Design of Gantry Robot

Design of Gantry Robot
Bahirdar University of Technology
Design of Gantry
Robot
Prepared: Mesfin B., Muluken T., Samson D., Abayneh T.
December 2014
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December 2014
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Contents
Chapter One............................................................................................................... 1
Introduction................................................................................................................ 1
1.1.
Recognition of Need....................................................................................... 1
1.2.
Problem Statement........................................................................................ 1
Objectives............................................................................................................ 2
Minimum Functional Requirements......................................................................2
What are the Constraints?.................................................................................... 2
Design Specification............................................................................................. 2
Chapter Two................................................................................................................ 3
Conceptual Design..................................................................................................... 3
2.1.
Description of criterias used.........................................................................3
A) Type of Actuation Used;................................................................................. 3

B) Control System.............................................................................................. 4
Suggested Alternative............................................................................................. 4
Making Decision...................................................................................................... 6
Final Design Specification........................................................................................ 7
Gripper Mechanism Selection............................................................................... 8
Chapter Three........................................................................................................... 15
Force Analysis........................................................................................................... 15
3.1.
Force Analysis at the Gripper.......................................................................15
3.2.
Force at the Vertical Cylinder.......................................................................16
3.3.
Force Analysis in each Vertical Beam...........................................................16
3.4.
Force Analysis on the Horizontal Beam........................................................18
3.5.
Force on horizontal cylinder:........................................................................19
3.6.
Gripper force analysis..................................................................................19
Chapter Four............................................................................................................. 21
Mechanical Components Design............................................................................... 21
4.1.
Design of cylinders and accessories............................................................21
4.1.1) Design of vertical cylinder and its accessories.........................................................21

4.1.2. Design of vertical cylinder and its accessories.........................................................28
4.1.3. Design of Gripper cylinder and its accessories.........................................................34
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4.2.
Design of structure (beams horizontal and vertical)....................................39
4.2.1) Design of Horizontal Beam......................................................................39

4.2.2) Design of Vertical Beam..........................................................................40
4.3.
Gripper Components Design........................................................................43
Design Evaluation................................................................................................. 47
Chapter Five............................................................................................................. 48
Design of Control System......................................................................................... 48
5.1) Selecting the type of control system to be used............................................48
5.2) Selecting the type of valve to be used...........................................................48
5.3) Motion cycle of the gantry system.................................................................51
5.4 The speed and flow rate calculation................................................................54
Conclusion and Recommendation...................................................................................... 57
Bibliography............................................................................................................. 58
Appendix.................................................................................................................. 59
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Chapter One
Introduction
1.1. Recognition of Need
Now days, the comfort of human being has got great consideration in the planning and developing a
certain manufacturing process, this because of the improvement of life standard of the people. In addition,
working environments which are dangerous and contaminated, repetitive in their nature, the use of human
labor will not be a satisfactory solution, and then introducing a methodology or mechanisms to solve
these problems is needed. Therefore automation or robotics becomes a very vital and important
engineering solution to such problems. Mostly in industry environment they become very crucial this is
for the purpose of increasing productivity, to minimize cost of manufacturing and minimize effort of and
risk at the work place of the workers
Considering so, in most of early installed soft drink and beverage industries, the loading of bottles from
the conveyor to the bottle box is manual process. Even though this work place has not significant health
problem due to the use of human labor it hinder the production rate of the industries. It is a
straightforward replacing this manual loading process with automated machine will result a better
production rate for the industries. To limit the design the process the designer consider one of the coca
cola bottling industry located in the capital of Ethiopia. The industry is one of the first installed soft drink
industry due to the long time service the bottle loading process is manual which decrease the production
rate of the industry significantly.
Generally, the basic aim of this project is to solve a problems that mostly become a challenge to the
bottling industry, more specifically on bottling station, by design an automated system which can be
manufactured domestically and have simple control system which can be operated by low technical
requirements.
1.2.
Problem Statement
In this century, the development of a country is highly dependent on the technology level that the
industries are using for production. Among the most necessary inputs, material handling equipments got
big attention. Because of the production speed, accuracy, product safety, capacity, cost and all others are
controlled the material handling equipment incorporated. Due this, developed countries are well
accounted with this equipments and still they are improving the quality, speed, performance by
innovating new material handling equipments .currently, robots are the tip material handling equipments.
More specifically in the domestic industries, most of the materials handling equipments are low
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efficiency, low speed and accuracy and also have other defects related to power consumption and control.
These factors are pulling back the development and the profitability of the industries; using one low speed
machine will slow down the product to be produced. In other way this may result unsatisfied customers
demand and low development rate. Considering the above conditions and efforts, the project aimed to
design material handling robot for coca cola bottles (palletizer) and modification method for the use of
other product transportation whenever needed. Generally, the project will bring improved material
handling equipment the will reduce manpower utilization, low operating and manufacturing cost, high
efficiency and speed, easy of control and to interface with other machines.
Objectives
The main objective of the project is stated as follows;
To design a pick and place material handling system (robot) for handling bottles and similar such
products, which will Function automatically replacing human effort.

