CAM system for a robot manipulator

CAM system for a robot manipulator

Journal of Materials Processing Technology 140 (2003) 100–104 Development of a CAD/CAE/CAM system for a robot manipulator H.S. Lee∗ , S.L. Chang Depa...

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Journal of Materials Processing Technology 140 (2003) 100–104

Development of a CAD/CAE/CAM system for a robot manipulator H.S. Lee∗ , S.L. Chang Department of Power Mechanical Engineering, National Huwei Institute of Technology, Yunlin, Taiwan, ROC

Abstract In this study, a CAD/CAE/CAM integrated system for a robot manipulator was developed. The D–H (Denavit–Hartenberg) coordinate transformation method was used to perform the robot position analysis, according to the transformation matrices, we used Matlab to calculate the robot position analysis. Pro/ENGINEER (Pro/E) was used to construct the robot manipulator parametric solid models, Pro/Mechanica was used to simulate the dynamic simulation and working space, MasterCAM was used to implement the cutting simulation, and the prototype was manufactured using a CNC milling machine. Finally, a CAD/CAE/CAM integrated system for a robot manipulator was developed. A demonstration example is presented to verify the design, analysis, and manufacture results (the demonstration is located at the website of http://www.sparc.nhit.edu.tw/∼jennifer/robot1/index.htm). This integrated system not only promotes automation capabilities for robot manipulator production, but also simplifies the CAD/CAE/CAM process for a robot manipulator. This integrated system is useful for developing a supplementary teaching tool for practical computer-aided mechanism design courses. © 2003 Published by Elsevier B.V. Keywords: CAD/CAE/CAM; Robot manipulator; Denavit–Hartenberg coordinate transformation

1. Introduction A number of studies have dealt with the principles of CAD/CAE/CAM integrated systems. Lu [1] discussed the kinematic analysis of the planar five-bar pantograph and designed and manufactured a manipulator based on this pantograph. Some kinematic properties of the five-bar pantograph configuration were studied. A simple controller was also designed to operate the manufactured manipulator. Lee and Chen [2] described the development of an automatic wheelchair-lifting device fixed inside a full-size van. The development process included the mechanism’s conceptual design, motion simulation, engineering analysis, prototype development and testing. Jou [3] using a parametric CAD system to express design concepts into solid models. Press moulds were developed, followed by mould manufacturing using a CAM system. Mould testing, powder formation, sintering and post-sintering procedures were conducted in professional powder metallurgy factories through cooperation with industry, to produce the final powder metallurgy products. Xu et al. [4] built an injection mould CAD/CAE/CAM system by integrating the



Corresponding author.

0924-0136/$ – see front matter © 2003 Published by Elsevier B.V. doi:10.1016/S0924-0136(03)00695-2

injection mould CAD/CAM software, based on the UG2 (unigraphics) universal CAD/CAM system, with the injection mould CAE software. A number of studies have dealt with the principles of robot and Internet control. Lai [5] used interactive and menu driven methods to development computer-aided instruction software for the kinematics and inverse kinematics of a manipulator to learn how to make the transformation matrix manipulator friendly. Huang et al. [6] presented a five-axis ac-servo robot with TCP/IP function controlled from a remote computer through the Internet. During robot movement, a CCD camera armed on the laboratory server shows the robot movements on the homepage. The remote computer can watch the real-time motion on the browser. In order to meet concurrent engineering requirements, we used the D–H coordinate transformation method to perform the robot position analysis; imported actual mechanical models into design, analysis, and manufacture simulation; manufactured the robot prototype; and provided an integrated website for the design and analysis of the robot manipulator. This paper not only can promote automation capability for the robot manipulator, simplify the robot design, analysis, and manufacture processes, but also can serve as a supplemental tool for educational use in college computer-aided mechanism design courses.

H.S. Lee, S.L. Chang / Journal of Materials Processing Technology 140 (2003) 100–104

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2. System structure

3. Principles and methods

The procedures of the presented system are as follows:

3.1. Design theory of the robot manipulator In this section, the kinematic analysis of a spatial robot manipulator, shown in Fig. 2, is studied. The gripping device position of the manipulator can be obtained using the theoretical study in this section. From the D–H coordinate transformation definition [7], 01 T transfers the position in the coordinate system S1 (X1 , Y1 , Z1 ) to a new coordinate system S0 (X0 , Y0 , Z0 ). The position of the gripping device shown in the base coordinate system can then be represented by the successive coordinate transformation 0 T = 0 T 1 T 2 T 3 T 4 T . The position of the gripping device 1 2 3 4 5 5 shown in base coordinate system S0 then can be obtained by substituting its coordinates into 05 T . The transformation matrices are shown in the following equations:

• Computer-aided design. The D–H (Denavit–Hartenberg) coordinate transformation was used to perform the robot position analysis, and Matlab to calculate the robot position. • Computer-aided drawing. With the concepts of parametric design and unitary database, Pro/ENGINEER was used to draw the 3D part and assemble the robot solid models. • Computer-aided analysis. In order to evaluate robot designs in the real world by creating virtual prototypes, the robot assembly solid model was transferred to Pro/Mechanica (which is integrated with the Pro/ENGINEER system). Material properties, constraints and drivers are applied on the model to simulate the working space. • Computer-aided manufacture. In order to implement cutting simulation with MasterCAM, 2D engineering graphics files should be transferred to ge3 files. Select the contour to form a chain, define cutting parameters, generate and verify tool paths. Finally, invert the NC codes, connect the DNC with the CNC milling machine, and then manufacture the robot prototype.

0 1T

= Rot(Z, θ1 ) Trans(0, 0, d1 ) Rot(X, −90◦ )    1 0 0 0 cθ1 −sθ1 0 0   sθ   1 cθ1 0 0   0 1 0 0  =    0 0 1 0   0 0 1 d1  0 

0

1 0  × 0 0

0

0 0 −1

0 1 0

1 0 0   0 cθ1   0   sθ1 = 0  0

0

0

1

0

0

0 −sθ1 0 cθ1 −1 0 0

Free hand drawing Coordinate system definition Mtarices transformation

Matlab

Posotion analysis 3D

Part drawing Draw

2D

Pro/E Assembly drawing

Integrated system

Front Page

pro/ Mechanica Prototype manufacture

0

 0 0    d1  1 (1)

Fig. 1 shows the structure of the proposed system.

Design

1

Kinametic analysis

Material properties, constaints, drivers loads definition Simulation

Working space

Tool bank planning Parameters input Manufacture

MasterCAM

Tool path simulation

NC code inversion

Fig. 1. The structure of the system.

CNC machine

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H.S. Lee, S.L. Chang / Journal of Materials Processing Technology 140 (2003) 100–104



0 0  = 1 0 4 5T

Fig. 2. The coordinate system definition. 1 2T

= Rot(Z, θ2 ) Trans(a2 , 0, 0)   cθ2 −sθ2 0 0 1  sθ    2 cθ2 0 0   0 =   0 0 1 00 

0

cθ2  sθ  2 =  0 0 2 3T

0

0

1

−sθ2

0

a2 cθ2

cθ2

0 1 0

0 0

0 

0

(2)

1

1 0

1 

0

0

0



1 cθ3 sθ3 0 0

a3 cθ3

0

0

0

1

0

0

(4)

0 1 0 0

0 0 1 0

 a5 0    0  1

)

 a3 0    0  1

1

= 01 T 12 T 23 T 34 T 45 T

(3)

= Rot(Z, θ4 ) Trans(0, 0, a4 ) Rot(Y, −90◦ )    cθ4 −sθ4 0 0 1 0 0 0  sθ    4 cθ4 0 0   0 1 0 0  =    0 0 1 0   0 0 1 a4  0 

0 0  × 1 0

0

0

0

−1

1 0 0

0 0 0

0

1 

0   0 1

0

0

0

(6)

3.2. Manufacture of the prototype



a3 sθ3    0  1

(5)

3.2.1. Solid model design Solid modelling technology can not only greatly reduce the development period, but also effectively increase the design quality and manufacturing of the industrial products. In order to implement virtual prototyping for the spatial robot manipulator shown in Fig. 2, we used Pro/E to draw and assemble each part of the robot manipulator parametric solid model. Fig. 4 shows the robot manipulator exploded assembly solid model.

0 0   0

0 0

0

0    a4 

−sθ4

0

According to the transformation matrices, we used Matlab to calculate the robot position analysis. When θ1 = 0◦ (fixed), θ2 = 25◦ , θ3 = 25◦ , θ4 = 45◦ , θ5 = 5◦ , the gripping device position is shown in Fig. 3.

1

a2 sθ2    0 

0

0 0  0 1  ×  −1 0 0 0  0 −sθ3  0 cθ3  =  −1 0 0 0

0 5T

−cθ4

= Rot(Z, θ5 ) Trans(a5 , 0, 0)   cθ5 −sθ5 0 0 1  sθ    5 cθ5 0 0   0 =   0 0 1 00 0 0 0 0 1   cθ5 −sθ5 0 a5 cθ5  sθ   5 cθ5 0 a5 sθ5  =   0 0 1 0  0

 a2 0    0 

0 0 1 0

= Rot(Z, θ3 ) Trans(a3 , 0, 0) Rot(Y, 90   cθ3 −sθ3 0 0 1 0 0  sθ    3 cθ3 0 0   0 1 0 =   0 0 1 00 0 1 0 

3 4T

0 1 0 0



−sθ4 cθ4

1

Fig. 3. The gripping device position.

