Table of Contents

1.0. Introduction ........................................................................................................................................... 2 2.0. Objective ................................................................................................................................................ 2 2.1. Sub Objectives.................................................................................................................................... 3 3.0. Methodology.......................................................................................................................................... 4 3.1. Data Collection ................................................................................................................................... 5 3.2. Material Data ..................................................................................................................................... 5 3.3. Machines ............................................................................................................................................ 5 3.4. Experimentation ................................................................................................................................ 5 3.4.1.Test for Parallel Manipulator ....................................................................................................... 5 3.4.3. Control test ......................................................................................................................................... 6 3.5. Design................................................................................................................................................. 6 3.6. Data Analysis and Interpretation ....................................................................................................... 7 4.0. EXPECTED RESULT .................................................................................................................................. 7 5.0. Project Cost ............................................................................................................................................ 8 6.0. Project Planning. .................................................................................................................................. 10 6.1. Work Breakdown Structure for my Project ..................................................................................... 10 6.2. Project Work Plan. ........................................................................................................................... 10 7.0 Conclusion. ............................................................................................................................................ 14 8.0. References. .......................................................................................................................................... 15

1.0. Introduction
The need for speed, accuracy and better payload in the packaging industry is enormous, as industries are shifting to fully automated manufacturing so as to save cost and have better production effectiveness. The use of robots has greatly enhanced the performance of manufacturing industries. For some application, a high acceleration, better inertia and payload are required; as such the serial manipulator may not be suitable. The parallel manipulator is the solution to such problems. Manipulators has ordinary been design as serial kinematic chains (Parasurama, S.Liang, and P.C.J 2010) with simple analysis and wider workspace. It has been desirable to have manipulators with better payload, low inertia, high stiffness and large acceleration. Parallel Kinematics Manipulators are attributed with such capabilities.( Andreas Muller 2008). Parallel Manipulators has its setbacks such as: smaller workspace as well as many singularities within the workspace. The application of robotics to the, manufacturing industry is what has spur the rapidly increasing study on robotics. In this project, I intend to design a parallel manipulator that will be use in the packaging industry. The manipulator is to pick the product to be package and place it on a wrapper. In real application, the wrapper is on a fast moving conveyor belt, the manipulator picks and places the product on the wrapper.

2.0. Objective
Generally, the main objective of this project is to Design and Fabricate a 3 DOF parallel Manipulator structure for packaging industry. Upon the completion of this project, one must be able to understand how this system works in the real world (that is how to apply the robotics manipulator to a packaging industry). In this project, I will be working to design and fabricate the structure of a parallel manipulator. This entails: Kinematics analysis of the structure of the parallel Kinematic manipulator (PKM): for a coherent design of the parallel manipulator, a thorough kinematics analysis will be carried out. This involves both analytical and numerical analysis.
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 Modeling of the parallel kinematic structure: For any engineering design, there are governing principles that guides it. In this modeling phase of the project, we seek to model the relationship between factors and parameters that affect the design of the PKM. Parameters here include size, shapes of components, torque, acceleration and orientation of the links and moving platform. The workspace modeling and the Jacobian of the PKM. Factors includes cost, weight of components, availability of materials, suitable actuation method, availability of software, time constraint, machining skills and proficiency level of the use of tools that will be use in the project such as solidworks, matlab and robotic simulator, etc. Fabrication of the parallel Kinematics structure: This involves Fabrication of the individual components and joining or assembly of the components.

2.1. Sub Objectives

1. Cad modeling of the parallel Manipulator (using Solidworks): this part concentrates mainly on cad modeling of the parallel manipulator. 2. Static structural analysis of the parallel Manipulator; this involves some static stress structural analysis of some of the major components. Where necessary, fatigue stress analysis will be carried out. 3. Control and Programming of the parallel Manipulator: this involves design of the control system for the project. Tools like Matlab and other control base software suitable for the application will be use.

