Robotic End Effector For Arc Welding Application

Robotic end effector for arc welding application
Project Team
Sl. No. Reg. No. Student Name

1 14ETME005010 HEMALATHA R
2 14ETME005014 NARESH P N
3 14ETME005065 SACHIN KOTEGAR
4 14ETME005069 SHREENATH P
Supervisors: 1. Dr Suresh
2. Mr. Arun Karthik
August 2018
B.Tech
FACULTY OF ENGINEERING AND TECHNOLOGY
M. S. RAMAIAH UNIVERSITY OF APPLIED SCIENCES
Bengaluru -560 054
Robotic end effector for arc welding application i

FACULTY OF ENGINEERING AND TECHNOLOGY
Certificate
This is to certify that the Project titled Robotic end effector for arc welding
application is a bona-fide work carried out in the Department of
Mechanical and Manufacturing Engineering by
Ms. HEMALATHA R bearing Reg. No. 14ETME005010
Mr. NARESH P N bearing Reg. No. 14ETME005014
Mr. SACHIN KOTEGAR bearing Reg. No. 14ETME005065
Mr. SHREENATH P bearing Reg. No. 14ETME005069
in partial fulfilment of requirements for the award of B. Tech. Degree in
Mechanical Engineering of M.S. Ramaiah University of Applied Sciences.
August 2018
Prof.H.K. Narahari DR.Suresh .
Supervisors
Dr. M. Arulanantham Prof. H. K. Narahari

Head Dept. of MME Dean-FET

M.S.Ramaiah University of Applied Sciences Faculty of Engineering and Technology (FET)
Declaration
The project work is submitted in partial fulfilment of academic requirements for the award
of B. Tech. Degree in the Department of Mechanical Engineering of the Faculty of
Engineering and Technology of M. S. Ramaiah University of Applied Sciences. The project
report submitted herewith is a result of our own work and in conformance to the
guidelines on plagiarism as laid out in the University Student Handbook. All sections of the
text and results which have been obtained from other sources are fully referenced. We
understand that cheating and plagiarism constitute a breach of University regulations,
hence this project report has been passed through plagiarism check and the report has
been submitted to the supervisor.
Sl. No. Reg. No. Student Name Signature

1 14ETME005010 HEMALATHA R
2 14ETME005014 NARESH P N
3 14ETME005065 SACHIN KOTEGAR
4 14ETME005069 SHREENATH
Date: 10 August 2018

Acknowledgements
At this joy full moment of successfully completing our project we would like to convey
our sincere thanks and gratitude to our project guides Dr Suresh and Mr Arun Karthik for
helping us in completing the project successfully.
We would like to thank our dean prof. H.K Narahari and head of the department Dr
Arulanantham for encouragement during the project.
We would like to thank the teachers of Mechanical and Manufacturing Engineering
department for the help and support during the project
We would like to sincerely thank lab assistant of workshop for helping us in completing
the project.
We would like to thank our parents and friends for helping us in completing the project
Robotic end effector for arc welding application ii

Summary
We have decided to make a robotic end effector for arc welding application. The concept
of robotic end effector for arc welding application was designed by considering the
workers problem. The working condition of the welder is typically unpleasant and
hazardous. The arc from the welding process emits ultra-violet radiations which is
injurious to human vision. Sparks and smoke are generated during the process are a
potential threat to operators. Because of the hazards for human workers in continuous
arc welding, it is logical to consider industrial robots for the purpose.
In industries, welding has a wide application. In this highly developing society time and
man power are critical constrains for completion of task in large scales. Welding robots
plays an important role to save human efforts and to increase productivity in industries.
We have to to study and analyze the existing systems of robotic end effector for welding
application and arrive at the concept by considering the advantages and disadvantaged of
each concept. We have to design the basic structure of the end effector, arrive at the
dimension of the end effector, find the forces acting on the system and develop a CATIA
model. We have to develop a prototype and fabricate the final model for robotic end
effector to perform arc welding operation.
We have designed and fabricated robotic end effector for arc welding application. Design
of the end effector was based on the electrode feed mechanism. We have used a screw
rod for linear moment. Screw rod is connected to the motor for the motion. As the motor
rotates, screw rod rotates which makes the arm move in vertical direction.
Robotic end effector for arc welding application iii