Implementing robotics principle and its operation to replace the human task and reduce the labor
cost.
Improving production rates with automation, and accuracy and repeatability with maximum
efficiency
To show the direction of manufacturing and modification of the design robot for other product use.
Minimum Functional Requirements
The material handling equipment should handle 24 bottles at a time,

The should deliver the bottles to the bottle box,
Minimum bottle damage due to the grippers.
What are the Constraints?
The speed of the machine should fit with speed of the production rate of the plant
The dimensions of the machine should also fit with the dimension of the plant conveyor and the
bottle box.
Design Specification
The size of the conveyors, and the gap between them, and the height from the ground should be
stated as equal to the corresponding dimensions in the factory. The gripper maximum height and
related dimensions can be determined form the height of the bottles and are included after the
conceptual design.
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Chapter Two
Conceptual Design
At this stage several solutions will be introduced and evaluated to choose one suitable solution among the
alternatives suggested. Among the possible solutions to do this job the most convenient three are
considered for detail investigations.
To achieve the primary objective of the project, among variety of robot available, by putting the following
criteria the type of robot is selected,
Degree of freedom
Number of link
The type of actuation used
Type of control
Cost of operation and manufacturing
Compatible of the technology
2.1. Description of criterias used

To evaluate and compare using the above criteria among robots the following point is found to be
important.
A) Type of Actuation Used;

For general case there are a number of actuation system available such as, electrical (motor either stepper
or servo), mechanical, hydraulic and pneumatic.
Since robots are mostly used either motors or pneumatic actuation for the purpose of simplicity they are
adopted as primary criteria for the type of the robot to be selected.
Motors: mostly used in robots is either stepper or servos which are special types among common types of
motors used to day. This is because integration with programming machine is possible for sequence
control. Such motors have complex control system because they have their own programming language
since mostly they are applicable in area of complex motion is desired.
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Therefore as compared to other means of actuation this motor is too costly and in related efficiency is too
high in achieving the desired goal.
B) Control System
There is different control systems available based on the type of actuation type used and the complexity
also vary as the type of actuation too. More generally the complexity decrease as;
Motor
Pneumatic/Hydraulic
Mechanically Actuated
Suggested Alternative
This picking and placing robot is intended to pick and place a bottle from conveyer and place it to the
box. For this purpose the geometry should be easy and have minimum of two degree of freedom. By
bearing this and the above mentioned criteria the following three best alternatives are suggested
Alternative One (A1)
3 degree of freedom and 3 motors used to achieve desired motion
Fig 2.1 Alternative one
3 number of link
Stepper/servo motor control system and Motor assisted gripper
This alternative has relatively lower number of components and more simple than the other alternatives.
But it has limited load carrying capacity and stability problem.
Alternative two (A2):
4 degree of freedom and 3 motors and 1 prismatic cylinder used
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Fig 2.2 Alternative two
4 number of link used
Stepper/servo motor control system and Motor assisted gripper
Such arrangement has stable structure with 4 input motion requirements. The system is more complex
than the first alternative because of the number of links used.
Alternative three (A 3):
Gantry type of robot and 2 degree of freedom
Fig 2.3 Alternative three
5 number of link
Mechanical or limit switch control system used and Pneumatic gripper
Gantry Robots offer significant advantages over articulated arm robots for high speed automation:
larger work envelopes (not restricted by arm length)

overhead mechanics (free up floor space)
better suited for multiple machines and conveyor lines
better handling of large or awkward payloads
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Making Decision
Now it is time to select the best alternative suitable for the intended application. To select the best
alternative the Weight Decision Matrix is used. The design criteria which are best suited for selecting
among alternatives are motioned below
A) Actuation system: this is selected as the main criteria for evaluating of robotics because it
governs the whole robotics system in relation to the cost of the system in
Control system cost and complexity
Cost of the whole robot
Simplicity in technology
Efficiency
Therefore by putting all this weight factor of = 0.3 is given

B) Operation cost: this is about where the energy source is? That is for motor electric power and for
pneumatic fresh air.
Note: For the gantry robot since it is possible to use the plant compressor for pneumatic source which is
air and the motor need additional cost for electric power supplies, therefore pneumatic actuation have low
operation cost as compared to motor actuation.
Then by considering all above facts weight factor of = 0.2 is given
C) Compatibility Technology of the robot: since among main objective of the project is designing
a robot to the domestic soft drink industries this become a primary criteria.
As mentioned above pneumatic actuation system have simple control system as compared to that of motor
actuated because of the possibly to use mechanical switch or limit switch in pneumatic then the
technology for pneumatics system is can be easily compatible to the domestic environment and for the
operators who supposed work on this machine.
Therefore by putting this in consideration weight factor of = 0.2 is given
D) Manufacturing: This criterion lies up on the probability of manufacturing the robot
domestically.
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For this reason this criteria has a weigh factor of = 0.2 is given
E) Efficiency: This criterion is used to measure the efficiency of the robot since efficiency matters in
productivity and profit and comes as basic evaluation tool. For general case pneumatic actuation
have less efficiency than motor actuation system.
Therefore this criteria weight factor of = 0.1 is given
Table 2.1: Decision Matrix
Design Criteria
Actuation
System
Operation
Cost
Compatibility
of Technology
Manufactura
bility
Efficiency
Total
Weight factor
0.3
0.2
0.2
0.2
0.1
Alternative One
75%
75%
22.5
Alternative Two
80%
Alternative Three
90%
85%
15
70%
24
14
75%
14
90%
16
90%
1
6
17
70%
80%
27
80%
15
85%
18
79.5%
9
70%
74%
86%
80%
17
Note: the above evaluation is based on the criteria and facts suggested above and high percentage is given
which is favorable to the criteria.
Therefore from decision matrix table alternative three has got the highest percentage as compared to the
other alternatives (86%) and based on this assessment the gantry type robot is selected as best solution for
the problem identified.
Final Design Specification

In this section the other over all dimension of gantry system are being decided. Note: some of the data are
taken as size of the plant standard (form the existing dimension of the plant).
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1) Sizes of the conveyor the plant have two row of conveyor for the purpose of hosting bottle and box.
For general case the two conveyor take size of the box, which is standards size of the box for coca
cola is:
26.5
Fig 2.4 Conveyor dimensions