3.0. Methodology

[20 marks]

PROJECT METHODOLOGY
RESEARCH
-Identification of the physical system and components of the manipulator. And Jacobians for the 3 Dof parallel manipulator. Suitable microcontroller and actuation. The Equipments/instruments required for the experiment include: spanners, screw drivers, gauge, lathe machine, soldering iron, weighing balance, measuring tape, general machining tools, welding machine Data to be collected: material properties, packaging information, data sheet of motors, weight of links, speed /rating of motors, acceleration, Velocity of the manipulator, orientation. Experiments: Test to measure speed of the manipulator Test to determine orientation of the manipulator

EXPERIMENT AND DATA COLLECTION

Modeling and Numerical Solution

CAD DESIGN: Solidworks is use to model the structure KINEMATICS ANALYSIS: SolidWorks motion Simulation is use to analyze the kinematics of the cad model. Robotics Simulation: Simulation using Robot studio/ any other

Analytical Solutions Fabrication

Mathematical modeling of the 3 DOFParallel manipulator Machining Processes: Cutting, milling, punching, drilling etc Joining Processes: Welding, screw, joint design etc Control system design using PD, PI or PID. Microcontroller Programming. PCB design of control system.

Control System

Design

Final Testing

Testing For performance 4

To actualize the objectives of the project stated above, the following methods and process will be employed:

3.1. Data Collection

Literature Data: data involving numerical numbers and standard such as how to develop mathematical models for the 3 DOF PKM, methods of solving the equations and obtain solution of the kinematics structure, types of joint design, actuation and controlling methods and the likes will be refer to from Robotics journals, books, and magazine.

3.2. Material Data

When the mathematical models has been solve and the parameters use for the design such as weight and size are to be considered, journals from the mineral metals and material society (TMS) will be considered for reference materials and properties. For the purchase of the material, shops in Pudu, and ChanChowlin will be considered.

3.3. Machines
The machines that will be used for the fabrication are: lathe machine for cutting, welding machines, filling machines and other machining operations machines. Many of which are in the schools mechanical workshop. Screws are to be design with standard size and will be purchase from retailers. Measuring instruments such as tape, gauges are in the mechanical workshops and will be used.

3.4. Experimentation
The experiment that will be conducted will be to determine if the structure is a parallel manipulator. The test for the number of degrees of freedom and a test for the speed.
3.4.1.Test for Parallel Manipulator: Parallel manipulator generally has specific characteristics

(distinctive features) which include: Parallelism, high payload capacity, high throughput movement (acceleration), high mechanical rigidity, and low moving mass.

3.4.2. Structural and Kinematics test 1. Test for Parallelism: the robot will be operated and the structure will be observed for the parallelism criteria. For this test, the links must be parallel and connected to a single fixed base and a moving platform. 2. Payload test: Objects of various weights will be picked by the manipulator, and the weight ratio of the pick object will be measured. 3. High through put Movement (acceleration): The time taken for the manipulator to pick and place and object will be measured and the distance covered, the speed and acceleration will be measured or calculated.

3.4.3. Control test

The robot will be operated and the desirable position as well as the time taken to reach this position will be measured. The position error will be calculated. This will be use to compare with the control simulation result.

3.5. Design
The design for this robot is in four steps. 1. Cad Modeling: the robot will be model using solidworks mechanical automation

software. Each component will be modeled and an assembly of the entire system will be produce and motion analysis will be carried out. Also structural analysis of some of the components especially the base to determine if the actuator can be attached directly, if it can bear the weight. 2. Mathematical Analytical model: the system will be model analytically; the workspace as well as orientations, and forces will be determined. 3. Fabrication: In this design phase the components of the manipulator will be fabricated and assembled together. Various machining operations will be carried out at this stage of the design.

4. Control system design: this involves the design of the controller to be use, such as PD, PI and PID. The design of the circuit for the entire system. The programming of the microcontroller. Though this project priority is the kinematics and static analysis of the parallel manipulator. This control design is necessary for demonstration of the capabilities and working principle of the system. Generally in this design phase, the workspace must be know, the torque of various links and platform. The method of actuation and the type of end effectors that will be utilize. The material properties such as yield strength will be considered.

3.6. Data Analysis and Interpretation

The data use or collected at various stage will be analyze .The experimental data will be compare to the simulation as well as the analytical results obtain. The workspace calculation and the simulated result will be compared. The torque required will be calculated. Graphs will be plotted to illustrate or compare data. Result obtain will also be listed in table manner for adequate understanding.