Table of Contents
Certificate .(ii)
Declaration...................................(iii)
Acknowledgements...(iv)
Summary ....(v)
Table of Contents.... (vi)
List of Tables.....(x)
List of Figures...(xi)
Nomenclature.(xii)
Abbreviations and Acronyms..(xiii)
Chapter-1: Introduction....01
Preamble to the Chapter
1.1 Introduction
1.1.1 Advantages of using industrial robots .01
Chapter-2: Background Theory
2.1 Types of end effector....02
2.2 Definition of Welding.03
2.3 Principle of arc welding.03
2.4 Advantage of welding robot .04
2.5 Problem Statement.04
2.6 Design Challenges..04
Chapter-3:Aim and Objectives
3.1 Title of the Project.06
3.2 Aim of the Project..06
3.3 Objectives of the Project06
Robotic end effector for arc welding application iv

3.4 Methods and Methodology07

Chapter-4: Problem Solving
4.1 Literature Review09
4.1.1 Concept 1: Double drive roll mechanism.09
4.1.2 Concept 2: Drive roll mechanism..11
4.1.3 Concept 3: Fixed support roll mechanism..13
4.2 Comparing the concept of each mechanism14
4.3 Arriving at the concept14
4.4 Design consideration for the end effector.15
4.5 Designing the structure of the end effector for vertical movement16
4.6 Components required for designing the end effector16
4.7 Construction of this mechanism.17
4.8 Working of this mechanism17
4.9 Dimension of the mechanism18
4.10 Details of the component used...19
4.11 Designing the structure of the end effector for horizontal movement..20
4.12 Components requited for designing this mechanism .23
4.13 Construction of this mechanism .24
4.14 Working of this mechanism24
4.15 Dimensions of the mechanism.25
4.16 Details of the components used.25
4.17 Selection of the motor..27
4.18 Calculations ..29
4.19 Simulation of horizontal mechanism in ADAMS simulation.32
4.20 Simulation of vertical mechanism in ADAMA simulation..33
4.21 CATIA model..33
Robotic end effector for arc welding application v

Chapter-5: Results
Chapter-6: Project Costing
Chapter-7: Conclusions and Suggestions for Future Work
References
Robotic end effector for arc welding application vi

List of Tables
List of tables
Table 2.1 Table containing methods and methodology.08
Table 4.1 Table containing comparison of each mechanism .14
Table 6.1 List of cost of the components..41
Robotic end effector for arc welding application vii

List of Figures
________________________________________________________________________
Figure 1.1 Working of arc welding 03

Figure 4.1 Double drive roll mechanism 09
Figure 4.2 Double drive roll mechanism 10
Figure 4.3 Drive roll mechanism 11
Figure 4.4 Drive roll mechanism 12
Figure 4.5 Fixed support roll mechanism 13
Figure 4.6 Fixed support roll mechanism 13
Figure 4.7 Dimension of the electrode 15
Figure 4.8 Structure of the end effector 16
Figure 4.9 Dimension of the end effector 18
Figure 4.10 Image of rail rod 19
Figure 4.11 Image of linear bearing 19
Figure 4.12 Image of screw rod 19
Figure 4.13 Image of the motor 20
Figure 4.14 Image of Arm 21
Figure 4.15 Image of U-clamp 21
Figure 4.16 Image of electrod gun with electrode 22
Figure 4.17 Structure for horizontal movement 23
Figure 4.18 Dimension of the structure for horizontal movement 24
Figure 4.19 Image or rail rod 24
Figure 4.20 Image of rail block 25
Figure 4.21 Image of plumber block with bearing 25
Figure 4.22 Image of linear bearing 26
Figure 4.23 Image of base plate 26
Figure 4.24 Image of the motor 27
Robotic end effector for arc welding application viii

Figure 4.25 Image of nut 27

Figure 4.26 ADAMS simulation for horizontal movement 32
Figure 4.27 ADAMS simulation for vertical movement 33
Figure 4.28 Front view of the end effector 33
Figure 4.29 Top view of the end effector 34
Figure 4.30 Isometric view 34
Figure 4.31 Four views of the end effector 35
Figure 5.1 Front view of the end effector 36
Figure 5.2 Back view 37
Figure 5.3 Top view 37
Figure 5.4 Side view 38
Figure 5.5 Top view of the mechanism for horizontal movement 38
Figure 5.6 Side view of the mechanism for horizontal movement 39
Figure 5.7 Isometric view 39
Figure 5.8 Front view of the mechanism for vertical movement 40
Figure 5.9 Side view of the mechanism for vertical movement 41
Robotic end effector for arc welding application ix

Nomenclature
Angular speed (rad/s)

I Current (Ampere)
F Force (N)
P Power (Watt)
T Torque (Nm)
V Voltage (Volts)
Robotic end effector for arc welding application x

