the design and fabrication of hydraulic boom trainer...
TRANSCRIPT
THE DESIGN AND FABRICATION OF HYDRAULIC BOOM TRAINER
WITH GRIPPER ATTACHMENT
MUHAMMAD FAIZ BIN OTHMAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
THE DESIGN AND FABRICATION OF HYDRAULIC BOOM TRAINER
WITH GRIPPER ATTACHMENT
MUHAMMAD FAIZ BIN OTHMAN
This report is submitted in partial fulfilment of the requirement for the degree
of Bachelor of Mechanical Engineering (Thermal-Fluids) with Honours
Faculty of Mechanical Engineering
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUNE 2013
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SUPERVISOR DECLARATION
“I hereby declare that I have read this thesis and in my opinion this report is
sufficient in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering (Thermal-Fluids)”
Signature : ......................................................
Supervisor : DR. AHMAD ANAS BIN YUSOF
Date : ......................................................
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DECLARATION
“I hereby declared that the work in this report is my own except for summaries
quotation which have been duly acknowledged”
Signature : ………………………..
Author : MUHAMMAD FAIZ BIN OTHMAN
Date : JUNE 2013
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This report is dedicated to my family. Thank you for your continuous support during
my vital educational years. Without their patience, understanding and most of all
love, the completion of this work would not have been possible.
To my beloved mother,
Noraini Binti Suhaimi
My siblings,
Emran Affendy Bin Othman
Norazlin Binti Othman
Norhasniza Binti Othman
Norhaslina Binti Othman
Norhashima Binti Othman
Muhammad Faizal Bin Othman
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ACKNOWLEDGEMENT
“In The Name Of Allah, The Merciful, The Beneficent”
Glory to Allah S.W.T. the most gracious and most merciful. All the worship
belongs to only Allah. We seek refuge with Allah from the wickedness within evil
and until I have done the project. I also praised to Allah S.W.T for giving us courage,
time, and knowledge in completing this report for Bachelor Degree Project.
Alhamdulillah, at last this report is complete to be submitted on the due date.
The successful of this project is because of the fully encouragement and support of
many people. I wish to express my gratitude to my supervisor, Dr. Ahmad Anas Bin
Yusof who was abundantly helpful and offered invaluable assistance, support and
guidance and also deepest appreciation to the members of the supervisory committee,
Mdm. Fadhilah Binti Shikh Anuar and Mr. Faizil Bin Wasbari. Without their
continued support and interest, this thesis would not have been same as presented
here.
Last but not least, I would like to thanks to all my friends who always been
here to give a motivation. I would also like to convey thanks to the Faculty of
Mechanical Engineering for providing the financial and laboratory facilities. I wish
to express my love and gratitude to my beloved families for their understanding and
endless love through the duration of my studies.
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ABSTRACT
Manipulator arm is a mechanical system that shows the movement of a robot
that consists of a composition link and joint which capable to form a controlled
movement. The application of this fabricated manipulator arm is connected to
existing hydraulic training system in laboratory as the source of system controller.
The process involved in completing this project consists of literature review,
projection and angle of motion review, blueprint design using SolidWork Software,
kinematics analysis, component procurement, fabrication and model testing. The
model testing is done by using pneumatic and hydraulic system as the system
controller where the movement testing and cylinder speed testing are conducted.
Movement testing indicates that the movement of manipulator arm by hydraulic
system is more stable and moving constantly than pneumatic system. Next, the
cylinder speed testing is performed where the operating pressure was setup from 4
bar to 8 bar for pneumatic system while for hydraulic system was setup from 10 bar
until 30 bar. The result shows that the time taken for cylinder speed by using
pneumatic system is slower and not moving constantly than hydraulic system since
the behavior of air is compressible and also affected by the gravitational and load
factor. Therefore, the most suitable system for this project is by using hydraulic
system and in term of application, this project can be further developed and
improved in order to fulfill the requirement for the future development.
