Team 5 Andrew Sloggy, Andrew Denbow, Evan Thurman, John Strudel, - - PowerPoint PPT Presentation

Team 5

Andrew Sloggy, Andrew Denbow, Evan Thurman, John Strudel, Elan Weinberg, Joey Suprick

Project Introduction

Design, build, program, and demonstrate a computer controlled welding torch adapter.

• Must hold a MillerMatic 212 welding torch and

accommodate strain relief

• Must terminate in a 12.7mm shaft to be mounted in a

CAT40 collet holder

• Provide 2 rotary degrees of freedom
• Presses, holds, and releases the switch on the welding

torch

• Performs a predermined homing and positioning sequence

Project Introduction

The project will be evaluated based on the following equation: Where:

• t is time in seconds
• m is mass in kilograms
• c is cost in dollars

230 33 16500 Score t m c   

Project Introduction

Based on this equation

• The time to complete the sequence should be 6.9 seconds
• The mass should be 1 kg
• The cost should be $495

230 33 16500 Score t m c   

Isometric View 1 Isometric View 2

Mechanism Introduction

An automated welding device that is mounted in a CNC milling machine, capable of actuating a welding torch. The device is programmed to carry out a sequence of movements as required by the operator.

Mechanism Introduction

Our Robot is composed of 5 subsystems:

• 1. The Base
• 2. Rotary Axis 1
• 3. Rotary Axis 2
• 4. Trigger Actuator
• 5. Control

Isometric View 1 Isometric View 2

Base

• The Base supports all other subsystems.
• It freely rotates around the collet adapter

○ It rests on a thrust bearing to support the load in the z-axis

Base Failure Analysis – Rotation 1

Max: 5.04MPa

Von Mises Yield Strength: 41.36 MPa 5.04 MPa 5.88 Pa 2.53 MPa Deflection 0.008 mm 0 mm 0.004mm

Max: 0.008 mm

Max: 5.76 MPa

Von Mises Yield Strength: 41.36 MPa 5.76 MPa 0 MPa 2.88 MPa

Base Failure Analysis – Rotation 2

Max: 0.017 mm

0.009 mm 0 mm 0.017 mm Deflection

Rotary Axis 1

• Rotary axis 1 is attached to the base and

provides 180° horizontal rotary motion

• A stepper motor and a micro switch will

control the movement. ○ The microswitch is located on top of the base and a flag that is attached to the collet adapter will trigger it as shown.

Rotary Axis 1

Stepper Motor 1 with Planetary Gearbox Collet Adapter Thrust Bearing Thrust Washer

Rotary Axis 1 – Switch Actuation

Calculations for Stepper Motor 1

Stepper Motor 1 Sizing Tool

Rotary Axis 2

• Rotary axis 2 controls the 45° vertical

motion ○ Movement is controlled by a stepper motor and a microswitch ○ The switch is located on the outside

• f the base and is triggered by a flag

that is attached to the shaft on the handle holder as shown

• This also carries the trigger actuator

which is controlled by a servo motor

Rotary Axis 2 – Overview & Switch Actuation

Calculations for Stepper Motor 2

Stepper Motor 2 Sizing Tool

Trigger Actuator

• This gives the ability to press, hold,

and release the trigger on the welding torch.

• The servo motor will attach directly to

the RP handle holder ○ A cable will be used to depress the trigger ○ A force of 8.5N is needed to adequately depress the trigger

Trigger Actuator

Trigger Actuator - Servo Calculations

Control

• Microswitch (x2)
• Arduino UNO

○ Power Supply

• Arduino v2.3 Motor Shield

○ Power Supply

Control

• The Arduino hardware and software will be used for controlling the electrical

components of the robot. The programming language is C++ or C.

• The Arduino Uno Rev3 will have a v2.3 Motor Shield stacked on top.

○ The v2.3 is optimal because of its h bridge circuit design that allows current load to flow in 2 directions for the stepper motors. ○ Allows 1.2 amps per bridge with 3 amps max for 20ms

• The microswitches will be used for home position calibration.
• Both stepper motors will be controlled independently of one another but will share

the same power source

• A 9 volt battery will supply 500mA of current to the servo. A 26-30 ohm resistor will

restrict current to 340mA.

Circuit Construction

Servo Stepper 2 Stepper 1 Power Supply from USB port into Barrel Jack Switches Servo Stepper 2 Stepper 1 Power Supply from USB port into Barrel Jack Switches Power Supply to Motor Shield

Code

Bill of Materials

Isometric View 1 Isometric View 2

Summary

Questions?