1. Introduction
We know how technology has improved from past few decades. Development in the technology
has increased competition. To be in the present competition we have to adapt new technologies.
Implementing a robotic solution can set a competition by allowing for faster completion and
delivery of products, ensuring consistent quality.
1.1 Introduction
The industrial robots are one of the most important devices for better, modern and safer
automation. Requirements of todays manufacturing industries are very high. To meet the
requirements of the market many companies decide to use industrial robots for better and
cheaper products. Present day industry is increasingly turning towards computer-based
automation mainly due to the need for increased productivity and delivery of end products with
uniform quality. The inflexibility and generally high cost of hard-automation systems, which have
been used for automated manufacturing tasks in the past, have led to a broad based interest in
the use of robots capable of performing a variety of manufacturing functions in a flexible
environment and at lower costs. The industrial robots can perform work in many areas of the
industry e.g. pick and place objects, assembly, welding, painting and many more.
1.1.1 Advantages of using industrial robots
Since the robots are flexible and possible to reprogram, increases the possibility of
changing in the production.
The working environment for the man becomes better and easier, because the robot can
carry heavy and do dangerous work.
More efficient production for a lower cost.
The robots can repeat the same work in exactly the same way, therefore the quality of
the production increases.
Highly accuracy and good reliability
Robotic end effector for arc welding application 1

2.Background Theory
In robotics, end effectors are a device at the end of a robotic arm, designed to interact with the
environment. An end effector enables the general-purpose robot to perform a specific task.
The end effector connects to the robot's arm and functions as a hand. This part comes in direct
contact with the material the robot is manipulating. Some robots are capable of changing end
effectors and can be programmed for different sets of tasks. The structure of an end effector and
the nature of the programming and hardware that drives it depend on the task the robot will be
performing.
2.1 Types of end effector

End effector is divided into two parts
1. Gripper
The gripper can perform the basic function of picking, holding and grasping of different shaped
objects. The objects are usually work-parts that are moved from one location to another in the
cell.
2. Tool
A tool is equipped in the robot for carrying out several operations on the work parts instead of
grasping it. Tools are used in applications where the robot must perform some processing
operation on the work-part. A tool acts as an end effector when it is attached directly to
the robots wrist. In each case the robot must not only control the relative position of the tool
with respect to the work as a function of time, it must also control the operation of the tool.
In this highly developing society time and man power are critical constrains for completion of task
in large scales. The automation is playing important role to save human efforts in most of the
regular and frequently carried works. One of the major and most commonly performed works is
welding jobs from source to destination.

In this project we have developed an end effector for arc welding application. In this case tool
acts as an end effector.
2.2 Definition of welding

Welding is the process of joining similar metals by the application of heat, with or without
application of pressure, in such a way that the joint is equivalent in composition and characteristics
of the metals joined.
Figure 1.1: Working of arc welding

2.3 Principle of arc welding:
A suitable gap is kept between the work piece and the electrode. A high current is passed through
the circuit. The electric energy is converted into heat energy, producing a temperature of 3000C
to 4000C. This heat melts the edge to be welded and molten pool is formed. On solidification the
weld joint is obtained.
Disadvantages of manual arc welding
Difficult
Expensive
Time consuming
More errors
High energy consumption
Strain on workers

Automated welding robots are used to overcome the disadvantages of manual welding.
2.4 Advantages of automated welding robots over manual welding

Decreased Production Costs
Increase productivity by decreasing defects
Shorter Cycle Times
Improved Quality and Reliability
Reduced Waste
Attract More Customers
Increased Safety
More Savings
2.5 Problem statement
We have to design the end effector
End effector should be able to hold the tool in proper alignment
We should design an end effector in such a way that there is no slippage of the tool
Having a rigid mechanical structure.
Ability to move the tool at define angle.
2.6 Design challenges
To design the end effector for welding application we have to understand the concept of welding
and the factors that has to be considered for proper welding
Correct electrode
It is very important that we use correct electrode. The electrode that we use should be of same
material of the work piece

Rod Angle
For welding on the flat surface, the rod should be angled 10 to 20 degrees from vertical and pulled
in the direction that has to be welded. The angle of the rod prevents the slag overtaking the rod
Arc Length
The arc length is the distance between the electrode and the weld pool. It should be roughly the
same as the diameter of the rod. Minimum 1mm gap should be given between the electrode and
work piece.
Travel Speed Faults
It is very important to maintain the correct welding speed. Excessive speed results in a thin, weak
weld. Welding too slowly results in a wide tall build-up of weld.
Maintaining Lead Angle and Arc Length
The rod becomes shorter as the weld progresses, and it takes a conscious effort to reduce the
length of the arc as the rod gets shorter. Excess arc length can lead to an unstable arc, excess heat
and undercutting and is probably the most common beginner fault.
The angle of the rod should also be maintained over the length of the weld. A little practice is
required to avoid decreasing the lead angle as the weld progresses, as this can result in slag
inclusions and even cause the arc to stall. The easy way to maintain rod angle is to focus attention
on moving the rod holder rather than the rod as the weld progresses.
Welding Motion
Usually the rod is moved in a straight line.

