it for the Nema 14 stepper motor
which will drive rotary axis 2. On the same side is the connection to the Nema 23. After going through
the calculations for the moment of inertia, it was best to select a larger stepper motor for arm 1. The
tradeoff of using a larger motor is that it weighs almost twice of the alternatives but it can supply more
torque.

1. Area of Inertia
The area of inertia needs to be calculated to in order to determine the bending stress according
to Equation 2.1. Although the cross section of our beam changes for arm 2, the bending stress
equation needs the area of inertia at the point of interest. The point of interest where the max
bending stress would be is at the far left of the beam of rotary axis one where the stepper
motors are mounted. At this location, the area of inertia is calculated as follows.
Figure 18: Beam Cross Section

3
𝑏ℎ3 𝑏𝑒𝑚𝑝𝑡𝑦 ℎ𝑒𝑚𝑝𝑡𝑦
𝐸𝑎𝑢𝑎𝑡𝑖𝑜𝑛 2.1: − 2( )
12 12

𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 2.24 ∗ 10−8 𝑚4

2. Beam FBD and Reaction Forces


The reaction forces were calculated by assuming the whole beam to be a rigid cantilever with
point forces at various locations. To obtain the forces created by the weight of each arm, the
volume of each and the density of ABS plastic were used. These forces were applied at the
center of mass locations of each arm.

Figure 19: FBD of Beam

𝐿1 = 0.075𝑚 𝐹1 = 0.57 𝑁 (𝐵𝑎𝑙𝑙, 𝑀𝑎𝑔𝑛𝑒𝑡, 𝐺𝑟𝑖𝑝𝑝𝑒𝑟, 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 𝐻𝑜𝑢𝑠𝑖𝑛𝑔, 𝑎𝑛𝑑 𝑐𝑟𝑎𝑛𝑘)

𝐿2 = 0.15𝑚 𝐹2 = 0. 392 𝑁 (𝑆𝑒𝑟𝑣𝑜 𝑀𝑜𝑡𝑜𝑟)

𝐿3 = 0.225𝑚 𝐹3 = 0.833 𝑁 ( 4 𝑇ℎ𝑟𝑢𝑠𝑡 𝐵𝑒𝑎𝑟𝑖𝑛𝑔𝑠 𝑎𝑛𝑑 𝐶𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑜𝑛 𝑆𝑐𝑟𝑒𝑤)

𝐿4 = 0.253𝑚 𝐹4 = 0.396 𝑁 (𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑅𝑜𝑡𝑎𝑟𝑦 𝐴𝑥𝑖𝑠 2)

𝐿5 = 0.3𝑚 𝐹5 = 1.86 𝑁 (𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑅𝑜𝑡𝑎𝑟𝑦 𝐴𝑥𝑖𝑠 1)

∑𝑀𝐴 = 0: 𝑀𝐴 + (𝐹5 ∗ 𝐿1 ) + (𝐹4 ∗ 𝐿2 ) + (𝐹3 ∗ 𝐿3 ) + (𝐹2 ∗ 𝐿4 ) + (𝐹1 ∗ 𝐿5 )

𝑀𝑎𝑥 𝑀𝑜𝑚𝑒𝑛𝑡 = 𝑀𝐴 = 0.624 𝑁 − 𝑚


∑𝐹𝑦 = 0: 𝑅𝐴 + 𝐹1 + 𝐹2 + 𝐹3 + 𝐹4 + 𝐹5

𝑀𝑎𝑥 𝑆ℎ𝑒𝑎𝑟 𝐹𝑜𝑟𝑐𝑒 = 𝑅𝐴𝑦 = 4.05 𝑁

3. Mass Moment of Inertia


For rotary axis one, the moment of inertia was calculated from Equation 2.2. All the variables in
this equation are listed below with a brief description. Team 2 expected this value to be large
because every single force on the beam contributed to it. The moment of inertia value for rotary
axis 2 is much smaller as it is only affected by forces on arm 2.

𝑚𝑓 (𝑚𝑎𝑠𝑠 𝑜𝑓 𝑓𝑙𝑎𝑛𝑔𝑒) = 0.046𝑘𝑔 𝐿𝑠 = 0.27𝑚 (𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑜 𝑆𝑒𝑟𝑣𝑜)

𝑚𝑤 (𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑒𝑏) = 0.0374𝑘𝑔 𝐿𝑚 = 0.3𝑚 (𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑜 𝑚𝑎𝑔𝑛𝑒𝑡)

𝑚𝐵 (𝑚𝑎𝑠𝑠 𝑜𝑓 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠 𝑎𝑛𝑑 𝑠𝑐𝑟𝑒𝑤) = 0.085𝑘𝑔 𝐿𝑏 = 0.15𝑚 (𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑜 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠)