2) The gap between the two conveyors: this gape should be decided so that using maintenance, an
operator can move freely in order to maintain and related operation.
For this the gap between the two conveyors is to be 500 mm. See fig 2.5
3) Height of the conveyor from ground: as part of the factory standard having height of 1 meter is taken
see fig 2.6
4) Maximum gripper height: this height can be determined from the height of a bottle and the height of
the box and by giving allowance of 50 mm.
height of box+ height of bottle +50 mm=280+250+50=580 mm see fig 2.6

5) The gap between the two position of the griper (horizontal): this is determined as;
450
2
450
2
+500
= 950 mm See fig 2.5
Gripper Mechanism Selection

Type and classification of end effectors
End effecter s may broadly classify as grippers, tools or sensors depending on their design and intended
purpose. Grippers represent by far the majority of end effector types.
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Robot grippers: The gripper of a robot is the only part that has mechanical contact with the object; its
main functions are to grip objects, hold objects, and release objects. Gripping establishes a defined
position and orientation of the object relative to the robot. Holding secures the defined position and
orientation relative to the robot during the material transfer route and assembly operation. When releasing
the object, the relationship between gripper and object is given up at a specified point. The possibilities of
executing different handling tasks are limited mainly by the flexibility of the gripper system. Generally, a
conventional gripping device for industrial robots to hand only one or few objects of similar properties
(shape, size, weight, etc.)
The main factors to be considered for selecting gripper:
The object to be handled.
Sequence of operation.
The robot mechanism.
Environmental conditions.
The object: The objects to grasp are the first thing to be considered when choosing a gripper. The object
influenced parameters are:
1. Geometrical parameters are:
Object size.
Number of potential gripping surface.
Position of potential gripping surface.
Distance of gripping surface.
Geometry of gripping surface.
2. Physical and technological parameters are:
Mass.
Material.
Inherent stability.
Delicacy of surface.
State of surface.
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Temperature.
Note: Variations of the above factors influence the required gripper flexibility and the force that must be
applied by the gripper to guarantee a safe grip. Therefore additional external resulting forces must be
considered while computing the necessary gripping forces in the range or assembly phase.
Feeding, storage, and fixture devices: The accessibility of parts, their minimum distances, and any
positioning uncertainties influence the design of the jaws and the smallest and widest possibility jaw
distances. Depending on the device, additional external resulting forces must be considered while
computing the necessary gripping forces in the designing of grippers.
Sequence of operation: The definition of the sequence of operations is a major point in the design of
gripper(s). It influences the cycle time of the work cell, and consequently its productivity, and it
determines the required flexibility of gripper(s).
It may note that all these objects properties are not static, but are subject to change during the
manufacturing process. Milling and assembly operations change object weight, size and geometry. The
variations of these factors influence the required gripper flexibility. The object size, its mass, the
orientation of potential gripping surfaces, and friction between gripper and object influences the force that
must be applied by the gripper to guarantee a safe grip. The geometry of potential gripping surfaces, the
delicacy of surfaces, and the expected object temperatures influence the design and the material of the
gripper jaw.
Mechanical grippers: The efficiency of mechanical grippers depends on the cargo and the nature of
contact that is point, surface. The gripping force can be calculated thus:
Gripping=applied force coefficient of friction

Note that the gripping force is independent of the area of contact. The stability and rigidity of the hold
component, however, may be improved by altering the mode of the application of the force. Because of
these; we use v-type of gripper for clamped circular type of bottles.
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Fig 2.5 Line contact, point contact, surface contact mechanical grippers
Mechanical grippers normally require the movement of one or more elements (usually some form of jaw)
under the control of (post-assisted) mechanism to achieve a gripping action on the Cal go. Extruded
surface on external surface of a coca cola bottle will enhances the grasping system more efficiently. These
are the basic advantages of mechanical grippers. Another advantage of the mechanical grippers is: the
same end effectors can be utilized in different applications by simply changing gripper jaw.
Classification of mechanical grippers:
One classification identifies coarse grippers or precise grippers depending on the accuracy and
sophistication of their construction and their intended purpose.
1. Coarse grippers: Coarse grippers are found in applications where components are to be held,
transported and manipulated often with in large spans of movement and with relatively little accuracy.
2. Precise grippers for accurate holding positioning and orientation of the cal go being manipulated.
They are deployed in loading and unloading of machine tools and other manufacturing processes,
pick and place applications, and assembly operations. By definition their design and construction are
articulated and efficient.
A second classification distinguishes between hard and soft grippers.
Hard grippers: they are mostly applicable to grasp a fixed size and shape. These grippers are designed to
take up the shape of the cal go, or being inserted inside a vessel, before pressure is applied to expand the
gripper to achieve the gripping action.
Soft grippers are useful in circumstances where:
A. There is number of different shaped products need transporting without requiring time consuming end
effecter changes.
B. The gripper needs to be tolerant of changing in size or shape as a single component.
C. It is desirable to equalize the gripping pressure on fragile component.
D. Marking of the component surface must be reduced to a minimum or eliminated.
Therefore from above necessary point of view, we select soft type grippers for safety purpose since the
product is glass.
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Third classification of mechanical grippers is based on the design and operation characteristics of the
gripper.
1. Parallel or translational jaw grippers: In these design, usually two jaws accomplish gripping via a
linear or parallel motion relative to each other. Gripper design may move both jaws towards and away
from each other or there may be one fixed and one moving jaw.
Fig 2.6: Parallel or translational jaw grippers