3. Aim and Objectives
In this chapter we will be explaining the aim and objectives of our projects. Methods and
methodology that has to be followed in completing the project is explained.
3.1 Title

3.2 Aim
To design and develop a robotic end effector to perform arc welding
application
3.3 Objectives
To study and analyze the existing systems of robotic end effector for
welding application.
To arrive at the concept of the robotic end effector for welding application
considering the limitation in the existing system
To design the robotic end effector to perform welding operation
To develop a model of the end effector to perform static and dynamic

analysis
To develop a prototype and fabricate the final model for robotic end
effector to perform welding operation

3.4 Methods and Methodology
Objective Statement of the Method/ Methodology Resources Utilised

No. Objective
1 To study and analyze Analysis the Books

the existing systems present system: Publications
of robotic end Study the existing system Patents
effector for welding used in industries to
application. understand its design,
working principle and
limitations.
Literature review:
Literature review can be
done through books,
publications, patents
2 To arrive at the Arriving at the concept: Books
concept of the robotic List down the Patents
end effector for existing methods Publications
welding application used in industries,
considering the with its
limitation in the advantages and
existing system limitations
Arrive at the
concept
considering the
limitations in the
existing method
3 To design the robotic Designing the end CATIA software

end effector to effector:
perform welding Designing the
operation basic dimensions
and structure of
the end effector
Identify the
components

required to design
the end effector
Identify the
material used to
construct the end
effector
4 To develop a model of Analysis the load ADAMS simulation

the end effector to acting on the
perform static and entire system
dynamic analysis Arrive at the
torque required to
run the motors
Perform static and
dynamic analysis
using ADAMS
simulation
5 To develop a Fabrication: Machine shop

prototype and Fabricating the
fabricate the final prototype of the
model for robotic end robotic end
effector to perform effector in
welding operation workshop and
testing the model
Table 2.1: Table containing Methods and methodology

4. Problem Solving
In this chapter, methods and methodology that we have followed in completing each objective
will be explained
4.1 Literature review (Objective 1)

In industries electrode feed mechanism is used in welding torch. The mechanism used in electrode
feed mechanism is explained below.
4.1.1 Concept 1: Double Drive Roll mechanism
Figure 4.1: Double drive roll mechanism
A roll of wire is installed into the machine. When the trigger of the gun is pressed the electrode
wire begins to feed. In this mechanism two pair of rollers are used. Electrode wire is feed between
two rollers. The upper roller runs in anti-clockwise direction and lower roller runs in clockwise
direction. Both the upper roller runs in same direction and lower roller runs in same direction.
When the roller rotated the electrode wire is fed to the welding gun. The roller put pressure on

the electrode wire, when the trigger of the gun is pressed the wire gets fed to the gun. Drive roll
should be installed correctly. If you are running a small wire and you have the drive rolls set on
too big of tracks, the drive rolls wont get any traction and your wire welder will feed erratically.
Figure 4.2: Double drive roll mechanism

Advantages of this mechanism
As there are two drive roll, the electrode wire will be fed to the gun without any damage.
Limitation of this mechanism

Drive roll should be installed correctly. The distance between the upper and lower drive
roll should be set correctly according to the dimension of the electrode wire. If the
distance between upper and lower drive roll is more, then the electrode wire wont be
fed properly to the gun. If the distance between the upper and lower drive roll is very less,
then it will damage the electrode wire
Slight variation in the drive roll may affect in working of this mechanism
Construction of this mechanism is difficult
The speed of the electrode should be set properly. If you set the wire feed speed wrong
or the voltage is off your wire will feed erratically

