A TECHNICAL REPORT WRITTEN
BY
UDOKANG GABRIEL BASSEY
18/EG/ME/1253
MECHANICAL AND AEROSPACE ENGINEERING,
FACULTY OF ENGINEERING
ON
ROBOTIC ARM FOR HEAT TREATMENT
FURNACE
TO BE SUBMITTED TO
DR. AONDONA PAUL IHOM
COURSE LECTURER
PRODUCTION ENGINEERING (MEE 515)
DEPARTMENT OF MECHANICAL AND
AEROSPACE ENGINEERING,
FACULTY OF ENGINEERING,
UNIVERSITY OF UYO.
JANUARY, 2024
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TABLE OF CONTENT
Cover page
Table of Content…………………………………………………………….1
List of figures………………………………………………………………..2
Abstract…………………………………………………………………….
Chapter 1
Introduction………………………………………………………………..
Chapter 2
Literature Review……………………………………………………………
Historical Review of heat treatment automation………………..…………
Robotic application in industrial heat treatment……………………………
Advantages and Challenges of Robotic systems in furnace operation
Existing Robotic arms design for Heat Treatment…………………………
Chapter 3
Design and Description of Components Part………………………………
Material Selection…………………………………………………………
Synthesis……………………………………………………………
Degree of Freedom in the design of Robotic arm for heat treatment
Chapter 4
Results and Testing……………………………………………………………
Conclusions……………………………………………………………………
References…………………………………………………………………….
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ABSTRACT
This report explores the design and implementation of a robotic arm for
loading and unloading components in a heat treatment furnace. Motivated by
the need for efficiency and precision in industrial processes, the robotic arm
aims to enhance operational reliability and safety. The abstract outlines the
project's goals, literature review on furnace automation, material selection,
and key aspects of the robotic arm's design. The report concludes with
findings, achievements, and considerations for future enhancements, making
it a valuable resource for those interested in advancing automation in heat
treatment processes.
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CHAPTER 1
INTRODUCTION
In the landscape of industrial automation, the integration of robotic systems
has become instrumental in enhancing efficiency and safety. This
introduction sets the stage for exploring a specific application—a robotic arm
designed for loading and unloading components in a heat treatment furnace.
A robot is a mechanical or virtual device that can perform tasks
automatically, without the need for human intervention. Robots are often
programmable, meaning they can be given a set of instructions that they
follow to complete their tasks. Robots can range in complexity, from simple
machines that perform repetitive tasks to highly sophisticated machines that
can think and learn independently. The word "robot" comes from the Czech
word "robota," which means "forced labor" or "drudgery." The first robot was
created in the early 20th century, and since then, the technology has advanced
rapidly. Today, robots are used in many industries, from manufacturing to
healthcare and entertainment.
As industries increasingly seek automated solutions, the rationale behind this
project lies in the pursuit of consistent, reliable, and controlled handling
within the demanding environment of heat treatment processes. This brief
overview outlines the key objectives, emphasizing the role of the robotic arm
in optimizing operational workflows and ensuring precise treatment of
components.
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CHAPTER 2
LITERATURE REVIEW
Historical Overview of Heat Treatment Automation
The evolution of heat treatment processes has undergone a significant
transformation throughout history, marked by a continuous pursuit of
efficiency, consistency, and precision.
Early Methods: In ancient times, heat treatment processes were primarily
manual, relying on the skills and expertise of craftsmen. Techniques such as
forging and quenching were handed down through generations, with little
mechanization involved. These traditional methods were often labor-intensive
and lacked the repeatability demanded by industrial production.
Industrial Revolution and Mechanization: The advent of the Industrial
Revolution in the 18th century brought about a paradigm shift in
manufacturing processes, including heat treatment. Mechanization allowed
for the development of furnaces with controlled atmospheres and
temperatures, enabling more precise and repeatable heat treatment. However,
the level of automation was still limited, and human intervention remained
integral.
The mid-20th century witnessed significant advancements in heat treatment
automation. Introduction of electric heating elements and improved
temperature control systems marked a leap forward. Automated conveyor
systems started to be employed for continuous processing, enhancing
efficiency and reducing manual labor. With the rise of computer technology,
the late 20th century saw a remarkable integration of automation and control
systems in heat treatment processes. Programmable logic controllers (PLCs)
and computer numerical control (CNC) systems became commonplace,
enabling more precise control over heating, quenching, and tempering.