2. Scissor or pivoted translational jaw grippers: In this design, gripping action results jaw movement
provided by the action of one or more links operating the pivots. This has the advantage that force
magnification can be achieved thus improving characteristics.
Fig 2.7: Scissor or pivoted translational jaw grippers:
3. Expansion grippes: Typical of soft grippers are the expansion and contraction grippers.
These involves inflation bladders which, when demand can be introduced in to holes or
cavities provided with component. once in place bladders can be inflated to take up the
internal shape of component and supply sufficient pressure to grip and lift the component
without external gripping, similar loose bags, filled with granular material such sand or
magnetic powder ; can dragged over the component cargo. An applied vacuum or an
electromagnetic field gives the granular material enough rigidity to hold the form of the
component, and enough strength to hold and or lift it. These grippers are especially suited to
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those applications where fragile and delicate components (such as glass containers, sand
cores etc) need to be handled without fear of breakage.
Disadvantages of expansion grippers:
Difficulty of sensing whether the object is present or not.
Gripping action is not precisely defined.
Difficult to predict the exact position of the gripped component relative to the end of the
robot arm.
Fig 2.8: Expansion grippers

Actuating or driving system
The most common drive concepts for mechanical grippers are pneumatic, hydraulic, electric and
electromagnetic.
1. Pneumatic actuator
In pneumatic system, compressed air is used to transporting medium for energy.
Pneumatic systems are characterized by simple construction, low cost, easy maintenance, short
reaction times, and very good performance for weight ratio.
With pressure reducer, different gripping forces can easily be realized. The major drawback of
this actuation is complicated control of the jaw position due to the compressibility of the medium.
The medium, air, is usually available in the environment of a robot and can even be used in
explosive environment.
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2. Hydraulic actuator system
They are generally more costly. Hydraulic oil must be supplied and oil pressure must be
generated. High force is possible with small unit. But in comparison to pneumatic ally actuated
grippers, it is more difficult to adjust the level of the clamping force. The hydraulic grippers
needs flow control unit and relief valve.
The working medium is oil rather than air, which is not easily available.
They are used for heavy duty application.
3. Electrical actuation system:

Electric motors require reduction gears, gripping force are generally lower than in pneumatic and
hydraulic systems and their control times are longer. The typical application for electric gripper systems is
handling and assembly of sensitive, lightweight parts. Examples are grippers for complementing
electronic boards with special chips or handling parts with no inherent stability.
Therefore we choose pneumatic drive system for our mechanical gripper by considering merits and
demerits of different kind of actuating system as listed above.
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Chapter Three
Force Analysis
For the purpose of this project a typical coca cola bottle is chosen because there is coca cola soft drink
manufacturing plant in the country which encountering problem in bottle handling that the project target
off.
Bottles
1) Height of the bottle: the currently updated coca cola bottle has a maximum height of 250 mm, the
Gripper
Bottlesgripping height of 220 mm and diameter of 30 mm, and maximum diameter of 50 mm.
Gripper
2) Weight of bottle: the maximum weight of a bottle that the bottle at loading condition is 720 gram.
3) Working load: for the 24 bottle to be handle the working load is to be calculated as
24 0.72 kg=18 kg
Considering service factor and gripper weight on vertical cylinder to be 1.75 the total pay load is to be
determined as;
F=mg 1.75=18 kg 10 1.75=315 N
3.1. Force Analysis at the Gripper

This section is backbone of the whole gantry system because it used to grip the bottle at the picking
position and release at placing position, therefore careful analysis should be done.
Bottles
To achieve this all the load acting on the gripper is taken as uniformly distribute.
Gripper
At each bottle gripper the individual force acting is the total pay load divide by total number of bottle to
be handle that is 24 as shown in fig 3.1., i.e. force on each gripper is 13.125N.
13.125N
Fig 3.1 Bottle at the gripper
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13.125N
13.125N

3.2. Force at the Vertical Cylinder
The purpose of this cylinder is to move the gripper in up and downward movement. Then the force
analysis is assumed that the given center of gravity is about 315 N (see fig 3.2)
Fig 3.2 Force set up in the vertical cylinder
3.3. Force Analysis in each Vertical Beam

This beam is (vertical) is used to support and make stable the gantry system and also maintain alignment
of the stricter. Force on the beam is compression load and bending moment. Since the effect of bending is
low as compared to the effect of compression force it is neglected.
The maximum load for this vertical beam is occurring when the vertical cylinder is at its three positions.
At the picking position
315/2 N
1275
325
A
Fig 3.3 Vertical Beam Loading at the Picking Place
Therefore the force at A and B is calculated from Newton second law.
M A=0 .(3.1)
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F B 1.6 m 315/2 N 1.275 m=0
Solving for FB,
F B=125.5 N
Note: In the above equation the total pay load is divided by two because it act at the center of gantry
system the center of gantry is being handled by the two vertical beams.
The force at A is calculated from the following equation 3.2
FY =0 .. ( 3.2 )
F A + F B315 /2 N=0
Solving for FA will be,
F A =315/2 N125.5 N=32 N
At the middle of span

315/2 N
800 mm
800 mm
Fig 3.4 Vertical beam loading at the middle of span

Then using Newton second law of motion the force at the two positions can be determined easily.
F B 1.6 m 315/2 N 0.8=0 , from equation 3.1

Solving for FB,
F B=78.75 N
Since the cylinder is at the middle of the beam the force at A and the force at B is equal,
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F A =F B =78.75 N
At the placing position
At this position since the then geometry is symmetric the force set up will be similar to that of the picking
position but the force at A and at B will be reversed. Then, FA =125.5 N and FB = 32 N
Therefore form above the design load should be the maximum force at either picking or placing fore.
Then, F=125.5 N is the design load.
3.4. Force Analysis on the Horizontal Beam

This beam (horizontal) is used to allow horizontal movement and support the two vertical and horizontal
cylinders. By taking the maximum carrying load of the cylinder that is 315 N, the force on each
horizontal beam is half of the maximum load. Fbeam= 157.5N
The possible maximum stress occurs at three positions these are:
At the picking position:
This beam is subjected to bending moment and free body diagram is
Fig 3.5 Horizontal beam loading at the picking position of span

