building competitive manipulators
DESCRIPTION
Building competitive manipulators. Greg Needel DEKA R&D, Rochester Institute of technology Owner, www.midnightinvention.com Mentor teams: 131, 1511. Strategy, Strategy, Strategy!. Read the rules Outline the game objectives Look for the “gimmie” robot design Try small simulators - PowerPoint PPT PresentationTRANSCRIPT
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Building competitive manipulators
Building competitive manipulators
Greg Needel
DEKA R&D, Rochester Institute of technology
Owner, www.midnightinvention.com
Mentor teams: 131, 1511
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• Read the rules
• Outline the game objectives
• Look for the “gimmie” robot design
• Try small simulators
• Whatever you choose STICK WITH IT!
Strategy, Strategy, Strategy!Strategy, Strategy, Strategy!
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Types of ManipulatorsTypes of ManipulatorsTypes of ManipulatorsTypes of Manipulators
• Articulating Arms
• Telescoping Lifts
• Grippers
• Latches
• Ball Systems
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• Example #1 - Lifting– Same force, different angle,
less torque
10 lbs
10 lbs
< DD
Arm: Forces, Angles & TorqueArm: Forces, Angles & Torque
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PowerPower
• Power = Force x Distance / TimeOR
• Power = Torque x Rotational Velocity
Power (FIRST def.) – how fast you can move something
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Arm: Power ExampleArm: Power Example
– Same torque, different speed
0.1 HP, 100 RPM Motor w/ 1” sprocket
0.2 HP, 200 RPM Motor w/ 1” sprocket OR 100 RPM w/ 2” sprocket
10 lbs10 lbs
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Arm DesignArm Design
• “Arm”: device for grabbing & moving objects using members that rotate about their ends
• Think of your materials (thin wall is good)• Every Pivot has to be engineered (less is more)• Linkages help control long arms.• Use mechanical advantage (it is your friend)
• Think of the drivers (pivots on pivots are hard)• Operator Interface (keep this in mind)
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Arm AdviceArm Advice
• K.I.S.S. doesn’t mean bad
• Feedback Control is HUGE– Potentiometers, encoders, limits– Automatically Take Action Based on Error – Design-in sensors from the start of design
• Think outside the box.
• Off the shelf components are good (andymark.biz, banebots.com )
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Four Bar LinkageFour Bar Linkage
•Pin Loadings can be very high Watch for buckling in lower member Counterbalance if you canKeep CG aft
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4 bar linkage example :229 20054 bar linkage example :229 2005
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Arm Example: 234 in 2001Arm Example: 234 in 2001
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Arm Example: 330 in 2005Arm Example: 330 in 2005
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Arm Example: 1114 in 2004Arm Example: 1114 in 2004
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Telescoping LiftsTelescoping Lifts
• Extension Lift
• Scissor Lift
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ExtensionExtension
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Extension Lift ConsiderationsExtension Lift Considerations• Should be powered down AND
up– If not, make sure to add a device
to take up the slack if it jams• Segments need to move freely• Need to be able to adjust cable
length(s).• Minimize slop / free-play• Maximize segment overlap
– 20% minimum– more for bottom, less for top
• Stiffness is as important as strength
• Minimize weight, especially at the top
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Extension - RiggingExtension - Rigging
Continuous Cascade
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Extension: Continuous RiggingExtension: Continuous Rigging
• Cable Goes Same Speed for Up and Down
• Intermediate Sections sometimes Jam
• Low Cable Tension• More complex cable
routing• The final stage moves
up first and down last
Slider(Stage3)
Stage2
Stage1
Base
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Extension: Continuous Internal RiggingExtension: Continuous Internal Rigging
• Even More complex cable routing
• Cleaner and protected cables
Slider(Stage3)
Stage2
Stage1
Base
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Extension: Cascade RiggingExtension: Cascade Rigging• Up-going and Down-going
Cables Have Different Speeds
• Different Cable Speeds Can be Handled with Different Drum Diameters or Multiple Pulleys
• Intermediate Sections Don’t Jam
• Much More Tension on the lower stage cables– Needs lower gearing to deal
with higher forces
• I do not prefer this one!