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Robotics began to play a crucial role in material handling and positioning
within furnaces.
Contemporary times: In the present era, heat treatment automation has
reached new heights with the incorporation of advanced robotics, artificial
intelligence, and Industry 4.0 principles. Robotic arms are now employed for
tasks ranging from loading and unloading components to intricate
manipulations within high-temperature environments.
Robotic Applications in Industrial Heat Treatment
Robotic applications have become indispensable, revolutionizing traditional
manufacturing processes. These versatile robotic systems contribute
significantly to efficiency, precision, and overall process optimization. Key
applications include:
1.Robotic arms excel in the handling of raw materials and workpieces,
ensuring precise placement and movement within the heat treatment
environment..
2. Loading and unloading of components into and from heat treatment
furnaces.
3. Robotic systems offer unparalleled precision in positioning components
within furnaces.
4. Performing of Complex Manipulation
5. Integration with Automated Lines
6. Quality Control checks during and after heat treatment
ADVANTAGES AND CHALLENGES OF ROBOTIC SYSTEMS IN
FURNACE OPERATIONS
Advantages
1. Precision and Consistency
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2. Increased Efficiency
3. Reduced Labor Intensity
4. Enhanced Safety
5. Flexibility and Adaptability
Challenges
1. Thermal Stress on Robotic Components
2. Integration Complexity
3. Cost of Implementation
4. Maintenance Requirements
5. Skill Requirements
EXISTING ROBOTIC ARM DESIGNS FOR HEAT TREATMENT
In the realm of heat treatment, existing robotic arm designs showcase a range
of configurations tailored to meet the demands of precision, durability, and
efficiency within high-temperature environments. Notable designs include:
1. Articulated Robotic Arms: These arms consist of multiple rotary joints,
providing a high degree of freedom. Articulated arms excel in tasks requiring
intricate movements, making them suitable for applications such as precise
component positioning in heat treatment furnaces.
2. SCARA (Selective Compliance Assembly Robot Arm) Robots: SCARA
robots feature a horizontal shoulder joint and a vertical elbow joint,
conferring both precision and speed. In heat treatment, SCARA robots are
often employed for tasks requiring rapid and repeatable movements, such as
loading and unloading components.
3.Parallel Robotic Arms:Parallel robotic arms use multiple parallel
mechanisms to control the end effector. Known for their stiffness and
accuracy, parallel arms find application in heat treatment processes
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demanding stability and precise control, such as handling delicate
components.
4. Delta Robots:Characterized by a parallel linkage design, delta robots
excel in high-speed tasks. In heat treatment, they are utilized for swift and
accurate operations, such as picking and placing components in rapid
succession.
5. Collaborative Robotic Arms: Designed for human-robot collaboration,
these arms are equipped with safety features that enable them to work
alongside human operators. In heat treatment scenarios, collaborative robotic
arms contribute to tasks where a combination of human and robotic dexterity
is advantageous.
6. Customized End Effectors: Many robotic arm designs for heat treatment
incorporate specialized end effectors. These could include grippers with
heat-resistant materials or mechanisms designed for specific component
shapes, ensuring precise and secure handling within the furnace.
7. Wireless Controlled Robotic Arms: Advancements in control systems
have led to the development of robotic arms that can be operated wirelessly.
This innovation enhances flexibility and allows operators to control the arm
from a safe distance, minimizing exposure to high-temperature environments.
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CHAPTER 3
DESIGN AND DESCRIPTION OF COMPONENTS PART
Fig 3.0 Full Assembly of the Robotic Arm
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Fig 3.1 Robotic Arm ( Front,Top and Side View)
1. Base: The base of the robotic arm serves as its foundational support and
attachment to the working environment. It provides stability and anchoring
for the entire system, ensuring a secure platform for precise movements. The
base often incorporates mounting mechanisms for easy integration into
different setups.
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Fig 3.2 - Base of the Robotic arm
2. Upper Arm: The upper arm is a pivotal section connecting the base to the
rest of the robotic arm. It houses crucial components like actuators and
motors responsible for lifting and lowering the arm. This section plays a
significant role in determining the arm's reach and lifting capacity.
Fig 3.3 Upper arm of the Robotic arm
3. Shoulder: The shoulder joint is a key articulation point, allowing the arm
to rotate horizontally. This rotational movement at the shoulder enables the
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robotic arm to navigate a broader working space. The design of the shoulder
is crucial for achieving both flexibility and stability during operation.