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ABSTRAK
Lengan penggerak adalah satu sistem mekanikal yang menunjukkan
pergerakan robot yang terdiri daripada pautan komposisi dan sendi yang mampu
untuk membentuk satu pergerakan terkawal. Aplikasi lengan penggerak ini direka
dan disambungkan kepada sistem latihan hidraulik yang sedia ada di makmal sebagai
sumber pengawalan sistem. Proses yang terlibat dalam menyiapkan projek ini terdiri
daripada kajian ilmiah, unjuran dan kajian pergerakan sudut, reka bentuk
menggunakan perisian SolidWork, analisis kinematik, pembelian komponen,
fabrikasi dan ujian model dimana ia terdiri daripada ujian gerakan dan ujian kelajuan
silinder. Ujian gerakan menunjukkan bahawa pergerakan lengan penggerak
menggunakan sistem hidraulik adalah lebih stabil dan lancar berbanding sistem
pneumatik. Seterusnya, ujian kelajuan silinder dilakukan dengan tekanan operasi
bermula dari 4 bar ke 8 bar bagi sistem pneumatik manakala bagi sistem hidraulik
bermula dari 10 bar ke 30 bar. Hasil kajian menunjukkan masa yang diambil untuk
kelajuan silinder dengan menggunakan sistem pneumatik adalah lebih perlahan dan
tidak lancar berbanding sistem hidraulik kerana faktor mampatan udara dan juga
faktor graviti dan beban. Oleh itu, sistem yang paling sesuai untuk projek ini adalah
dengan menggunakan sistem hidraulik dan bagi tujuan aplikasi, projek ini boleh terus
dibangunkan dan diperbaiki untuk memenuhi keperluan pembangunan masa
hadapan.
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TABLE OF CONTENT
CHAPTER TITLE PAGE
DECLARATION
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ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENT vii
LIST OF FIGURES ix
LIST OF TABLES xiii
CHAPTER I INTRODUCTION 1
CHAPTER II
1.1 Background
1.2 Problem Statement
1.3 Project Objective
1.4 Project Scope
LITERATURE REVIEW
2.1 Introduction to Manipulator Arm
2.2 Manipulator Arm for Educational and Research
Purpose
2.3 Simulation and Modeling Review
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4
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CHAPTER III
CHAPTER IV
CHAPTER V
CHAPTER VI
METHODOLOGY
3.1 Flow Chart
3.2 Projection and Angle of Motion Review
3.3 Blueprint Design using SolidWorks Software
3.4 Kinematics Analysis
3.4 Component Procurement and Fabrication
Process
3.5 Model Testing
RESULT AND ANALYSIS
DISCUSSION
CONCLUSION AND RECOMMENDATION
REFERENCES
BIBLIOGRAPHY
APPENDICES
Attachment 1 : PSM 1 Work Progress
Attachment 2 : PSM 2 Work Progress
Attachment 3 : Gantt Chart
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LIST OF FIGURES
FIGURE TITLE PAGE
1.1 Hydraulic System 2
2.1 Manipulator Arm with (3) three degree of freedom 6
2.2 Manipulator Arm using Syringe 8
2.3 DS4 Training System 9
2.4 Three-link Manipulator Arm 10
2.5 KUKA youBot Manipulator Arm 11
2.6 Robotnik Hydraulic Manipulator Arm 11
2.7 Robotic Arm 2 Basic Kit 12
2.8 Robotic Arm Trainer 12
2.9 Four DOF Robotic Arm Combo Kit 12
2.10
2.11
2.12
2.13
2.14
3.1
3.2
3.3
Programmable Hydraulic Valve
Hydraulic Manipulator Arm Motion Control
Pneumatics Manipulator Arm using Microcontroller
Manipulator Arm with Four Degree of Freedom
Denavit-Hartenberg Notation
Flow Chart of Project
Angle Motion of 3 DOF of Manipulator Arm
SolidWorks Design of Manipulator Arm
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3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
Cylinder Parts
Cylinder Design Full Assembly
Gripper Attachment Parts
Gripper Attachment Full Assembly
Arm parts
Manipulator Arm Full Assembly
Manipulator Arm Projection View
Free Body Diagram for Each Link
Free Body Diagram for Link ABC
Free Body Diagram for Link CDE
Free Body Diagram for Link DEF
Free Body Diagram for Each Link based on Cylinder
Displacement
Free Body Diagram for Link ABC
Free Body Diagram for Link DEF and DFG
Free Body Diagram for Link HIJ
Free Body Diagram for Gripper Attachment
Free Body Diagram for basement rotational
Graph of Validation Result for Cylinder 1
Graph of Validation Result for Cylinder 2
Graph of Validation Result for Cylinder 3
Graph of Validation Result for Cylinder 4
Graph of Validation Result for Cylinder 5