4.0. EXPECTED RESULT

[5 marks]

This project is a fabrication project as such; the mechanical structure of the robot will be built. It is expected that a parallel manipulator is fabricated. Parallel manipulator has two or more links that connect a moving platform to a single base. (Ayssam Elkady, 2008). The design of the parallel manipulator should fulfill this requirement links joining base and moving platform). Payload Capacity: The manipulator should be able to carry a reasonably load to its structure. More on this will be determine after the first meeting with my supervisor when the project commences. The robot achieved the desirable trajectory with a position error less than 20 103 m after 5 seconds. This is a test for the positioning accuracy of the robot as well as the programming and the acceleration. Since this robot will be use for the packaging industry, it is necessary that this positional accuracy is achieved.
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 Cad Model: there should be proof of the cad model of the system. 2D draft as well as 3D models of each individual components and there assembly. The Cad models will be printed and use for both the poster presentation as well as the final report.

5.0. Project Cost

[5 marks]

Economists, engineering managers, project managers, and indeed any person involved in decision making must be able to analyze the financial outcome of his or her decision. The decision is based on analyzing and evaluating the activities involved in producing the outcome of the project. These activities have either a cost or a benefit. Financial analysis gives us the tools to perform this evaluation. Often the decision to make is to proceed or not to proceed with a project. In cases involving investment, we want to know if the project is economically viable in order to proceed. In effect, we compare the net benefit of proceeding with the project against the consequences (good or bad) of not proceeding (the null alternative). Sometimes we are confronted with two or more courses of action (alternatives); in this situation, we want to know which alternative produces the greatest net benefit. To be able to make the go/no go decision or to compare different projects, systems, or courses of action, we have to find a common measure to reflect all the costs and benefits and their time of occurrence. Financial analysis methods will give us this capability (Abol Ardalan, 2000). The cost estimate below is an overview of the cost of this project and is presented in table 2 below.

Table2: Cost Estimate S/No QUANTITY DESCRIPTION UNIT COST DISCOUNT TOTAL (RM) 1 2 3 4 1 4 1 24 Material for base AL bars for links AL sheet, moving part nuts
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(RM) 225 400 100 36

225 100 100 1.5

5 6 7 8 9 10 11 12 13 14 15 16 17 18

24 24 4 2 4 1 1 30 4 6 2 3 1 1

screws washer Cutting operation Microcontroller IC Servo motors Soldering Iron toolbox Tool hiring Welding transportation Software hiring Paint Spray gun Miscellaneous

1.5 0.5 10 150 200 25 45 5 15 45 200 20 150 500

10% 5% Total

36 12 40 300 800 25 45 135 57 270 400 60 150 500 3,591

The estimate above does not include some of the labor cost, such as the machining, the handling, the assembly etc. Those operations will be carried out by the student (Nangi Ebughni.). However I have included a miscellaneous of Rm 500. This is to cover any unforeseen rise of material prices. Also the project will commence next year, meaning there might be increase in tax or cost of labor or fixed cost like rent and these might leads to rise in prices, to avoid the effects of those increases, I have included the miscellaneous. The total cost for this project is worth Rm 3591 which is approximately Rm 3600.

6.0. Project Planning.

[10marks]

The entire project has been broken down into finitely individual tasks so as to be able to estimate the time and resources needed for this project. First, the work breakdown structure. Then the table showing the list of task and then project management tools like gannt chart and network diagram has been use for adequate planning.

6.1. Work Breakdown Structure for my Project

FABRICATION OF 3 DOF PKM Research Design of System Fabricate
Modeling & Simulation

Control Design

Fig.2. WBS for the project. (James P. Lewis, 2007) Check appendix 1 for a compete draft of the WBS.