𝑚𝑓 (𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑔𝑛𝑒𝑡 𝑎𝑛𝑑 𝑏𝑎𝑙𝑙) = 0.015𝑘𝑔 𝐿 = 0.3𝑚 (𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑜 𝑒𝑛𝑑)

𝑚𝑆 (𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑒𝑟𝑣𝑜) = 0.01𝑘𝑔 𝑏2 = 0.005𝑚

𝑏1 = 0.03𝑚

𝑚𝑓 𝑏1 2 𝑚𝑓 𝐿2 𝑚𝑤 𝑏2 2 + 𝑚𝑤 𝐿2
𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2.2: 𝐽 = 2 ( + )+( ) + 𝑚𝐵 𝐿𝐵 2 + 𝑚𝑀 𝐿𝑀 2 + 𝑚𝑆 𝐿𝑆 2
12 3 3

𝐽 = 0.011 𝑘𝑔 − 𝑚2

4. Angular Speed, Acceleration and Resolution


The angular speed is determined from the motor speed and the gear ratio. The NEMA 23 motor
specs say it can rotate at 90RPM. With a gear ratio of 2.4:1 then the output angular speed can
be determined by Equation 2.3.

𝑀𝑜𝑡𝑜𝑟 𝑆𝑝𝑒𝑐 𝑆𝑝𝑒𝑒𝑑 90 𝑅𝑃𝑀


𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2.3: 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑆𝑝𝑒𝑒𝑑 = = = 37.5 𝑅𝑃𝑀
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 2.4

The angular speed was used to calculate the angular acceleration given the time inputs. Angular
acceleration is then used to calculate the torque required for the motor.

𝑟𝑒𝑣 𝑚𝑖𝑛 2𝜋𝑟𝑎𝑑


(37.5 𝑚𝑖𝑛)(60𝑠𝑒𝑐 )( 𝑟𝑒𝑣 )
𝛼=
0.1𝑠𝑒𝑐
𝑟𝑎𝑑
𝛼 = 39.26
𝑠2
𝑑𝑒𝑔
𝑆𝑡𝑒𝑝𝑝𝑒𝑟 𝑀𝑜𝑡𝑜𝑟 𝐷𝑒𝑔𝑟𝑒𝑒 𝑝𝑒𝑟 𝑆𝑡𝑒𝑝 ∗ 2 0.9 𝑠𝑡𝑒𝑝 ∗ 2 𝑑𝑒𝑔𝑟𝑒𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝐷𝑒𝑔𝑟𝑒𝑒𝑠 𝑃𝑒𝑟 𝑆𝑡𝑒𝑝: = = 0.75
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 2.4 𝑠𝑡𝑒𝑝

5. Motor Torque
The motor torque is calculated form Equation 2.4. The calculation shows that a stepper motor
with at least 0.402 N-m of torque is required. To ensure our robot will work efficiently, a safety
factor of 2 will be implemented and the required torque becomes 0.804 N-m.

𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2.4: 𝑇𝑜𝑟𝑞𝑢𝑒 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝐽 ∗ 𝛼

𝑟𝑎𝑑
𝑇𝑜𝑟𝑞𝑢𝑒 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (0.0102 𝑘𝑔 − 𝑚2 ) ∗ (39.26 ) = 0.402 𝑁 − 𝑚
𝑠2

𝑇𝑜𝑟𝑞𝑢𝑒 𝑤𝑖𝑡ℎ 𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 2 = 0.402𝑁 − 𝑚 ∗ 2 = 0.804 𝑁 − 𝑚

With a torque required of 0.804 N-m, Team 2 decided to select the NEMA 23 motor which can
produce 0.9 N-m of torque. This torque will yield a safety factor of 2.25.

6. Failure Analysis
To ensure the beam will not fail, the bending stress must be calculated and compared with the
yield stress of the material. For our case, this material is ABS plastic.

𝑀𝑐
𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 1.1: 𝜎𝑏𝑒𝑛𝑑𝑖𝑛𝑔 =
𝐼

(0.624 𝑁 − 𝑚)(0.0125𝑚)
𝜎𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = = 348 𝐾𝑃𝑎
2.24 ∗ 10−8

𝑁𝑜𝑡𝑒: 𝑈𝑛𝑖𝑡𝑠 ℎ𝑎𝑣𝑒 𝑏𝑒𝑒𝑛 𝑐𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑎𝑛𝑑 𝑛𝑜𝑡 𝑠ℎ𝑜𝑤𝑛 𝑓𝑜𝑟 𝑠𝑖𝑚𝑝𝑙𝑖𝑐𝑖𝑡𝑦