SolidWorks simulation in fully retract position
SolidWorks simulation in desired position
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3.28
3.29
3.30
3.31
.3.32
3.33
3.34
3.35
3.36
3.37
3.38
3.39
3.40
3.41
3.42
3.43
3.44
3.45
3.46
3.47
3.48
3.49
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4.1
4.2
Work Space area of the end-effector
Hydraulic Cylinder
Wood Piece
Bolt, Nut, Washer and Spacer
Hydraulic Gripper
Fabricated Gripper Attachment
Flow of Fabrication Process
Completed Fabrication Process
Fitted on portable table
Pneumatic and Hydraulic Circuit
Push Button, DCV, T-connector and tube
Flow Control Valve (FCV)
Pressure Regulator
Hydraulic Power Unit
Pressure Relief Valve
Hydraulic Hose
Manual Lever DCV
Pressure Gauge
Hose Connector
Flow Control Valve (FCV)
Cylinder Position
Connected Pneumatic Tube
Connected Hydraulic Hose
Cylinder Speed Extend Position Data using Pneumatic
Extend position for cylinder 1
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4.3
4.4
4.5
4.6
4.7
4.8
5.1
Extend position for cylinder 2
Graph of Retract Position using Pneumatic System
Retract position for cylinder 1
Retract position for cylinder 2
Graph of Cylinder Speed Extend Position using
Hydraulic System
Graph of Cylinder Speed Retract Position using
Hydraulic System
Concept of Forward and Inverse Kinematics
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LIST OF TABLES
TABLE TITLE PAGE
2.1
3.1
4.1
4.2
4.3
4.4
Manipulator Arm Configuration
Degree of Angle from Equation and SolidWorks
Simulation
Cylinder Speed Extend Position Data using Pneumatic
Cylinder Speed Retract Position Data using Pneumatic
Cylinder Speed Extend Data using Hydraulic System
Cylinder Speed Retract Data using Hydraulic System
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CHAPTER I
INTRODUCTION
1.1 BACKGROUND
According to Esposito (2009), fluid power is the technology which involves
the use of pressurized gas or fluid in order to generate, transmit and control power.
Nowadays, fluid power is one of the major technologies that been applied in almost
factory in the world weather in heavy industries or in small industries and also been
applied in non-industry sector such as in medical and food processing sector. Besides
that, fluid power technology is one of the subject that been though in schools and
institutions of higher education. There are a lot of application that used this
technology such as fluid power steer and brakes automobiles, offshore, launches
spacecraft, drives machine tools and mines coal. The application of fluid power
technology is useful in order to perform a certain work that could not be done by
human capability. For example lifting heavy load, movement limitation, pull and
push heavy load and regulate almost all machines in industries which directly make a
work easier and faster. In fact, there is almost all worldwide manufactured that hasn’t
been used this technology at specific stage or at certain level in their production or
distribution.
Fluid power is divided into two main systems which are hydraulic system and
pneumatics system. Hydraulic system used a pressurized liquid such as oil and water
as a working fluid and pneumatic system used a compressed air as source of power.
Both system works with specific equipment and component for the system to be
functional based on require purpose. In this paper, the project proposed is related
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Figure 1.1 Hydraulic System
(Source: http://prayitnoagus.blogspot.com/)
with hydraulic system where actually has two difference types which is fluid
transport and fluid power transmit. Fluid power transport is used in delivery a fluid
or liquid from one place to another that mostly considers the total amount of
transported fluid. Then, fluid power transmit is designed in order to perform a
specific work according to require purpose. This type of hydraulic system used a
pressurized liquid to transmit power that been generate from hydraulic power unit
and been supply to the cylinder for a linear motion and fluid motor for a rotary
motion. Figure 1 shows the application of hydraulic system in lifting a load.