197 Nm
51.8 Nm
Fig 3.6 Bending moment diagram 157.5 N
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A
1275
325

At the placing position:
Direction of slide
At this point since the gantry is symmetric the bending moment is as similar to that of the placing
Sliding surface
position. But the moment at A will take the moment at B in picking position. The same is to that of B.
Horizontal beams
Normal force (N)
3.5. Force on horizontal cylinder:
The force on this cylinder will determined by assuming the whole vertical load is taken by the horizontal
beams so there is no vertical load on this cylinder and cylinder rod. This supporting mechanism helps our
cylinder from failure due to bending. But the cylinder force applied should withstand frictional resistance
during sliding motion of the member on the horizontal beams.
This force can be calculated as follow:
Frictional force (Ff)
Fig 3.7: Force on horizontal cylinder
F f =N .. .(3.3)
Where: N: normal force which is the total vertical load = 315 + weight of components suspended
vertically (we take it 12.5% of the pay load = 315(1+ .125) = 354.375 N
is coefficient of friction = 0.15 for cast iron cast iron components
Therefore, Ff = 0.15 345.375 = 53.15 N, The working or the minimum requirement of the cylinder is: =
53.15 N
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3.6. Gripper force analysis
The total number of bottle to be handled is 24 having weight of 0.75 kg each, therefore total of 315 N
force is applied by the 24 bottle and each bottle has 13.125 N force on each gripper.
In the following force at different parts of the gripper are analyses
A) Force at the gripper link: this link resistant cap outer plastic coverage
P
30 mm
12.5 mm
Fig 3.8 Force at the gripper link
The force applied on the actuating cylinder is calculated as follows
F=mg=N ..(3.4)
Where: is coefficient of friction
Then
=0.3 for rubber covered material at dry condition
=0.18 for rubber cover material at wet condition

N is normal force;
Then
N=mg
f = m g=0.18 13.125 N=2.52 N
To calculate the value of P taking moment at point A it can be determined then
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P 0.007+ f 0.03=0 from equation 3.1
P=
30
2.25 N =10.8 N
7
Then having the above value the reaction at pivot A can be determined as follows from the following
equation
FAx=2.52 N form equation 3.2
FAy=10.8 N form equation 3.2
Therefore the actuating force on the reciprocating rod is must be greater than the vertical force that is 10.8
N. Then, the total force on the gripper actuating cylinder is to be
24 10.8=259.2 N
Chapter Four
Mechanical Components Design
The mechanical components design to be carried out at this section categorized in to three parts as;
1. Design of cylinders and its accessories
2. Design of structure (beams horizontal; and vertical)
3. Design and selection of the gripper
The design process is planned be done as first based on the force and conceptual design results the
dimensions of each components are designed to withstand the type of load applied. This process is based
on the conventional mechanical design procedure and relationships. The final results of the previous stage
are modeled for further design verification and optimization. For this stage the convenient CAD and CAE
will be incorporated.
4.1. Design of cylinders and accessories

The design of cylinder and its accessories contain the three cylinders which are:
a) Design of vertical cylinder and its accessories
b) Design of horizontal cylinder and its accessories
c) Design of gripper cylinder and its accessories
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4.1.1) Design of vertical cylinder and its accessories
The major parts of this vertical cylinder are; design of cylinder, Design of cylinder flange, Piston road
design, Design of piston, Joint design and Piston ring. All this parts are stated as below.
Design of cylinder
A) Prior decision
The following pointes are addressed as prior to design of this cylinder to make all design effort simple.
Application for vertical motion of the robot arm
Minimum force requirements: for loaded movement = 315 N

For unloaded (return) movement only weight of the gripper = 0.12531 = 32.39 N
Working pressure is 1 bar
Working fluid air at ambient temperature and pressure (STP)
To get the required amount of force from the cylinder let us determine the minimum required cross
sectional area;
P=
F
F
=
..(4.1)
A D2
Solving for D will gives
D=(
4F
4318
)1/2=(
)=63.3 mm=64 mm
P
0.1
The diameter of the cylinder takes as 80 mm from standards.

B) Determine the thickness of the cylinder
Assumption: only internal pressure is applied to this vertical cylinder.
Material selected for this cylinder is Gray cast iron (ASTM 20) and having the stress values are
S ut=181 MPa , S uc=572.2 MPaSe=68.9 MPa
December 2014
Page 22

Since the pressure is less than 1/6 of the allowable tensile stress it is assumed as thin or
t=
Pd
.(4.2)
2 t
Where: p is internal pressure = 0.1N/mm

d is inner diameter of the cylinder = 80mm
St is tensile stress = 0.125 Sut = 189N/mm2
t=
0.1 80
=0.01 mm
2 389
But according to ASTM boiler code for safety reason there is 6 -12 mm allowance then the thickness will
be 13mm. Therefore the cylinder have 80 mm bore diametr,13 mm thickness, the stroke length is 600
mm (from geometry analysis) and type of cylinder is double acting cylinder.
Design of cylinder flange
Material selection: the selected material has designation of ASIM 20 having stress value Sut =181MPa
and factor of safety of 2
The outside diameter can be determined form the following empirical formula
d o=d p+3 d 1
d p=D+2 t+3 d 1=80+ 213+ 3 20=166 mm
Therefore,
d o=D+ 2t +6 d 1=80+2 13+ 6 20=226 mm
Then the thickness will calculated by considering by bending at the connection between the flange and
the cylinder wall, under the effect of Bolts.
X
e
December 2014
Page 23
X
Fig 4.1 The section view the flange