Slider(Stage3)
Stage2
Stage1
Base
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Team 73 in 2005 elevatorTeam 73 in 2005 elevator
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Scissor LiftScissor Lift
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Scissor Lift ConsiderationsScissor Lift Considerations• Advantages
– Minimum retracted height - can go under field barriers
• Disadvantages– Tends to be heavy to be stable
enough– Doesn’t deal well with side
loads– Must be built very precisely– Stability decreases as height
increases– Loads very high to raise at
beginning of travel
• I recommend you stay away from this!
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Team 158 in 2004Team 158 in 2004
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Arm vs. LiftArm vs. Lift
Feature Arm LiftReach over object Yes No
Fall over, get back up Yes, if strong enough No
Go under barriers Yes, fold down No, limits lift potential
Center of gravity (Cg) Can move it out from over robot
Centralized mass over robot
small space operation No, needs swing room Yes
How high? More articulations, more height (difficult)
More lift sections, more height (easier)
Complexity Moderate High
Accumulation 1 or 2 at a time Many objects
Combination Insert 1-stage lift at bottom of arm
<-
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Braking: Prevent Back-drivingBraking: Prevent Back-driving
• Ratchet Device - completely lock in one direction in discrete increments - such as used in many winches
• Clutch Bearing - completely lock in one direction • Brake pads - simple device that squeezes on a rotating
device to stop motion - can lock in both directions– Disc brakes - like those on your car– Gear brakes - applied to lowest torque gear in gearbox
• Note : any gearbox that cannot be back-driven alone is probably very inefficient
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PowerPower
• Summary– All motors can lift the same amount (assuming
100% power transfer efficiencies) - they just do it at different rates
• BUT, no power transfer mechanisms are 100% efficient – Inefficiencies (friction losses, binding, etc.)– Design in a Safety Factor (2x, 4x)
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GrippersGrippers
• Gripper (FIRST def) grabbing game object
• How to grip
• How to hang on
• Speed
• Control
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How to gripHow to grip
• Pneumatic linkage grip– 1 axis– 2 axis
• Motorized grip• Roller grip• Hoop grip• Pneumatic grip
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Pneumatic linear gripPneumatic linear grip
• Pneumatic Cylinder extends & retracts linkage to open and close gripper
• 254 robot: 2004, 1-axis
• 968 robot: 2004, 1-axis
Recommended
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Pneumatic linear gripPneumatic linear grip
• Pneumatic Cylinder, pulling 3 fingers for a 2-axis grip
• 60 in 2004
Recommended
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Motorized Linear GripMotorized Linear Grip
• Slow• More
complex (gearing)
• Heavier• Doesn’t use
pneumatics• 49 in 2001Not
recommended
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Roller GripRoller Grip• Slow• Allows for
misalignment when grabbing
• Won’t let go• Extends object as
releasing• Simple
mechanism• 45 in 98 and 2004
Recommended
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Hoop gripHoop grip
• Slow
• Needs aligned
• Can’t hold on well
• 5 in 2000
Not
recommended
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Pneumatic GripPneumatic Grip
• Vacuum:– generator &
cups to grab• Slow• Not secure• Not easy to
control• Simple• Problematic
Not recommended
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Hang on!Hang on!