6.2. Project Work Plan.

The list of table 3 bellow has been use to prepare the gannt chart and the network diagram. Table 3. Project Work plan (Work break down Table) S/No Task 1 2 3 4 5 6 7 8 9 Research 1st Progress Presentation Workspace Calc. Data Sum. 2nd Progress presentation Cad Modeling Kinematics Simulation Robot Simulation Analytical Solutions 3rd Progress Presentation Assigned letter A B C D E F G H I
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Predecessor A A,B B A E A,C A,F,G H

Duration (days) 15 1 5 1 4 4 7 15 1

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Conceptual design Purchase of Materials Fabrication of Components Assembly 4th Progress Presentation Control System Design
Implementation of control system

J K L M N O P Q R S T U V W X Y Z

D J J,K L L G,H O P M,P R R,S T R,S V H,M,P,S W X T,U,V,W,X,Y

2 10 19 5 1 5 18 1 1 1 4 1 6 5 8 5 12

5th Progress Presentation 1st Testing 2nd Testing Redesign, Ergonomics etc 6th Progress Presentation Aesthetics & Finishing Experimentation & Testing Result Analysis: Interpretation Poster Design, Viva, PPP Report Compilation, Thesis

The figure below shows the gannt chart the complete chart is attached on the appendix.

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Figure 6. The gannt Chart (detail copy is on the appendix)

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Fig. 6.1 Network diagram (A more clear copy is attached on the appendix).

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7.0 Conclusion.
This proposal presents the work schedule, the resources as well as the result that will be achieved upon the completion of this project. The fabrication of the PKM, its control and the analytical as well as numerical solutions are the methods that will be use for the actualization of this project. Tools like matlab, Robot studio and solid works will be use. Tools like matlab, solidworks cosmos simulation and other Robotics kinematics Simulator will be use for this project. I am sincerely grateful to my supervisor for the guidelines throughout this project proposal. I beg you indulgence sir to help reach out to the technicians and permit me to use the mechanical

works of Legenda educational group so as to complete this assignment within the stipulated resources on my cost estimates.

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8.0. References.
Abol Ardalam., 2000. Economics & Financial Analysis for Engineers & Project Managemnt. Anatoly Pashkevich, D. Chablat, P.Wenger, R. Gomolisky, 2009. Parallel Manipulator, New development.I-tech Publisher, Austria. Andreas Muller, 2008. Redundant Actuation of parallel manipulator. I-tech towards new application, Book pp506, Vienna Austria. Ayssam Elkedy, Galal Elkobrosy, Sarwat hanna, Tarek Sobh, 2008. Cartesian Parallel Manipulator modeling and Control. Parallel Manipulator towards new applications, ISBN 978-3-902613-40. Pp506. I-Tech Education and Publising Vienna, Astria. Charman Lal Sabharwal. January, 2009. Introduction to Robotics Lecture series. . Daniel Glozman, Moshe Shoham, 2009. Robotica pg1-5. Cambridge University Press. Cambridge England. Houssem Abdellatif, Bodo heiman, Jens Kotlarski, 2008 Institute Robotics Hannover Centre of Mechatronics. Leibniz University. I-Tech. Croatia.

Jagdish M. Prasapati, Feb., 2011 Synthesis of parallel mechanism based robot manipulator from structural point of view. International Journal of Engineering Science and Technology (IJEST). Vol.3. No.2. pg 1227-1232.

Jan Baksa, Anton Dekret, 2010. Asymptotic Motion of three Parametric Robot Manipulator. Acta Universitatis Matthiae Belli Ser. Mathematics, pg 3-19. J.P Merlet, D. Dany, 2004. Appropraite Design of Parallel Manipulator. INRIA SophiaAntipolis. France. K. Chen, J.S. Wong & J.C.1999. Ho, A heuristic algorithm to minimize tardiness for parallel machines Proceedings of ISMM\International Conference. ISSM-ACTA Press, Anaheim CA, USA pp. 118-121.

Larry Ross, S.Fardo, J.Masterson,R.Tower,2011. Robotics Theory and industrial application. 2nd edition. Goodheart Wilcox Publisher. Masahiro Takaiwa, Toshiro Norifsugu,2008 Positional Control of Pneumatic Parallel Manipulator. International Journal of Automation Technology. Vol.2. No.1.

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Richard Eugene Stamper. 3-DOF parallel Manipulator with only translational degrees of freedom. Institute for system research. University of Maryland. Maryland. Saeed B.Niku, PhD, 2001. Introduction to Robotics Analysis, Systems and applications. San Luis Obispo, California. Parentic Hill. Stefan Uhlar, Peter Betsch, 2008. Conserving Integrators for Parallel Manipulators. Itech publishing,. Austria. Tarik Cakar, 2008. Publishing. Austria. Parallel Robot Scheduling with Genetic Algorithms. I-tech

Appendix

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