Then,
e=
d p d1
( +t)=166 /2( 20/2+ 13)=60 mm
2
2
The load on each bolt = 83.77 N

Bending moment on section X-X is see fig 4.1
P 8=83.77 60=5026.2 N mm
Radius of section X X=cylinder radius+thickness of the cylinder wall
( D)/2+t=40+13=53 mm
Width of section xx =
2 R 2 83
=
=55 mm
12
6
Section modules q=1/6 w t 2=1 /6 85.5 t 2=9.25 t 2 mm
Therefore,
545
75.835
S b=
5.026 103 0.543 103 545 Sut 181.67

2
=
= 2 =
=
=75.835 N mm ,
2
2
2
2
9.28 t
t
t
t2 =
= 2.675 mm for the purpose of avoiding casting problem and to consider manufacturing
defects it is taken as: t = 13 mm

Piston road design
Piston road is subjected to tensile loading of F = 315 N during working cycle and 78.78N which is
weight of gripper during return then this road will subjected to fatigue loading.
Material selection the selected material is have designation of SAE/AISI1006 steel, having strength of
Sus = 330 MPa , Sy = 230 MPa, HB = 95, Elongation in % = 20%
The maximum force on the road is Fmax. = 318 N and the minimum force Fmin. = 78.75 N
December 2014
Page 24

The mean and average force will be
F mean .=
F avr .=
F max+ F min.
=196.87 N ..(4.3)
2
F maxF min .
=118.125 N ..( 4.4)
2
Then the required diameter of the piston road can be found from the Goodman Design Criteria for
fluctuating load which is defined in equation 4.5
1 Smean Kt Sv Kf
=
+
..(4.5)
fs
Su
Sea
Where: Smean =
Sava. =
Fmean
D2 /4
Fava
2
D /4
196.874
D2
= 250.6/ D
118.1254
2
D
=150.4/ D
S ea=K sur K si K r K a K t K i S e
Where: Ksur is surface factor =0.574
Ksiz is size factor and it is =0.78336
Kr is reliable factor and given by =1
Ka is axial loading factor =0.8
Kt is temperate factor =1
Ki is impact factor = 1
The endurance limit calculated and gives as:
S ea=0.574 0.78336 1 0.8 1 1121 MPa=43.525 MPa
December 2014
Page 25

The taking the factor of safety to be 1.5 and by putting the above values in to equation 4.5, the diameter
of the rod will be; then, D = 3.05 mm
For the purpose of manufacturing ,to take account the effect of impact ,creep and other hazardous
condition in operation the project adopt ,D=20mm
The endurance limit calculated and gives as:
S ea=0.574 0.78336 1 0.8 1 1121 MPa=43.525 MPa

The taking the factor of safety to be 1.5 and by putting the above values in to equation 4.5, the diameter
of the rod will be; then, D = 3.05 mm
For the purpose of manufacturing ,to take account the effect of impact ,creep and other hazardous
condition in operation the project adopt , D = 20mm.
Design of piston
The primary functions of piston are to transform fluid power in to piston rod, to guide the reciprocator
motion the rod.
Material selection: the selected material for piston is steel having designation of AISI 1006, Sut =
330MPa, Sy = 230 MPa and having factor of safety of 1.5 and heat conductivity factor of K=46.6W/ oC.
Since its external diameter is 64 mm it better to integrate with the piston road during manufacturing and it
should have good strength in both face this is due to double acting cylinder is used.
The minimum thickness of piston can be calculated using Grashoff formula as shown below;
3 P D2
t=
.(4.6)
16 t
Where: p is internal diameter of cylinder which is 64 mm
t is permeably tensile strength which is = 220 MPa, then
3 0.1 802
=0.738 mm
16 220
December 2014
Page 26

But at the end of stroke there is an impact force so with this it may failure for this reason the thickness
adopted to be t =10 mm.
For the purpose of minimizing assembling effort and the number of part the piston and piston rod are
integrated components.
Piston ring
It used to maintain the seal between the piston and the cylinder wall. They are standards material it can
then be selected from catalog. For this condition circular piston ring with thickness of 8mm and bore
diameter of 72mm.
Joint design
There a lot of types of joints are available among those bolted joint is selected because of its advantages
(i.e. easy of assembling and disassembling, reliability, and efficiency). To avoid the need of thread
making on cylinder flange and cylinder head through bolt with securing nut is additionally adopted. The
bolts are subjected to both external tensile load as well as clamping or initial loads.
The bolt design is as ASTM specification and our responsibility is to calculate the minimum proof
strength and minimum tensile strength and select the proper grade for the bolts standard catalogue.
p=
The external tensile load on each bolt is
p A
(4.7)
n
Where p = pressure in the cylinder = 0.1 MPa

A = inner area of the cylinder
= 402 = 5024mm2
n= number of bolts to get leak proof joint we adopt = 6
Therefore, p =
0.15024
6
= 83.73N
The pre load in the other hand can be calculated as follow;

Fi = 0.75 Fp (for non-permanent connection), Where: F p is proof load
December 2014
Page 27

To find the proof load we need to choose bolt from standard by trial, we select M16 and property class =
4.8(from ASTM standard table)
Minimum Proof strength, Sp=310mpa
Minimum Tensile strength St =420mpa
Minimum yield strength Sy = 340mpa
Material = low carbon or medium carbon
Hexagonal head
Tensile area, At = 129.18mm2
Therefore,
Fp=S p A t (4.8)
310 129.18=40045.8 N
F i=0.75 Fp=0.75 40045.8=30.034 kN
The total load on each bolt will be
F b=CP+ F i .(4.9)
Where C= stiffness ratio of the member and the bolts material, for grip length of 2in =0.168
F b = 0.168 83.73+ 30034 = 30.1177kN, this is the total load on each bolt during operation of the
cylinder.
Now let us find the stress induced in each bolt,
Sb =
Fb
At
30.1177 kN
129.18 mm2
=232.0318 MPa
But the minimum proof strength for the selected material is 310 MPa, so we have to check for the factor
of safety.
Factor of safety =
December 2014
Fp
Sb
310
232
= 1.33, therefore, it is safe design.
Page 28