4.1.2 Concept 2: Drive Roll Mechanism
Figure 4.3: Driver roll mechanism

A roll of wire is installed into the machine. When the trigger of the gun is pressed the electrode
wire begins to feed. In this mechanism one pair of rollers are used. Electrode wire is feed between
two rollers. The upper roller runs in anti-clockwise direction and lower roller runs in clockwise
direction. When the roller rotated the electrode wire is fed to the welding gun. The roller put
pressure on the electrode wire, when the trigger of the gun is pressed the wire gets fed to the
gun. Drive roll should be installed correctly. If you are running a small wire and you have the drive
rolls set on too big of tracks, the drive rolls wont get any traction and your wire welder will feed
erratically.
Figure 4.4: Drive roll mechanism

Advantage of this mechanism

Easy to construct this mechanism
Less cost
Limitations of this mechanism

Drive roll should be installed correctly. The distance between the upper and lower drive
roll should be set correctly according to the dimension of the electrode wire. If the
distance between upper and lower drive roll is more, then the electrode wire wont be
fed properly to the gun. If the distance between the upper and lower drive roll is very less,
then it will damage the electrode wire
Slight variation in the drive roll may affect in working of this mechanism
Construction of this mechanism is difficult
The speed of the electrode should be set properly. If you set the wire feed speed wrong
or the voltage is off your wire will feed erratically
4.1.3 Concept 3: Fixed Support Roll Mechanism
Figure 4.5: Fixed support roll mechanism

In this mechanism only one drive roll is used. The electrode from the electrode winding tube is
passed through the fixed support. This mechanism helps in setting tension on the wire feed roll.
Tension is set to ensure that there is no winding of the electrode wire is caused.

Figure 4.6: Fixed support roll mechanism

Advantage of this mechanism
Easy to construct the mechanism
Less cost
Limitation of this mechanism

The electrode wire will be damaged if the tension set on the wire feed roll is high
4.2 Comparison of each mechanism
Parameters Concept 1: Double Concept 2: Drive roll Concept 3: Fixed

drive roll mechanism mechanism support mechanism
Cost High Fairly low Low
Design complexity Complex design Fairly simple design Easy design
Ease of use Very difficult Easy to use Difficult
Rate of working High High Low
Maintenance Low Low Maintenance needed
Conclusion This mechanism has Suitable mechanism,
The design of the
many disadvantage its fairly simple to
mechanism is easy,
compared to other design, rate of
but rate of working of
two concepts. working of this
this mechanism is
mechanism is highvery low, because of
the tension caused in
the electrode wire
Table 4.1 Table containing the comparison each mechanism

By comparing the advantages and disadvantages of the of the three concept, we can conclude
that concept two that is drive roll mechanism is more suitable compared to other two
mechanisms. The design of drive roll mechanism is easy and it takes less cost to design the
mechanism.
4.3 Arriving at the concept

Tool acts as an end effector in welding robots. Electrode feed mechanism is used in robotic
welding tool. In our project we are using welding electrode instead on continuous
electrode feed wire. We have to arrive at the new design by considering electrode feed
mechanism as the base.
We can make use of the screw rod for vertical moment. We know that as the welding takes place
the electrode will be melting so we need to design a vertical motion so that as the electrode melts,
the electrode gun is moved vertically. In this project we will be using electrode instead of the
electrode wire. In continuous electrode feed mechanism, gun will be fixed and the electrode will
be moving. In this case as we are used electrode, the welding gun has to move. So we have to
design a mechanism for the welding gun to move in vertical direction.
4.4 Design consideration for the end effector

As the electrode melts, the electrode gun should be moving in vertical direction
Tool should be place in a proper alignment
We should design an end effector in such a way that there is no slippage of the tool
Having a rigid mechanical structure.
Ability to move the tool at define angle.
The structure of the end effector has to be designed by considering the dimensions of the
electrode

Figure 4.7: Dimensions of the electrode
4.5 Designing the structure of the end effector for vertical movement
The structure of the end effector has to be designed by considering the dimensions of the
electrode. The below image shows the basic structure of the end effector.
Figure 4.8: Structure of the end effector

4.6 Components required for designing the end effector

Two rail rods
Linear bearing
Screw rod
Nuts and bolts
Electrode holder
Motor
4.7 Construction of this mechanism

Two rail rods are connected to the supporting arm. Rail rods are used for support of the arm and
proper sliding of the arm. Screw rod is connected to the supporting arm. Motor is place on the
supporting arm. Motor is connected to the screw rod. Arm is connected to screw rod and rail rod.
Linear bearing is attached to the rail rods. This is done to prevent the arm form slipping and for
smooth movement of the arm. Arm is the slider. Electrode gun is attached to the arm. Electrode
is placed in the electrode holder.
4.8 Working of this mechanism:

Screw rod is connected to the motor. When the motor rotates in clockwise direction, the arm
moves downwards and when the motor rotated anti-clockwise direction, the arm moves in
upward direction.
Mechanism used: Linear mechanism with one degree of freedom

In this mechanism we will be using a screw rod for linear moment. Screw rod is connected to the
motor for the motion. As the motor rotates, screw rod rotates which makes the arm move in
vertical direction.
4.9 Dimension of the mechanism

Dimensions of the end effector has to be designed by considering the electrode dimensions.