Fig 3.4 Shoulder of the Robotic arm
4. Forearm: Connecting to the upper arm, the forearm supports components
responsible for bending and extending the arm. It plays a crucial role in
determining the range of motion and flexibility of the robotic arm. The
forearm is a vital link between the upper arm and the components that
interact with the working environment.
Fig 3.5 Forearm of the Robotic arm
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5. Elbow: The elbow joint facilitates the bending and extending motions of
the forearm. It is a key articulation point that determines the arm's ability to
reach and maneuver in confined spaces. The design of the elbow is critical
for achieving precision in various operational tasks.
Fig 3.6 Elbow of the Robotic Arm
6. Wrist: The wrist section connects to the forearm and enables rotational
movement. This rotational capability enhances the versatility of the robotic
arm, allowing it to approach components from different angles. The wrist is
pivotal for achieving optimal positioning and orientation during tasks.
Fig 3.7 Wrist of the Robotic arm
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7. Wrist Pitch: The wrist pitch joint allows the end effector to tilt,
introducing an additional degree of freedom. This tilting capability is
essential for adapting to the orientation of components within the working
environment. The wrist pitch enhances the arm's ability to handle objects
with varied orientations.
8. Gripper: The gripper, or end effector, is the component responsible for
grasping and releasing objects. It is the point of direct interaction with the
working environment. The design of the gripper varies based on the nature of
the objects it handles, ranging from simple pincers to more complex
mechanisms for precise gripping.
Fig 3.8 Gripper and Wrist Pitch of the Robotic arm
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MATERIAL SELECTION
Table 1.0
System Integration
● Control System: Orchestrates the movements and actions of each
component.
● Sensors: Provide real-time feedback on the arm's position and
conditions.
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● End Effector Integration: Ensures seamless interaction with
components in the heat treatment furnace.
SYNTHESIS
Synthesis in robotic arm design involves the integration of three fundamental
elements: kinematics, dynamics, and control systems. This process is
essential for achieving optimal performance, precision, and adaptability in the
challenging environment of heat treatment.
1. Kinematics: Kinematics deals with the study of motion without
considering the forces causing the motion.In the design of a robotic arm for
heat treatment, kinematics focuses on determining the arm's range of motion,
joint angles, and the coordination of movements required for loading and
unloading components into and from the furnace.
2. Dynamics: Dynamics involves the study of forces and torques affecting
motion.For a robotic arm in heat treatment, dynamics considerations delve
into understanding how external forces, such as the weight of components or
resistance within joints, impact the arm's movement. This analysis ensures
that the arm operates efficiently and with minimal energy consumption.
3. Control Systems: Control systems regulate the behavior of the robotic arm
by manipulating its inputs to achieve desired outputs. In heat treatment
processes, control systems ensure precise positioning, movement, and
coordination of the arm's components. This involves feedback mechanisms
from sensors to adjust the arm's actions in real-time, adapting to varying
conditions within the furnace.
INTEGRATION OF KINEMATICS, DYNAMICS, AND CONTROL
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- Kinematic Model: The kinematic model defines the relationships
between joint angles and end effector position, determining the arm's
reachable workspace.
- Dynamic Model: Dynamics calculations consider the impact of external
forces on the arm's motion, ensuring stability and minimizing undesired
effects.
- Control Algorithms: These algorithms translate desired end effector
positions into joint movements, taking into account the dynamic forces and
constraints identified in the previous steps.
Challenges in Synthesis
- High Temperatures: Synthesizing a robotic arm for heat treatment
involves overcoming challenges related to the extreme temperatures within
the furnace. Materials must withstand thermal stress, and electronic
components should operate reliably in such conditions.
- Precision Requirements:Achieving the required precision in positioning
and movement, especially in tasks like grasping components, demands
careful consideration of kinematic and dynamic factors.
Benefits of Effective Synthesis
- Efficiency: A well-synthesized robotic arm operates with efficiency,
reducing cycle times and increasing overall productivity.
- Precision: Precise synthesis ensures accurate positioning of components
within the furnace, contributing to the quality of heat treatment outcomes.
- Adaptability: A synthetically optimized robotic arm adapts to varying
conditions, enhancing its versatility in different heat treatment scenarios.
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DEGREE OF FREEDOM IN THE DESIGN OF ROBOTIC ARM FOR
HEAT TREATMENT
Degree of freedom (DOF) in robotic arm design refers to the number of
independent parameters or directions in which a component or system can
move. In the context of a robotic arm for heat treatment, understanding and
optimizing its degree of freedom are crucial for achieving the desired
flexibility, precision, and adaptability in navigating the furnace environment.
