Department of Mechanical Engineering

ME18611 – Design & Fabrication Project

Academic Year – 2022-2023
Design and Fabrication of Parallel Manipulator
In-House project
Members (Batch-10)
1. Rishab Sethuraman (201001058)
2. Sanjay Kumar S (201001064)
3. Tharun Rajan S (201001075)
4. Tushit Dev M (201001076)

Project Supervisor
Mr.J.SIVARAMAPANDIAN 1
Assistant Professor
CONTENTS
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● Introduction ● Steps for fabrication
● Literature survey ● Structural Analysis
● Literature survey summary ● Fabrication
● Scope and objective ● Programming
● Methodology ● Testing
● 3D Modelling ● Working video
● 2D component drawing ● Advantages
● Materials required ● Applications
● Bill of materials ● Time schedule
● Selection of materials ● Conclusion
● Design calculation ● References

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INTRODUCTION
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● A parallel manipulator can be defined as a closed loop kinematic chain
mechanism whose end effector is linked to the base by several independent
kinematic chains.
● Applications for the parallel manipulator are evolving steadily and are being
used in equipment for space exploration, precise manufacturing, and medical
science.
● Even though traditional serial manipulators have a big workspace and excellent
agility, parallel manipulators have started to gain wide acceptance.
● It’s being used when high carrying load and precise positioning capability is
needed.

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INTRODUCTION
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● The development of parallel manipulators can be dated back to the early 1960s,
when Gough and Whitehall first devised a six-linear jack system for use as a
universal tire testing machine.
● Later, Stewart developed a platform manipulator for use as a flight simulator.
Since 1980, there has been an increasing interest in the development of parallel
manipulators.

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LITERATURE SURVEY
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● S. Soumya and K.R. Guruprasad, Model-based Distributed Cooperative Control of
a Robotic Manipulator, IEEE International Women in Engineering (WIE)
Conference on Electrical and Computer Engineering 2015 (WIECON-ECE 2015), 19-
20 December 2015, Dhaka, Bangladesh.
● S Soumya and K R Guruprasad, “Model-based Manipulator Control and the
Computational Cost”, Journal of Advanced Research in Dynamical and Control
Systems, vol 10, issue 12, pp. 319-326, 2018. [Scopus]

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LITERATURE SURVEY SUMMARY
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● In this work the inverse kinematics solutions are derived from the closed form.
All possible solutions of this analysis are calculated by change in limb lengths
through linear actuators, and also position and orientation equations of mobile
platform with respect to fixed base platform are analyzed.
● Study of dynamic analysis of parallel manipulators to control the movement of
limbs.

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SCOPE & OBJECTIVE
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● To manufacture automated stretcher beds which can be used in any kind of
medical emergency purposes in order to efficiently transport casualties.
● It can also be used in various applications such as simulators, cranes, 8D
theatres and etc.
● To achieve the above, we have planned to use the principles of kinematics and
design a parallel manipulator consisting of 6 DOF which acts as a base for
actuation.

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METHODOLOGY
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Design and Fabrication of Parallel Manipulator

Rough 3D sketch

Selection of Materials & Components DOF Calculation

• Fabrication
Motor code implementation • Testing of motors

Assembly

Conclusion
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3D MODELLING
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2D COMPONENT DRAWING
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MATERIALS REQUIRED
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● Aluminium pipe
● Rubber bush
● Screws and Nuts
● Aluminium Sheets
● Servo Motors (MG996R 2.5A(6V) )
● Arduino board
● Motor driver
● Power supply
● Wires

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BILL OF MATERIALS
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S.No. COMPONENTS QUANTITY PRICE (INR)

1 Aluminium pipe 10 300

2 Rubber bush 12 240

3 Screws and Nuts 12 20

4 Aluminium sheet 3 Sq.ft 360

5 Servo motors 6 1200

6 Arduino board 1 1200

7 Motor drive 1 500

8 Power supply 2 1000

9 Wires As required 100

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SELECTION OF MATERIALS
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Aluminium is an extremely versatile metal with a number of advantages, it is recognised for being both
lightweight and flexible. It can be cast, melted, formed, machined and extruded meaning that it can be
manufactured into a variety of shapes and then subsequently fabricated to suit a whole variety of uses.