Figure 4.9 Dimensions of the end effector

4.10 Details of the components used
Rail rod
Figure 4.10: Image of rail rod

Dimensions of rail rod:

Length of the rod is 420mm
Diameter of the rod is 12mm
Material of the rod is aluminium
Reason for using aluminium: light weight
Linear bearing
Figure 4.11: Image of linear bearing

Length of the bearing: 30mm
Outer diameter of the bearing: 18mm
Inner diameter of the bearing: 12mm
Material used: Stainless steel
Reason for using stainless steel: To reduce friction
Screw rod
Figure 4.12: Image of screw rod

Length of the screw rod: 420mm

Diameter of the screw rod: Metric 12

Material used: mild steel: less cost
Motor
Figure 4.13: Image of the motor

Motor speed: 100 rpm
Voltage: 12V
Current carrying capacity is 2.4A
Gear tooth
Shaft diameter 6mm
Arm
Figure 4.14 Image of arm

Length: 118mm
Breadth: 66mm
Thickness: 10mm
Material used: aluminium
Reason for using aluminium: Light weight
U-clamp(for placing electrode gun)
Figure 4.15: Image of U-clamp

Length: 10mm
Breadth: 3mm
Material used: steel
Arm support
Figure 4.15: Image of arm support

Length: 485mm
Breadth: 60mm
Width: 37mm
Material used: mild steel
Reason for using this material: high strength compared aluminium
Electrode gun
Figure 4.16 Image of the electrode gun with electrode
4.11 Designing the structure of the end effector for horizontal movement
Figure 4.17: Structure of horizontal movement

4.12 Components required for designing this mechanism

Two rail rods
Two Linear bearing
Two pillow block bearing
Four rail block
Screw rod
Two screw nuts
Nuts and bolts
Base plate
Motor
4.13 Construction of this mechanism

The ends of the screw rod are connected to pillow block bearing. This is done to obtain the proper
rotation of the screw rod. The ends of the rail rods are connected to rail block. Rail block and
pillow block bearing are fixed to a plate. Linear bearings are attached to rail rods. Linear bearing
is attached to the rail rods for smooth movement. Two nuts are attached to screw rod. A plate is
attached to the screw nut. Base plate acts as a slider. Plate is attached to the screw nuts by using
nuts and bolts. Motor is connected one end of the screw rod.
4.14 Working of this mechanism:

Screw rod is connected to the motor. When the motor rotates in clockwise direction, the base
plate moves in forward direction and when the motor rotated anti-clockwise direction, the base
plate moves in backward direction.
Mechanism used: Linear mechanism with one degree of freedom

In this mechanism we will be using a screw rod for linear moment. Screw rod is connected to the
motor for the motion. As the motor rotates, screw rod rotates which makes the base plate to
move in horizontal direction.

4.15 Dimension of the mechanism.
Figure 4.18 Dimension of the structure for horizontal movement
4.16 Details of the components used
Rail rod
Figure 4.19 Image of rail rod

Length: 1000mm
Diameter: 16mm
Material used: stainless steel
Reason for using this material: for smooth movement and less friction between contact parts

Rail block
Figure 4.20: Image of rail block

Hole diameter: 16mm
Plumber block with bearing
Figure 4.21: Image of plumber block with bearing

Internal hole dimeter: 20mm

Linear bearing
Figure 4.22: Image of linear bearing

Internal hold diameter: 16mm
Base plate
Figure 4.23: Image of base plate

Length: 295mm
Breadth: 295mm
Thickness: 5mm
Reason for using this material: light weight

Motor
Figure 4.24: Image of the motor

Shaft radius is 9mm
Current carrying capacity is 5V
Voltage= 12V
Speed of the motor is 100rpm
Nut
Figure 4.25: Image of nut

Inner diameter: M20
Material: mild steel

4.17 Selection of motor

1. Dc motor
It is an electric motor that runs on direct current
Advantage of DC motor
It can be easily installed
Speed can be controlled over a wide range
Provide excellent speed control for acceleration and deceleration
Easy to understand design
Less cost
Dc motor draws less current and power from the source
Disadvantage of DC motor
High maintenance required
Need switching control
2. Stepper motor
The stepper motor is a specialized motor that can be used in open loop and closed loop positioning
system. Its operation begins with supply a pulse of direct current to its winding and the stepper
will move a specific number of degrees
Advantages of stepper motor:
High rate of accuracy
No maintenance
High reliability
No feedback components are needed
Low cost
Simple construction
Can be used in robotics in a wide scale.