• Friction: High is needed (over 1.0 mu)– Rubber, neoprene, silicone, sandpaper
• Force: Highest at grip point– Force = multiple x object weight (2-4x)– Linkage, toggle: mechanical advantage
• Extra axis of grip = More control
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SpeedSpeed
• Quickness covers mistakes– Quick to grab– Drop & re-grab
• Fast– Pneumatic gripper
• Not fast– Roller, motor gripper, vacuum
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Grip controlGrip control
• Holy grail of gripping:– Get object fast– Hang on– Let go quickly
• This must be done under excellent control– Limit switches– Auto-functions– Ease of operation
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LatchesLatches
• Spring latches
• Hooks / spears
• Speed & Control
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Latch example: 267 Latch example: 267
• Pneumatic Latch
• 2001 game• Grabs pipe• No “smart
mechanism”
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Latch example: 469 Latch example: 469 • Spring-
loaded latch
• Motorized release
• Smart Mechanism
• 2003
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Latch example: 118Latch example: 118• Spring-
loaded latch• Pneumatic
release• Smart
mechanism• 2002
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Latching adviceLatching advice
• Don’t depend on operator to latch, use a smart mechanism– Spring loaded (preferred)– Sensor met and automatic command given
• Have a secure latch• Use an operated mechanism to let go• Be able to let go quickly
– Pneumatic lever– Motorized winch, pulling a string
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Ball SystemsBall Systems
• Accumulator = rotational device that pulls objects in
• Types:– Horizontal tubes - best for gathering balls
from floor or platforms– Vertical tubes - best for sucking or pushing
balls between vertical goal pipes– Wheels - best for big objects where alignment
is pre-determined
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Conveying & GatheringConveying & Gathering
• Conveyor - device for moving multiple objects, typically within your robot
• Types:– Continuous Belts
• Best to use 2 running at same speed to avoid jamming
– Individual Rollers • best for sticky balls that will usually jam on belts
and each other
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ConveyorsConveyorsWhy do balls jam on belts?- Sticky and rub against
each other as they try to rotate along the conveyor
Solution #1- Use individual rollers- Adds weight and complexity
Solution #2- Use pairs of belts- Increases size and
complexity
Solution #3- Use a slippery material for the
non-moving surface (Teflon sheet works great)
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Roller example: 188Roller example: 188
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Accumulator example: 173 & 254Accumulator example: 173 & 254
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Questions?Questions?Thanks to:
Andy Baker (45)
www.chiefdelphi.com
www.robotphotos.org
www.firstrobotics.net
www.firstrobotics.uwaterloo.ca
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Extra StuffExtra Stuff
• Pneumatics vs. Motors
• Materials
• Shapes / Weights
• Fabrication processes
• Environment
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Pneumatics vs. MotorsSome, but not all important differences
Pneumatics vs. MotorsSome, but not all important differences
• Cylinders use up their power source rather quickly • the 2 air tanks we are allowed do not hold much• Motors use up very little of the total capacity of the battery
• Cylinders are great for quick actuations that transition to large forces• Motors have to be geared for the largest forces
• Our ability to control the position of mechanisms actuated by cylinders is very limited• We are not given dynamic airflow or pressure controls• We are given much more versatile electronic controls for motors
• Since air is compressible, cylinders have built-in shock absorption
• Cylinders used with 1-way valves are great for Armageddon devices - stuff happens when power is shut off• This could be good or bad - use wisely
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MaterialsMaterials• Aluminum, thin-wall tubing• Polycarbonate sheet, PVC tubing• Fiberglass (used rarely, but advantages)• Spectra Cable
– Stronger than steel for the same diameter– Very slippery
• Easy to route• Needs special knots to tie
– Can only get it from Small Parts and select other suppliers• Pop Rivets
– Lighter than screws but slightly weaker - just use more– Steel and Aluminum available– Great for blind assemblies and quick repairs
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ShapesShapes• Take a look at these two extrusions - both made from
same Aluminum alloy:– Which one is stronger?– Which one weighs more?
1.0”
1.0” 0.8”
0.8”
Hollow w/ 0.1” walls Solid bar
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Shapes, cont.Shapes, cont.
• The solid bar is 78% stronger in tension
• The solid bar weighs 78% more
• But, the hollow bar is 44% stronger in bending– And is similarly stronger in torsion
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Stress CalculationsStress Calculations
• It all boils down to 3 equations:
IMc
A
Ftens
tens
A
Fshear
Where: = Bending StressM = Moment (calculated earlier)I = Moment of Inertia of Sectionc = distance from Central Axis
Where: = Tensile StressFtens = Tensile ForceA = Area of Section
Where: = Shear StressFshear = Shear ForceA = Area of Section
Bending Tensile Shear
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Structural ShapesStructural Shapes
• I am willing to bet that none of our robots are optimized with respect to strength to weight ratios– We all have more material than we need in some
areas and less than we need in others.– It would take a thorough finite element analysis of our
entire robot with all possible loading to figure it all out– We only get 6 weeks!!
• But, this does not mean we cannot improve
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Fabrication ProcessesFabrication Processes
• Laser cutting causes localized hardening of some metals– Use this to your benefit when laser cutting
steel sprockets
• Cold forming causes some changes in strength properties– Some materials get significantly weaker– Be aware of Aluminum grades and hardness's
• Welding - should not be a problem if an experienced welder does it