Highly Flexible Design for Gantry Robot Systems Team: F08-77-FLXGANT1 Client: Logic One Robots Contact: Bill Egert, Engr VP

Team 77 Faculty Advisor: Dr. Ajay Mahajan Project Manager: Garth McDermott Team Members: Justin Behrens Ryan Engelman Jeremy Vaughan Doug Wright

Acknowledgements Team 77 would like to thank: Dr. Ajay Mahajan Logic One Robots The ME 495 Instructors Bishop Wisecarver and Danaher Motion Eric Roe 6/3/ Introduction3

Outline Ryan Engelman Outline Doug Wright Executive Summary / Cost Justin Behrens Options Studied / Subsystem Designations Garth McDermott, PM System Performance Data Jeremy Vaughan 3D Models and Configurations Summary

Project Background Gantry Robots - common automation tools used for a variety of applications. They perform tasks within a working envelope defined by a X, Y, and Z axes. Application specific designs limit adaptability to new tasks. Robot designs need to be modular and highly flexible to accommodate new applications. Keys to Design: Axes interchangeable in orientation and size, multiple configurations and motion patterns, system strength and load bearing capability for a variety of applications

Expectations and Outcome Expectations Specified: Z-Axis Stroke Lengths: 600mm, 800mm, 1000mm, 1200mm X-Axis Stroke Lengths: 500mm, 1000mm, 2000mm, 3000mm Y-Axis Stroke Lengths: 1500mm, 2500mm, 3500mm, 4500mm All Axis: velocity- 5mm/s to 5m/s from Accelerations- 6 to 9 m/s 2 cycle time- 10 to 12 seconds Payload- up to 160 lbs For a Payload of 160 lbs. and accelerations of 6m/s 2 Double Y-Axis System: Z-Axis Max Length- 1450mm X-Axis Max Length- 4900mm Y-Axis Max Length- 5500mm Cantilevered System: Z-Axis Max Length- 1050mm X-Axis Max Length- 1125mm Y-Axis Max Length- 5500mm Our Design One cantilevered system and one double Y-axis system that are both highly flexible, built from the WH120 and HDLS95W which can both function as structural supporting linear actuators for a range of X, Y, and Z axes and are capable of maneuvering loads at and above the desired velocities and accelerations

Costs and Recommended Developments Recommended Future Developments: C & A Axes (tooling for applications) Z-Axis gearboxes position control systems and sensors motors, cable trays for wiring and air lines legs and hanging mount stiffening beams and counterweight failure testing and analysis Targeted price for this size system: $32,500

Options Studied Rack and Pinion Drives for all axes Too loud and expensive Pneumatics for Z and X axes Excessive side loads on the Z axis Cylinders would be too long for X axis Belt drives for all axes Belts are inexpensive Belts are quiet Easier to change axis lengths

Support beams in sections Lowers Bending Moment of Inertia Less rigidity, more deflection Design the entire robot Design would not be proven Less time for analyzing possible deployments Find and analyze an existing system Options Studied

Benefits of analyzing an existing system Existing systems are already proven Versatile mounting options Controllers are available Accessories are available Less implementation time Less parts in inventory Customizable No need for in house machining Small personnel requirement Great for a start-up company Options Studied

S UBSYSTEMS Z-Axis Z subsystem elements: Guides of Motion, Supports and Mountings, & Drive System X-Axis X subsystem elements: Guides of Motion, Supports and Mountings, & Drive System Controls Y subsystems elements: Guides of Motion, Supports and Mountings, & Drive System Y-Axis Robot Stand and Base Gantry Robot

2 Leg Cantilevered Robot X and Y Axes: HDLS95W from Bishop Wisecarver Withstands the forces from payloads and axis weights The horizontal orientation supports large moments (Y) The vertical orientation has little deflection (X) The axis meets deflection requirements It has multiple mounting options Z-Axis: WH120 from Danaher Motion Lighter than the HDLS95W to meet weight requirements Light weight reduces the deflection of the X axis It will be great for building smaller robots

4 Leg Double Y-Axis Robot X, Y, and Z Axes: HDLS95W from Bishop Wisecarver Withstands the forces from payloads and axis weights The horizontal orientation supports large moments The vertical orientation has little deflection The axis meets deflection requirements It has multiple mounting options

Implementation Schedule

Excel Design Notes Excel programs measure for worst case scenarios Measure the forces and moments inside the axes as well at the carts and end caps The limiting factors on system failure are: Deflection of axis– caused forces and moments at the end caps Cart failure – cause by forces and moments at the cart

Excel Design Notes The forces and moments on the carts and end caps are the same that connect the axes Therefore when looking for mounts to connect axes, use these values Bishop Wisecarver and Danaher Motion both have axis mounts The forces and moments from the Y-axis also transfer into the base Both vendors also have stands available

Excel Programs 4 Excel Programs 2 for generic axis (any type of axis can be evaluated) Cantilever Program.xls Double Y-Axis Program.xls 2 specially tailored for the WH 120 and HDLS – 95 W Recommended Cantilever.xls Recommended Double Y-Axis Program.xls

Excel Programs Cantilever Program.xls Recommended Double Y-Axis.xls Recommended Cantilever.xls

Excel Programs These programs allow for an extremely high level of design flexibility Logic One can create robot configurations based on individual client needs Specific loads and tooling forces can be entered and tailored to any gantry robot They can also be used for other axis systems If there is another product desired these programs can be configured to analyze the new system

Excel Data The forces and moments of 8 different robot configurations were analyzed Load varied from 160 to 0 lbs tooling force – 75 lbs, acceleration – 6 m/s 2 Cantilever 800z/1000x/4500y 600z/1000x/4500y 800z/500x/4500y 600z/500x/4500y Double Y-Axis 1200z/3000x/4500y 1000z/3000x/4500y 1200z/2000x/4500y 1000z/3000x/4500y

Excel Data Axis lengths analysis under different tooling force, accelerations, and payloads 3 accelerations were considered (4, 6, and 8 m/s 2 ) The payload was dropped incrementally from 160 – 0 lbs The allowable axis length was plotted vs. payload Cantilever: both the Z-axis and X-axis changed Double Y-Axis: only the Z-axis changed X-axis and Y-axis can be any max desired length or lower

3D Models Two Main configurations Cantilevered (2-legs) Double Y (4-legs) Several configurations with in each All configurations depend on loading specifications and size of working area No bases, mounts, tooling etc. 6/3/ Introduction

Cantilevered For smaller working areas and lighter loads Can be mounted cart-to cart or cart to motor X and Y are same model(HDLS) Z axis is the WH120 Can be a number of different lengths 6/3/ Introduction

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Double Y Designed for larger working areas and larger loads Can be mounted in different ways like the cantilevered Utilizes the same axis(HDLS) Can also be a number of different lengths for each axis 6/3/ Introduction

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Video Team 77 Movie.wmv 6/3/ Introduction

Summary Executive Summary / Cost Options Studied / Subsystem Designations System Performance Data 3D Models and Configurations 6/3/ Introduction28

Questions????? 6/3/ Introduction29