Length of the bolts:
Grip length=t head+ t flange=13+13=26 mm

Length of thread part=2 D+12 mm=2 16+12=44 mm
Total length of the bolts = 44 + 26 = 70mm
Bolt hole diameter = 20mm
Pitch circle diameter,
DP =D+2 t+ 3 d=50+2 12+3 20=134 mm
To maintain wrench clearance bolts should be placed at least three diameters apart to check this we have
the following relation.
D P
6 ..( 4.10)
nd
134
6
6 20
3 3.4 6, it is satisfactory spacing.

4.1.2. Design of vertical cylinder and its accessories
Similarly, the major parts of this vertical cylinder are; design of cylinder, Design of cylinder flange,
Piston road design, Design of piston, Joint design and Piston ring. All this parts are stated as below.
Design of cylinder
The horizontal cylinder has also the same similar par like that of vertical cylinder.
Application: the purpose of this cylinder is for horizontal movement of the robot arm.
Assumption: to avoid bending of the cylinder rod the whole vertical load that is the weight of the
equipment to be handling is supported by the horizontal frame with the contact of cylinder head this
implies that there is no vertical load on the rod.
The design load will be the frictional load in the axial direction only.
December 2014
Page 29

A) Calculating the frictional load:
Normal load = 315 N + (weight of the cylinder component +gripper weight +cylinder road
weight)
315 N + 12.8 N =354 N

Friction coefficient of surface between the beam and the cylinder head to be 0.15 this is by assuming both
the upper and lower surface with low surface finishes.
Ff =N f 0.15=53.15 N
Therefore;
The working load can be calculated from the flowing formula by giving the surface factor of 1.25
Then
1.25 53.15 N =66.4453 N
The working or operating pressure used is the same as regulator for both cylinders and taken as 1 bar.
B) Calculating the required amount of diameter for the cylinder, it can be calculated from the
following relation, pressure is equal to force over area.
P=
F
2
D /4
Solving for D
D=
4F
466.4453 N
=
=29.08 mm
2
0.1
D
From standard table the nearest value is 50 mm as the diameter of the cylinder.
And from geometry analysis the gap between the two stations that is the loading and unloading stations
which is 950 mm. so that the cylinder stroke should be greater than or equal to 950 mm in addition to this
a clearance value will be added of the thickness of the piston calculation.
C) Material selection: gray cast iron having designation of ASTM 20 is selected. And having the
strength of
S ut=166 MPa , S uc=686 MPa , E=82 GPa ,MB=120
Therefore the thickness will be based on hoop stress and since the working pressure is 1/6 of the
allowable stress and it assumed as a thin wall of cylinder. The thickness can be calculated by equation 4.2
December 2014
Page 30

t=
Pd 300.1
=
=0.049 mm
2 t
166
But according to ASTM for safety reason there is 6 -12 mm to be added then the thickness be 12 mm.
The design of the vertical cylinder is carried out by similar principle as that of the horizontal cylinder, so
reduce the repetition only the results of the analysis are presented.
Table 4.1: The design result of the vertical cylinder and its accessories
No
1
Part name
Cylinder
Material
ASTM 20
Dimension
Dp =134 mm
Do = 194 mm
D =50 mm
tf =1.5 mm
t = 12mm
Flange
2
Cylinder
ASTM 20
Factor of safety used

1.5
Remarks
Satisfactory
1.5
Satisfactory
Head
The designs of the remaining parts are stated below.
Joint design
There a lot of types of joints are available among those bolted joint is selected because of its advantages
(i.e. easy of assembling and disassembling, reliability, and efficiency). To avoid the need of thread
making on cylinder flange and cylinder head through bolt with securing nut is additionally adopted.
The bolts are subjected to both external tensile load as well as clamping or initial loads.
Our bolt design is as ASTM specification and our responsibility is to calculate the minimum proof
strength and minimum tensile strength and select the proper grade for the bolts standard catalogue.
The external tensile load on each bolt is
P=
p A
n
Where p = pressure in the cylinder = 0.1 Mpa

A = inner area of the cylinder
r 2 = 252 = 1962.5mm2
n = number of bolts to get leak proof joint we adopt = 6
December 2014
Page 31

Therefore, P =
0.11962.5
6
= 32.72N
The pre load in the other hand can be calculated as follow;

Fi = 0.75 Fp (for nonpermanent connection)
Where: Fp is proof load
To find the proof load we need to choose bolt from standard by trial, we select M16 and property class =
4.8
Minimum Proof strength, Sp=310mpa
Minimum Tensile strength =420mpa
Minimum yield strength = 340mpa
Material = low carbon or medium carbon
Hexagonal head
Tensile area, At = 129.18mm2
Therefore, Fp = Sp At = 310129.18 = 40045.8N
Fi = 0.75 Fp = 0.75 40045.8 = 30.034KN
The total load on each bolt will be
F b=CP F i
Where C= stiffness ratio of the member and the bolts material, for grip length of 2in =0.168
Fb = 0.168 32.72 + 30034 = 30.039kN, this is the total load on each bolt during operation of the
cylinder.
Now let us find the stress induced in each bolt,
S b=
F b 30.0389 kN
=
=232.5 MPa
A t 129.18 mm 2
December 2014
Page 32

But the minimum proof strength for the selected material is 310 mpa, so we have to check for the factor
of safety.
Factor of safety =
F p 310
=
=1.33 , therefore we have safe design.
S b 232
Length of the bolts:
Grip length=t head+ t flange=12+12