Disadvantages of stepper motor
Require a dedicated control circuit

Use more current than D.C. motors
Torque reduces at higher speeds
Resonances can occur if not properly controlled
Not easy to operate at extremely high speeds
3. Servo motor
The servo motor is a mechanical motorize device which can be instructed to move the output shaft
attach to servo arm to specific position. The servo motor is built in gearing and feedback control
loop circuitry. It needs to be controlled by pulse sending called pulse width modulation from
electronic device to their receiver to be translated. Usually servo motor is unable to continually
rotate, so suitable to use in arms robot and legs.
Advantages of servo motor:
Very efficient
Can run at high speed
Disadvantage of servo motor
High cost
Difficult to understand design
Dc motor has many advantages compared to stepper motor and servo motor. Servo motor is used
in robotic field. We have used DC motor, because the installing stepper and servo motor is difficult.

4.18 Calculations
MOTOR 1
We have to calculate the load carrying capacity of the motor used for horizontal movement
Current carrying capacity of the motor is 5A
Voltage of the motor is 12V
We can calculate the power of the motor by using the below formula
=
Where I is the current carrying capacity of the motor (Ampere)
V is the voltage(volt)
= 5 12 = 60
Power of the motor is 60W
Speed of the motor (N) is 100rpm
We can calculate the angular speed of the motor by using below formula
2
=
60
Where is the angular speed(rad/s)
N is the speed of the motor (rpm)
2 100
=
60
= 10.46667/
Angular speed of the motor is 10.4667rad/s
We can calculate the torque of the motor by using the below formula

=

60
=
10.4667
= 5.732
Torque of the motor is 5.732Nm
We have to calculate the load carrying capacity of the motor. The equation to find the load
carrying capacity of the motor is given below
=


=

Shaft radius of the motor is 6mm
5.732
= = 95.933
0.06
Load carrying capacity of the motor is 95.933/9.81=9.738kg
Load carrying capacity of the motor is 9.738kg
MOTOR 2
We have to calculate the load carrying capacity of the motor used for vertical movement
Current carrying capacity of the motor is 2.4A
Voltage of the motor is 12V
We can calculate the power of the motor by using the below formula
=
Where I is the current carrying capacity of the motor (Ampere)
V is the voltage(volt)
= 2.4 12 = 28.8
Power of the motor is 2.8W
Speed of the motor (N) is 100rpm
We can calculate the angular speed of the motor by using below formula
2
=
60
Where is the angular speed(rad/s)
N is the speed of the motor (rpm)
2 100
=
60
= 10.46667/
Angular speed of the motor is 10.4667rad/s
We can calculate the torque of the motor by using the below formula

=

2.8
= 2.7515
10.4667

Torque of the motor is 2.7515Nm

We have to calculate the load carrying capacity of the motor. The equation to find the load
carrying capacity of the motor is given below
=

=

Shaft radius of the motor is 6mm
2.7515
= = 91.7194
0.03
Load carrying capacity of the motor is 91.719/9.81=9.349kg
Load carrying capacity of the motor is 9.349kg
4.19 Simulation of horizontal mechanism in ADAMS simulation
Figure 4.26: ADAMS simulation for horizontal movement

4.20 Simulation of vertical mechanism in ADAMS simulation
Figure 4.27: ADAMS simulation for vertical movement
4.21 CATIA model
Figure 4.28: Front view of the end effector

Figure 4.29: Top View of the end effector
Figure 4.30: Isometric view

Figure 4.31: Four views of the end effector

5. Results
We have designed and fabricated the end effector to perform arc welding operation
Figure 5.1: Front view of the end effector

Figure 5.2: Back view
Figure 5.3: Top view

Figure 5.4: Side view
Horizontal movement
Figure 5.5: Top view of the mechanism for horizontal movement

Figure 5.6: Side view of the mechanism for horizontal movement
Figure 5.7: Isometric view of the mechanism for horizontal movement

Vertical movement
Figure 5.8: Front view of the mechanism for vertical movement
Figure 5.9: Side view of the mechanism for vertical movement