● Light weight - It’s about a third of the weight of steel, which makes it easier and cheaper to transport
than most other metals. The strength of aluminium can be adapted using varying alloying elements to
provide better benefits including higher strength or easier formability.

● Corrosion Resistance - Aluminium is a corrosion resistant metal that naturally generates a protective
coating. The coating formed is extremely thin and is generated when aluminium comes into contact
with an oxidising environment. This protective aluminium oxide layer helps protect the surface of the
metal from corrosion.

● Reflectivity and Ductility - Another benefit of Aluminium is that it serves as a good reflector. It is used
in rescue blankets and light fittings because of its ability to reflect both light and heat.
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DESIGN CALCULATIONS (For Manufacturing)
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The following parameters are known and listed below:

Mass of each link= 294g= 0.294kg

Since we have six links, mass= 6*0.294= 1.764kg

Mass of top plate= 250g= 0.250kg

=> Mass distribution over each link= 0.250/6= 0.041kg

Total Mass M= 2.014kg

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DESIGN CALCULATIONS (For Manufacturing)
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STEP 1: MATERIAL SELECTION
We have selected Aluminium 24345 as our material in reference with the PSG data book
pg.1.30.
Tensile stress [σ]= 480 N/mm2
STEP 2: CALCULATION OF DESIGN TORQUE:
Motor specifications: V= 6V, I= 2.5A, N=58.82rpm

Power P= V*I
= 6*2.5
P = 15W 15
DESIGN CALCULATIONS (For Manufacturing)
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Also, P= 2πNT/60
=> T= 60P/2πN
= 60*15/(2*3.141*58.82)
Design torque, [T]= 2.43 N-m
STEP 3: PAYLOAD CALCULATION, FOR SINGLE LINK:
Force, F= m*g
where, m= mass distribution over a single link= 2.014/6
m= 0.335kg
=> F= 0.335*9.81= 3.28 N
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DESIGN CALCULATIONS (For Manufacturing)
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Torque, T= F*r
where r= crank radius fixed at the
upper plate= 4cm= 0.04m
T= 3.28*0.04
T= 0.131 N-m < [T]
=> DESIGN IS SAFE
STEP 4: CHECK FOR STRESS:
i) on joints,
Here the joint is an L-clamp. So, maximum stress will occur at the minimal area of the
cross-section, i.e. at the top face of the clamp.
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DESIGN CALCULATIONS (For Manufacturing)
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Cross-sectional area of the clamp, Aj = l*b
where l= 1.5cm, b=1cm
=>Aj = 1.5*1= 1.5 cm2= 0.015 mm2

Weight acting on the joints,Fj=*g

where mj= m+payload distribution of each link

Let us take payload distribution load as 1kg
=>payload distribution of each link= 1/6 = 0.16kg
mj= 0.328+0.16= 0.488kg

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DESIGN CALCULATIONS (For Manufacturing)
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Fj= 0.488*9.81= 4.787 N

Tensile stress, σj= Fj/Aj= 4.787/0.015

σj= 319.15 N/mm2 < [σ]

=> DESIGN IS SAFE.

ii) on links,
length of the link, l= 42cm and width, w= 1.5cm
Cross-sectional area, Al= l*w= 42*1.5
= 63 cm2
Al=0.63 mm2
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DESIGN CALCULATIONS (For Manufacturing)
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Weight acting on the links,Fl= ml*g
where ml= mass distribution on the link
= mass of a single link+ mass distribution of the plate
over a single link
= 0.294+ 0.250/6
ml= 0.33kg

=> Fl= 0.33*9.81= 3.23 N

Tensile stress, σl= Fl/Al

= 3.23/0.63
σl= 5.138 N/mm2 [σ]
=> DESIGN IS SAFE
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DESIGN CALCULATIONS (Working)
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Angular displacements:

Yaw (𝝋) along Z-axis

Pitch (𝜽) around Y-Axis
1.
2.
3. Roll (ɸ) Around x-Axis

Diagram to be inserted

= x’cos(𝝋) - y’sin(𝝋)
x=OA-BC

=x’sin(𝝋) + y’cos(𝝋)
y=AB+PC

z=z’ 21
DESIGN CALCULATIONS (Working)
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Considering Yaw (𝝋):

Where Rz( 𝝋 ) is the rotation matrix, it can be represented as shown below,

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DESIGN CALCULATIONS (Working)
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Similarly considering the Pitch (𝜽) we get:

Similarly considering Roll (ɸ) we get:

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DESIGN CALCULATIONS (Working)
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For rotating platform relative to the base:

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DESIGN CALCULATIONS (Working)
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Consider the leg
leg of
of Stewart
Stewart platform:
platform:

Using pythagorean theorem we also have

On Rearranging the above Equation,

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DESIGN CALCULATIONS (Working)
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The above Equation on further solving reduces to,

In general Mathematics Relation the above equation is said to be in the form of ,

Using the Trigonometry Identity for the sum of sine waves

Where c= and

=b/a

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DESIGN CALCULATIONS (Working)
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Therefore ,

Where ,

The above equations have enough data to calculate the lengths of effective length of all legs and
associated servo arm angles.

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STEPS FOR FABRICATION
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1. Design and Planning:
- Determine the type and configuration of the parallel manipulator based on the required application
and specifications.
- Perform kinematic and dynamic analysis to optimize the design.
- Create a detailed design using computer-aided design (CAD) software, including the dimensions,
joints, links, and actuators.

2. Material Selection:
- Select appropriate materials for the manipulator's structure, considering factors such as strength,
weight, and durability.
- Choose materials for the links, joints, and other components based on their mechanical properties.

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STEPS FOR FABRICATION
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3. Manufacturing Components:
- Fabricate the individual components of the parallel manipulator, such as the links, joints, brackets,
and actuators.
- Use machining processes like milling, turning, and drilling to shape the components according to
the design specifications.
- Ensure accuracy and precision during the manufacturing process to maintain the required
tolerances.

4. Assembly:
- Gather all the fabricated components and prepare them for assembly.
- Align the components according to the design and use fasteners (e.g., bolts, screws) to join them
together.
- Follow the assembly instructions or guidelines provided by the design to ensure proper alignment
and fit.
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STEPS FOR FABRICATION
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5. Motor Installation:
- Install the motors at the specified locations on the manipulator's structure.
- Connect the actuators to the corresponding joints or links using appropriate mechanical couplings
or transmission mechanisms.

6. Calibration and Testing:

- Perform calibration procedures to ensure the manipulator's accuracy and precision.
- Test the parallel manipulator's functionality and kinematic performance using predefined motion
patterns or test cases.
- Make adjustments as necessary to achieve the desired performance and accuracy.

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STRUCTURAL ANALYSIS
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STRUCTURAL ANALYSIS
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FABRICATION
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PARTS USED

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FABRICATION
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DURING ASSEMBLY

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FABRICATION
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AFTER ASSEMBLY

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PROGRAMMING
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⦁ In our project, the significant factor will be motors for the movement of
links
⦁ The working of the motors is controlled using an Arduino board
⦁ Embedded C program is being used for coding

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INITIAL TESTING
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● After assembling every parts together using screws and nuts,
we have coded the Arduino board with the sufficient codes
to operate the motor to get the required motion with the 6
kinematic links.
● Initially we faced consequences such as irregular tilt and
uneven working of motors.
● After 2 / 3 trials we rectified the issue and the manipulator
works with the code properly by achieving high accuracy and
required angle of tilt and height of the bed is either increased
or decreased.

