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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
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
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.
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.
𝑟𝑎𝑑
𝑇𝑜𝑟𝑞𝑢𝑒 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (0.0102 𝑘𝑔 − 𝑚2 ) ∗ (39.26 ) = 0.402 𝑁 − 𝑚
𝑠2
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
3200 𝑝𝑠𝑖
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑆𝑎𝑓𝑡𝑒𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 = = 63.33
50.52 𝑝𝑠𝑖
𝜎𝑥 = 353𝐾𝑃𝑎 𝜎𝑦 = 0.00𝐾𝑃𝑎
𝜏𝑥𝑦 = 39.6𝐾𝑃𝑎
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
8. Deflection
For the deflection the entire beam was treated as a cantilever beam. The minimum cross
Arm Deflection
𝑃 = 0.392𝑁
𝑎 = 0.253𝑚
𝐸 = 1.63 ∗ 109 𝑃𝑎
𝐼 = 1.34 ∗ 10−8 𝑚4
𝐿 = 0.3𝑚
𝑃 = 1.223𝑁
𝑎 = 0.15𝑚
𝐸 = 1.63 ∗ 109 𝑃𝑎
𝐼 = 1.34 ∗ 10−8 𝑚4
𝐿 = 0.3𝑚
𝑃 = 1.86𝑁
𝑎 = 0.075𝑚
𝐸 = 1.63 ∗ 109 𝑃𝑎
𝐼 = 1.34 ∗ 10−8 𝑚4
𝐿 = 0.3𝑚
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
𝑃 = 0.571𝑁
𝐸 = 1.63 ∗ 109 𝑃𝑎
𝐼 = 1.34 ∗ 10−8 𝑚4
𝐿 = 0.3𝑚
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
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.