Key Considerations In Degree Of Freedom
1. Joint Movements: The joints in a robotic arm provide the primary sources
of freedom. Understanding and optimizing joint movements determine the
arm's ability to reach various positions within the furnace.
- Consideration:Balancing the number and type of joints allows for a
fine-tuned design that meets the specific requirements of loading and
unloading components in heat treatment.
2. End Effector Orientation:
- Role in Design: The end effector's ability to orient itself contributes to the
overall flexibility of the robotic arm. This is particularly important when
manipulating components with varied orientations within the furnace.
- Consideration:Designing the end effector with additional degrees of
freedom for rotation or tilting enhances the arm's capability to handle
components in different orientations.
3. Adaptability to Furnace Constraints:
- Role in Design: The degree of freedom directly influences the arm's
adaptability to the spatial constraints and challenges posed by the furnace
environment.
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- Consideration: Optimizing the degree of freedom ensures that the robotic
arm can navigate within confined spaces, reach components at varying
heights, and adapt to the dynamic conditions of the heat treatment process.
OPTIMIZATION CHALLENGES
1. Balancing Complexity: Increasing the degree of freedom adds complexity
to the robotic arm design. Finding a balance between complexity and
functionality is essential to ensure efficient and reliable operation.
- Optimization: Iterative design and simulation can help optimize the
degree of freedom to meet the specific needs of the heat treatment
application.
2. Control System Requirements: Higher degrees of freedom demand more
sophisticated control systems. Ensuring that the control system can handle the
increased complexity is crucial.
- Optimization: Choosing control algorithms that efficiently manage the
increased degrees of freedom while maintaining real-time responsiveness.
BENEFITS OF OPTIMIZED DEGREE OF FREEDOM
1. Versatility: An optimized degree of freedom allows the robotic arm to
perform a wide range of movements and tasks, enhancing its versatility in
heat treatment processes.
2. Precision: Precise control over each degree of freedom ensures accurate
positioning and manipulation of components, contributing to the quality and
efficiency of heat treatment operations.
3. Efficiency: A well-balanced degree of freedom optimizes the robotic arm's
efficiency in navigating the furnace environment, reducing cycle times and
increasing overall productivity.
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CHAPTER 4
RESULTS AND TESTING
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Fig 3.9 3D HD SEQUENCE
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Fig 4.0 3D HD RENDERS
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CONCLUSION
In wrapping up, the robotic arm designed for heat treatment brings efficiency
and precision to loading and unloading tasks. From historical evolution to
existing designs, it's clear that automation is reshaping industrial processes.
Despite challenges like thermal stress, careful material selection and
continuous innovation play a key role. The synthesized approach, combining
kinematics and dynamic analyses, ensures seamless operation in
high-temperature environments.
Optimizing the degree of freedom strikes a balance between complexity and
functionality, enhancing the arm's adaptability. In essence, this robotic arm
not only automates tasks but also sets the stage for a future where precision
and efficiency redefine heat treatment in manufacturing.
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REFERENCES
[1] B.O. Omijeh, R. Uhunmwangho, M. Ehikhamenle, “Design Analysis of
a Remote Controlled Pick and Place Robotic Vehicle”, International Journal
of Engineering Research and Development, Volume 10, PP.57-68, May 2014.
[2] Elias Eliot, B.B.V.L. Deepak, D.R. Parhi, and J. Srinivas, “Design &
Kinematic Analysis of an Articulated Robotic Manipulator”, Department of
Industrial Design, National Institute of Technology-Rourkela.
[3] Sanjay Lakshminarayan, Shweta Patil, “Position Control of Pick and
Place Robotic Arm”, Department of Electrical Engineering MS Ramaiah
Technology, Bangalore, India.
[4] Mohamed Naufal Bin Omar, “Pick and Place Robotic Arm Controlled
By Computer”, Faculty of Manufacturing Engineering, April 2007.
[5] Ankit Gupta, Mridul Gupta, NeelakshiBajpai, Pooja Gupta, Prashant
Singh, “Efficient Design and Implementation of 4-Degree of Freedom
Robotic Arm”, International Journal of Engineering and Advanced
Technology (IJEAT) ISSN: 2249 – 8958, Volume-2, June 2013.
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