In addition, the application of hydraulic system also been applied for
educational and research purpose. The example of a hydraulic system application for
educational and research purpose is hydraulic boom trainer or also known as
hydraulic manipulator arm trainer. Actually, hydraulic manipulator arm is one of the
application that been used in most industries with various scale and size. The purpose
of this application is to react as a human arm in order to do a work with a certain
limitation and system configuration. There are various types of manipulator arm for
educational and research purpose such as KUKA youBot and Robotnik. The
development of the manipulator arm for research and educational purpose is getting
rapidly expanding due to widespread usage of manipulator arm application in
industries or non-industries. Therefore, this project is proposed which required a
design and fabrication of hydraulic manipulator arm or boom trainer for educational
and research purpose.
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1.2 PROBLEM STATEMENT
By referring to Luca & Sicilianot (1993), in reducing costs and improving
capability and efficiency of work in the production of a product, the approach of
using hydraulic manipulator arm applications is enhanced and expanded. Hydraulic
system is one of the subjects in engineering courses in institutions of higher
education and the basic of this system also been taught in schools. Hydraulic training
kit that commonly used in schools and institutions of higher education only provide
the basic equipment, component and tools. Therefore, this hydraulic boom trainer
project is proposed in order to provide additional components for hydraulic training
kit for future development.
1.3 PROJECT OBJECTIVE
The objective of this project is divided into several specific points:
i. To design and fabricate hydraulic boom or manipulator arm trainer with
the concept of gripper attachment with various angle movements which
consists of five hydraulic cylinders for the purpose of education and
research.
ii. To conduct a testing which is includes the discussion and analysis on
smoothness of the movement, angle of motion and cylinder speed.
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1.4 PROJECT SCOPE
The scope of the project is used to show the limitation of the research and
give the clearest view of the project. In this project, there is several scope of study
involved which is:
i. To design and fabricate a small scale of manipulator arm system for
educational purpose or as a training kit.
ii. To develop a manipulator arm system that will be fitted on a portable
table and connected with current hydraulic power trainer in Hydraulic
and Pneumatic Lab, FKM, UTeM.
iii. To test and compare the performance of the boom trainer using
maximum pressure of 30 bar, with different working medium,
involving pneumatic and hydraulic oil.
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CHAPTER II
LITERATURE REVIEW
2.1 INTRODUCTION TO MANIPULATOR ARM
In Koivo (1989), the word "robot" comes from the Czech word "robota"
meaning work. Meanwhile, according to Webster's dictionary, robot is defined as a
robotic device that shows the functions of human behavior. A more complete
definition developed by the RIA (Robot Institute of America), they said robot is a
programmable multifunctional manipulator reset (multifunctional reprogrammable
manipulator) designed to move material, equipment or appliance. According to Craig
(1986), degree of freedom (DOF) is the linear motion or rotation along or around the
axis at the manipulator arm. In the case of industrial robots, manipulator arm is an
open circuit and each joint position is usually determined by a single variable which
means the number of joint is equal to the number of DOF. Faris et al. (2012)
emphasized that degrees of freedom is the maximum number of variables needed to
define the motion of an object and movement resulting from the joint manipulator
arm. Joint between the two arms were connected to formed by its nature as a joint
revolute (rotary) or prismatic (slide). Figure 2.1 displays the (3) three DOF of
manipulator arm. Other researcher Iqbal et al. (2012), stated that in process of
modeling a manipulator arm, the solutions by using inverse kinematics should be
taken into consideration when constructing and facing with numerous DOF in order
to obtained the best analytical solution. Inverse kinematics is able to evaluate the
needed equivalent joint angle based on preferred position and angle of motion of the
manipulator arm end effector.
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Figure 2.1 Manipulator Arm with (3) three degree of freedom
(Source: (Faris et al. 2012))
By referring from previous research Hemami (1988), human arm has (7)
seven degree of freedom which capable to do a lot of works with high flexibility of
movement while mostly there are only (5) five to (6) six degree of freedom of
manipulator arm that already exist in industries. However, human arm has high
limitation of doing heavy job and workspace limitation. Therefore, the purpose of
developing robotic manipulator arm is to react as a human arm in order to do the
works that beyond human capabilities. Robotic manipulator arm has been widely
applied in the world industry, such as welding robot, handling robot, punching and
cutting robot, machine tools robot and also widely applied for research and
educational purpose.