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑀𝑜𝑑𝑢𝑙𝑒𝑠 𝐴𝐵𝑆 𝑃𝑙𝑎𝑠𝑡𝑖𝑐 = 3200 𝑝𝑠𝑖


Figure 20: Rotary Axis 1 FBD

3200 𝑝𝑠𝑖
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑆𝑎𝑓𝑡𝑒𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 = = 63.33
50.52 𝑝𝑠𝑖

7. Rotary Axis 1 Mohr’s Circle

Figure 21: Rotary Axis 1 Stress Element

𝜎𝑥 = 353𝐾𝑃𝑎 𝜎𝑦 = 0.00𝐾𝑃𝑎

𝜏𝑥𝑦 = 39.6𝐾𝑃𝑎

𝜎𝑝1 = 353𝐾𝑝𝑎 > 𝜎𝑝2 = 0.00𝐾𝑃𝑎 > 𝜎𝑝3 = −4.44𝐾𝑃𝑎

𝜏𝑚𝑎𝑥 = 174𝐾𝑃𝑎
Arm 1 Mohr's Circle
0.03

0.02

0.01
𝜏 MPa

0
-4.5 45.5 95.5 145.5 195.5 245.5 295.5 345.5
-0.01

-0.02

-0.03
σ KPa

Figure 22: Rotary Axis 1 Mohr’s Circle

8. Deflection

Figure 23: Beam FBD

For the deflection the entire beam was treated as a cantilever beam. The minimum cross

section, rotary axis 2, was used in the deflection calculation.

Arm Deflection

Deflection from Servo Motor (Equation 2.6)

𝑃 = 0.392𝑁
𝑎 = 0.253𝑚

𝐸 = 1.63 ∗ 109 𝑃𝑎

𝐼 = 1.34 ∗ 10−8 𝑚4

𝐿 = 0.3𝑚

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 𝑠𝑒𝑟𝑣𝑜 = 0.0890 𝑚𝑚

Deflection from thrust bearings and bolt (Equation 2.6)

𝑃 = 1.223𝑁

𝑎 = 0.15𝑚

𝐸 = 1.63 ∗ 109 𝑃𝑎

𝐼 = 1.34 ∗ 10−8 𝑚4

𝐿 = 0.3𝑚

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 2 𝑏𝑎𝑙𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠 = 0.113 𝑚𝑚

Deflection from weight of arm 1 (Equation 2.6)

𝑃 = 1.86𝑁

𝑎 = 0.075𝑚

𝐸 = 1.63 ∗ 109 𝑃𝑎

𝐼 = 1.34 ∗ 10−8 𝑚4

𝐿 = 0.3𝑚

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 𝐷𝑖𝑠𝑡𝑟 𝑓𝑜𝑟𝑐𝑒 𝑎𝑟𝑚 1 = 0.0473 𝑚𝑚

Deflection from weight of arm 2 (Equation 2.6)

𝑃 = 0.396𝑁

𝑎 = 0.225𝑚

𝐸 = 1.63 ∗ 109 𝑃𝑎

𝐼 = 1.34 ∗ 10−8 𝑚4

𝐿 = 0.3𝑚
𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 𝐷𝑖𝑠𝑡𝑟 𝑓𝑜𝑟𝑐𝑒 𝑎𝑟𝑚 2 = 0.0742𝑚𝑚

Deflection from Force at the end (Equation 2.5)

𝑃 = 0.571𝑁

𝐸 = 1.63 ∗ 109 𝑃𝑎

𝐼 = 1.34 ∗ 10−8 𝑚4

𝐿 = 0.3𝑚

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 𝐷𝑖𝑠𝑡𝑟 𝑓𝑜𝑟𝑐𝑒 𝑎𝑟𝑚 2 = 0.722𝑚𝑚

𝑃𝐿2
𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2.5: 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑀𝑎𝑥 𝑓𝑜𝑟 𝑝𝑜𝑖𝑛𝑡 𝑓𝑜𝑟𝑐𝑒 @ 𝑒𝑛𝑑 =
𝐸𝐼

𝑃𝑎2
𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 2.6: 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑀𝑎𝑥 𝑓𝑜𝑟 𝑝𝑜𝑖𝑛𝑡 𝑓𝑜𝑟𝑐𝑒 𝑛𝑜𝑡 @ 𝑒𝑛𝑑 = (3𝐿 − 𝑎)
6𝐸𝐼

𝑇𝑜𝑡𝑎𝑙 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = 1.045𝑚𝑚

9. Mass
The mass chart is shown in Figure 24. The values were calculated the same way as done for
rotary axis one. There is a column showing who will be supplying the material as well.

Figure 24: Rotary Axis 1 Mass Breakdown

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