6. Project Costing
In this chapter we will be discussing the cost of all the components used
Components Used Cost

Stainless steel rail rod 700+700
Screw rod 300
Two Pillow block bearing 300
Horizontal movement Four rail block 200
Two Linear bearing 300
Base plate 100
Motor We used old motor
Two Aluminium rail rod 100
Screw rod 55
Vertical movement Linear bearing 120
Motor 300
Arm support ---
Total cost 3175
Table 6.1: List of cost of the components

7. Conclusions and Suggestions for Future Work
Conclusion
We have designed and fabricated the end effector to perform arc welding operations. The
objectives that we set in doing the project is successfully completed. The end effector is fabricated
according to the desire mechanism.
Suggestion for future work

1. We are using DPDT switch for the motor to run in clockwise and anticlockwise direction. Instead
of using switch we can use control system and a feedback system to automatically change the
direction of rotation of the motor
2. We have designed the mechanism only for linear welding, we can further continue the design
for circular welding
3. We are using welding electrode in our project, we can use a continuous feed rod mechanism
for continuous electrode feeding

References
Cary, Howard B. and Scott C. Helzer (2005). Modern Welding Technology. Upper
Saddle River, New Jersey: Pearson Education. Page 316. ISBN 0-13-113029-3.
Gilchrist. "Modern Robotic Welding Technology". GMFCO. Retrieved 19 April
2013.
Turek, Fred (June 2011). "Machine Vision Fundamentals, How to Make Robots
See". NASA Tech Briefs magazine. 35 (6). pages 60-62
Crowder R.M, Automation and Robotics
J. Kerr, and B. Roth, The International Journal of Robotics Research, 4(4), 1986,
3-17.
Websites
1. http://www.metalartspress.com/books/chapters/chapter-6-wire-feed-welding
2. http://www.freestylemetalart.com/blog/arc-wire-and-drive-roll-options-
freestyle-metal-art
3. http://www.fabricatingandmetalworking.com/2011/08/-the-wire-feed-system/

Robotic End Effector For Arc Welding Application

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Robotic end effector for arc welding application

Sl. No. Reg. No. Student Name

Robotic end effector for arc welding application i

Prof.H.K. Narahari DR.Suresh .

Dr. M. Arulanantham Prof. H. K. Narahari

Robotic end effector for arc welding application i

Robotic end effector for arc welding application

Sl. No. Reg. No. Student Name Signature

Date: 10 August 2018

Robotic end effector for arc welding application i

Robotic end effector for arc welding application ii

Robotic end effector for arc welding application iii

Robotic end effector for arc welding application iv

3.4 Methods and Methodology07

Robotic end effector for arc welding application v

Robotic end effector for arc welding application vi

Robotic end effector for arc welding application vii

Figure 1.1 Working of arc welding 03

Robotic end effector for arc welding application viii

Figure 4.25 Image of nut 27

Robotic end effector for arc welding application ix

Angular speed (rad/s)

Robotic end effector for arc welding application x

1.1.1 Advantages of using industrial robots

Robotic end effector for arc welding application 1

2.1 Types of end effector

Robotic end effector for arc welding application 2

2.2 Definition of welding

Figure 1.1: Working of arc welding

Robotic end effector for arc welding application 3

2.4 Advantages of automated welding robots over manual welding

2.5 Problem statement

We have to design the end effector

End effector should be able to hold the tool in proper alignment

Having a rigid mechanical structure.

Ability to move the tool at define angle.

2.6 Design challenges

Robotic end effector for arc welding application 4

Travel Speed Faults

Maintaining Lead Angle and Arc Length

Robotic end effector for arc welding application 5

3. Aim and Objectives

Robotic end effector for arc welding application

To design the robotic end effector to perform welding operation

To develop a model of the end effector to perform static and dynamic

Robotic end effector for arc welding application 6

3.4 Methods and Methodology

Objective Statement of the Method/ Methodology Resources Utilised

1 To study and analyze Analysis the Books

3 To design the robotic Designing the end CATIA software

Robotic end effector for arc welding application 7

4 To develop a model of Analysis the load ADAMS simulation

5 To develop a Fabrication: Machine shop

Table 2.1: Table containing Methods and methodology

Robotic end effector for arc welding application 8

4.1 Literature review (Objective 1)

4.1.1 Concept 1: Double Drive Roll mechanism

Figure 4.1: Double drive roll mechanism

Robotic end effector for arc welding application 9

Figure 4.2: Double drive roll mechanism

Limitation of this mechanism

Robotic end effector for arc welding application 10

4.1.2 Concept 2: Drive Roll Mechanism