H.S. Lee, S.L. Chang / Journal of Materials Processing Technology 140 (2003) 100–104

Fig. 4. The exploded assembly solid model.

103

Fig. 7. The oscillating arm tool path simulation.

Fig. 8. The oscillating arm cutting simulation.

Fig. 5. The robot kinematic constraint model.

Fig. 6. The working space.

3.2.2. Kinematic analysis In order to predict kinematic analysis results of the robot before manufacture, we used Pro/Mechanica to define robot assembly model, in order to complete the robot manipulator kinematic constraint model. Define items include: coordinate system (shown as Fig. 2), material properties (defined

Fig. 9. The driving robot manipulator.

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H.S. Lee, S.L. Chang / Journal of Materials Processing Technology 140 (2003) 100–104

Fig. 10. The example demonstration.

as medium density polyethylene), drivers (define amplitude, period, phase and offset), constraint (defined revolution pair as pin), then completed the robot manipulator kinematic constraint model, dynamic simulation and working space. Fig. 5 shows the robot kinematic constraint model, Fig. 6 shows the working space.

d1 = 360 mm, a2 = 200 mm, a3 = 300 mm, a4 = 200 mm, a5 = 150 mm. Motion angle range: θ1 = 0◦ (fixed), θ2 = 0–210◦ , θ3 = 0–210◦ , θ4 = 0–360◦ , θ5 = 0–45◦ .

3.2.3. Manufacture process In order to perform the planning process of robot manipulator manufacturing, the 2D part DXF files were transferred into ge3 files. In order to complete cutting simulation with MasterCAM, we defined cutting parameters (such as contour depth, tool diameter, spindle speed, feed rate, depth cut, diameter offset), tool path generation and invert NC codes. Fig. 7 shows the oscillating tool path simulation. After inverted NC codes, we manufactured the robot manipulator prototype with the CNC. Fig. 8 shows the oscillating arm cutting simulation. Equipped with gears, step motors and 89C51 microprocessor, we completed the driving robot manipulator, as shown in Fig. 9.

Combined with FrontPage, Matlab, Pro/E and Pro/Mechanica, a CAD/CAE/CAM integrated system for a robot manipulator was completed. This system not only promotes automation capabilities for robot manipulator production, but also simplifies the CAD/CAE/CAM process for a robot manipulator. This integrated system is helpful for developing supplementary teaching tools for practical computer-aided mechanism design courses.

4. Example demonstration The importance and advantage of computer network is gradually being recognized. Design, analysis, and manufacture companies are beginning to use more Internet associated techniques to support their business operations. In order to integrate the results of the robot design and analysis on the browser, we used FrontPage to hyperlink the images of dynamic simulation, position analysis and working space. The example demonstration can be accessed globally on the web. The website is http://www. sparc.nhit.edu.tw/∼jennifer/robot1/. Fig. 10 shows frame of the example demonstration. The robot design parameters:

5. Conclusions

References [1] D.M. Lu, Kinematic design of pantograph and its application to manufacture a manipulator, J. Technol. 15 (1) (2000) 149–155. [2] M.Y. Lee, S.H. Chen, Design and development of an automated wheelchair lifting device, J. Technol. 16 (1) (2001) 45–50. [3] M. Jou, A study of automatic design and manufacturing of metal and ceramic powder processed products, J. Technol. 15 (3) (2000) 463–468 (in Chinese). [4] Y. Xu, Z.Y. Wang, R.Q. Huang, Y.Q. Zhang, System integration of injection mould CAD/CAE/CAM, J. Shanghai Jiaotong Univ. 32 (1) (1998) 26–29 (in Chinese). [5] Y.S. Lai, Development of computer-aided instruction software for the manipulator kinematic and reverse kinematic, in: Proceedings of the Sixth Conference on Technology and Vocational Education, 22–23 March 1991, Taipei, pp. 20234–20239. [6] S.A. Huang, M.R. Cheng, M.A. Ker, C.C. Lo, M.J. Wu, Internet remote control of five-axis ac-servo robot, in: Proceedings of the Fifth International Conference on Automation Technology, 20–22 July 1998, Taipei, pp. [B2-2] 1–6. [7] J. Denavit, R.S. Hartenberg, A kinematic notation for lowerpair mechanism based on matrices, ASME J. Appl. Mech. 22 (1955) 215–221.