There are various type of manipulator arm which is applied various
configuration depending on the level of difficulty of the task or works. This
manipulator arm has the advantage of flexibility in the (2) two dimensional work
area space so that it is suitable to be applied in most industrial robots. In order to
carry out their duties, it needs a planning system movement of the manipulator from
the initial conditions to the final conditions in accordance with the tasks that have
been given. There are several algorithms that have been raised by some experts to
plan the movement of the manipulator to accomplish a task that has been given.
According to Budiono et al. (2011), some things that underlie the use of robot
is that the robot has many advantages that humans do not have such as produce the
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Table 2.1: Manipulator Arm Configuration
(Source: http://didiktristianto.dosen.narotama.ac.id)
same output when working a task repeatedly. So it can be re-programmed functioned
for several different tasks and has low percentage of mistakes than humans make, as
well as numerous other benefits. However, the movement of the robot control
artificial intelligence sometimes still has limitations in some cases such as for more
actual movement or more flexible that it is still necessary control is done manually.
Due to the variety of shapes and sizes, the manipulator arm also has a variety of
movement skills. Physically, there are several configurations can be formed. Most of
manipulator arm possess (1) one of the (4) four basic configurations which are polar
configuration, cylindrical configuration, Cartesian configuration and Jointed-arm
configuration. Table 2.1 shows the figure of manipulator arm configurations.
Cartesian Configuration:
Based on 3-axis or plane, the axis is x, y and
z.
Cylindrical configuration:
Comprised of 3-axis, consisting of θ
represents the rotary axis and z axis represents
the movement up and down along the R axis
which represents the movement of elongated
or shortened.
Polar configuration:
It also has a 3-axis which is θ, β, and R. This
system is symmetrical because the latitude of
robot sphere (ball).
Articulate configuration:
Defined by 3-axis, θ (theta), upper arm (w)
and elbow (U). Wick provides the greater
flexibility.
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Figure 2.2 Manipulator Arm using Syringe
(Source: http://www.cse.iitk.ac.in/users/amit/courses/768/00/atandon/)
In the meantime, due to the rapid development of the use of manipulator arm
as one approach to make work become easier and faster, the knowledge about the
usage and advantages of manipulator arm was introduce starting from earlier
education in school. In schools, most of the project on constructing a manipulator
arm is using syringe to react as a cylinder and also as a controller to move the
manipulator arm. The purpose of this concept is to discuss and analyze the principle
of fluid power which is use the under pressure fluids to generate, control, and
transmit power. In Sobh et al. (2001) research, most of student in schools were only
exposed to the theoretical lesson and spend a lot of time in classroom. Most of the
time, they could not adopt and apply practically what they had learn in class in order
to analyze result and won’t be able to discuss and doing comparison between
theoretical and experimental result. The existing manipulator arm either using
pneumatic, hydraulic or servo motor as the main source of power generally is quite
expensive and large in size. Besides, the systems of the existing products are more
complicated and too sophisticated to be analyzed by student in schools and
universities. By developing and constructing the manipulator arm for educational and
research purpose which is small in size and with the system that not too complicated,
student will be able to understand and learn about the functionality of the system and
the main concept of the design. Figure 2.2 shows the example of hydraulic
manipulator arm using syringe.
In institution of higher education such as Universiti Teknikal Malaysia
Melaka (UTeM) specifically in Faculty of Mechanical Engineering (FKM), there is a
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hydraulic training kit in laboratory that been provided for student to learn about the
hydraulic system which consists of specific components and tools. The model of this
training kit is DS34 Training system which been supplied by Rexroth Bosch Group
from Germany. The features of this training kit are to provide training system for
basic and advanced due to practical requirement. The main components are consists
of stable, steerable castors with integrated hydraulic power unit, an electrical switch
box, a tool container, a measuring glass, and a P/T distributor. Therefore, the idea of
this project is proposed in order to give other alternative method in learning process
and to clearly understanding the application concept that relate to the hydraulic
system. Figure 2.3 shows the actual DS4 Training System in FKM Laboratory.
2.2 MANIPULATOR ARM FOR EDUCATIONAL AND RESEARCH
PURPOSE
In previous research by Sobh et al. (2001), they had developed concurrent
design of a three-link manipulator prototype. They explained the steps on how to
produce the proposed prototype in efforts to expand the manufacture on prototyping
development for educational and research purpose. Indirectly, they also want to
provide a practical approach amount student in order to give the opportunity for them
Figure 2.3 DS4 Training System