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WORKING VIDEO
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ADVANTAGES
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⦁ Low cost automation project
⦁ Less power consumption
⦁ Operating principle is very easy
⦁ Installation is very easy
⦁ Simple in construction
⦁ Accuracy can be achieved
⦁ It has various useful applications

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APPLICATIONS
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● Flight simulators make use of the platforms 6 DOF to simulate orientation and
motion. The Stewart Platform can accurately orient to the correct roll, pitch
and yaw, and their high-dynamic capability can create linear and nonlinear
forces, like a bump.

● Shaketables make use of this capability to create high-acceleration, low-

displacement moves.

● Fiber-optic equipment can be aligned using a Stewart Platform because they

must be accurately positioned and oriented, enabling the light to refract and
the optic signal to operate properly.

● Major industrial applications of this devices are in Flight simulators and

Automobile simulators.

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TIME SCHEDULE
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Activities/Time period
FEB MAR APR MAY

Literature review

Parameter Selection

Modelling

Preliminary experimentation

Experimentation with influential parameters

Metallurgical and Mechanical Characterization

Post-processing of WAAM component

Report preparation

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CONCLUSION
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● The prototype of our project “PARALLEL MANIPULATOR” is completed, ie., creating a
6 arm connecting two parallel plates which can move without any constraints with 6
Degrees of freedom which can be used in various applications.

● Circuit connections of our project is completed.

● Initial testing is done and links are verified to be working with the given commands.

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REFERENCES
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1. Chung M., Malone E., Tolley M. T., Chepaitis A. J., Lipson H., (2008) “Object Augmentation for the Visually Impaired Using RP”, Proceedings of the 19th
Solid Freeform Fabrication Symposium, Austin TX, Aug 2008
2. Dafoui, El-Mouloudi, (1998) “Analysis and Design of a Six-DOF Parallel Manipulator, Modeling, Singular Configurations, and Workspace”, IEEE Transactions
on Robotics and Automation, Volume 14, No. 1
3. Grenouilleau J. C., O. Housseini, and F. Pérès., (2000) “In-Situ Rapid Spares Manufacturing and Its Application to Human Space Missions”, Proceeding of
Space 2000, p.42-48.
4. Jongwon Kim, Chongwoo Park, Sun Joong Ryu, Jinwook Kim, Jae Chul Hwang, Changbeom Park, Iurascu, C.C., “Design and analysis of a redundantly
actuated parallel mechanism for rapid machining” , IEEE Transactions on Robotics and Automation, August 2001, Volume 17, Issue 4, p. 423-434.
5. Kang, Ji-Yoon, (1996) “Robust Tracking Control of Stewart Platform”, Proceedings of the 35th Conference on Decision and Control, Kobe, Japan,
December 1996
6. Lazard, Daniel, “The (true) Stewart Platform Has 12 Configurations”, IEEE 1994
7. Lipson, H., (2006) "A Relaxation Method for Simulating the Kinematics of Compound Nonlinear Mechanisms", ASME Journal of Mechanical Design,
Volume 128, Issue 4
8. Malone E., Lipson H., (2007) “Fab@Home: The Personal Desktop Fabricator Kit”, Rapid Prototyping Journal, Vol. 13, No. 4, pp.245-255
9. Masuda, T., “Specific Kinematic Changes in a Linear-Actuated Parallel Mechanism According to Differences in Actuator Arrangement”, Proceedings of the
2000 IEEE/RSJ Internal Conference on Intelligent Robots and Systems
10. Merlet, J. –P, “Solving the Forward Kinematics of a Gough-Type Parallel Manipulator with Interval Analysis”, The International Journal of Robotics
Research 2004, Volume 23, No. 3
11. Petko, M., Karpiel, G., “Mechatronic Design of a Parallel Manipulator for Milling”, 2005 Proceedings IEEE/ASME International Conference on Advanced
Intelligent Mechatronics., p.759-764
12. Weiss, L. and Prinz, F., 1998, "Novel Applications and Implementations of Shape Deposition Manufacturing,” Naval Research Reviews 1, Office of Naval
Research
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Title

THANK YOU

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