Length of thread part=2 D+12 mm=2 16+12=44 mm
Total length of thebolts=44+24=68 mm

Bolt hole diameter=20 mm
Pitch diameter
, D P=D+ 2 t+3 d=50+2 12+3 20=134 mm
To maintain wrench clearance bolts should be placed at least three diameters apart to check this we have
the following relation.
D P
6( equation 4.10)
nd
134
6 3 3.4 6, it is satisfactory spacing .
6 20
Design of Piston Rod

This part is subjected to bolt compression and tensional loading during rotating of the cylinder that will
compress and during return it will subjected to tensile loading. So that it is under fatigue loading
specifically completely reversed having sinusoidal stress.
A) Material selection: the select material for the connecting rod is having designation of AISI 1006 and
Sut =330Mpa, Sy=280Mpa, HB =98 and taking factor of safety to be 2.5
Therefore Fmax. = +66.44 N
December 2014
Page 33

Fmin. = -66.44 N
Then the mean and the variable force will be;
Fmean. =
F max .+ F min .
2
Fvar. =
F maxF min .
=
2
66.44 N 66.44 N
2
66.44 N + 66.44 N
2
= 0 (i.e.completly reversed loading)
= 66.44 N
Therefore buy using modified Goodman relation for the analysis that is given in equation 4.5
Sa Sm
1
+
=
Se Sut F . S
Where
S a=
Fa 4 66.4 N 84.6
=
= 2
A
D2
D ,
S m=0
Se=KaKb Kc Kd Ke Sue
Where Ka is surface finishes factor which is =2.67 Sut -0.465 = 0.574
Kb is the size factor then for axial loading there is no size factor =1
Kc is loading factor =1.23 Sut -0.0778 =0.78336 for axial loading
Kd is the temperature factor since the working condition is at room temperature Condition it =1
Ke is shear stress concentration factor which is =1
Se=0.574 1 0.78336 1 1 330 10 6=148.38 106
Then,
Therefore by putting all the above values the diameter of the rod can be calculated as
84.6 10 6
1
=
=0 .4 mm
D 148.38 10 6 2.5
2
B) Design based on buckling:
December 2014
Page 34

The length of the road is found to be 950 mm +allowance (50 mm) =1000 mm
The critical load will calculated based on Euler formulae equation 4.13 by assuming the rod end is fixed
at the piston side and also fixed at the sliding part of the machine.
P cr=
C 2 EI
.(4.13)
L2
Where L is length of the rod

E is modules of elasticity which is =206 Gpa
C =1.2 recommended value for end condition
I=
D
64
Using factor of safety to be 2.5 the critical force can be as follows;

2
P cr=2.5 F var .=2.5 66.44 N=166.1 N=
1.2 206 10Gpa D

1000 64
Then solving for D, D=1.08 mm

For the purpose of manufacturing ,to take account the effect impact ,creep and other an expected
hazardous condition in operation the project adopt ,D=20mm
Design of piston
The primary functions of piston are to transform fluid power in to piston rod, to guide the reciprocator
motion the rod.
A)
Material selection: the selected material for piston is steel having designation of AISI 1006 and
strength of Sut =330Mpa, Sy =230 Mpa and having factor of safety of 1.5 and heat conductivity factor of
K= 46.6W/oC..
Since its external diameter is 64 mm it better to integrate with the piston road during manufacturing and it
should have good strength in both face this is due to double acting cylinder is used.
December 2014
Page 35

B) Calculating thickness; the minimum thickness of piston can be calculated Grashoff formula see
equation 4.6 which is.
t=
3 P D2
16 t
Where: p is internal diameter of cylinder which is 64 mm

St is permeably tensile strength which is = 220 MPa
Then the calculated value of the thickness will be
3 0.1 50
=0.738 mm
16 220
But at the end of stroke there is an impact force so with this it may failure for this reason the thickness
adopted to be t =10mm
For the purpose of minimizing assembling effort and the number of part the piston and piston rod are
integrated components.
C) Piston ring
It used to maintain the seal between the piston and the cylinder wall. They are standards material it can
then be selected from catalog. For this condition circular cross section ring with thickness of 8mm and
bore diameter of 42mm is selected.
4.1.3. Design of Gripper cylinder and its accessories
Application for the purpose of actuation of the 24 grippers and the type of cylinder to be used is single
acting spring return. Stroke length 5mm and the minimum force required for actuation is 259.2 N see
gripper design and selection section.
Design of cylinder
A) Material for cylinder; ASIM 20 having Sut=181.67Mpa Suc=572 Mpa and MB 156, Working
pressures 0.1 Mpa
To provide the required amount of force i.e. 259.2 N the design is carried as follows
December 2014
Page 36

F = 259.2 N service factor, taking in this service factor to be 1.28, F = 324 N
F
A
P=
Then
which is
0.1=
324 F
2
D
D=64.22 mm
solving for D,
From standard the list diameter of D=80mm is selected. And the thickness of the cylinder will be
calculated by assuming thin cylinder. The maximum stress is the Hoop stress so the design should be
based on this stress rather than longitudinal stress.
t=
Then
Pd
2 t
Where P is pressure which is 0.1 MPa, d is inner diameter
Sut
St is allowable stress = F . S
t=
181.67 MPa
1.5
80 mm
=101.3 MPa
0.1 80
=0.039 mm
2 101.67
But according to AISM boiler code for safety the thickness has allowance of 6-12 mm for the cylinder the
t=12 mm is adopted.
Table 4.2: Design result of gripper cylinder
No.
1
Part Name
Cylinder
Material
ASIM 20
AISI1006
AISI1006
Standard
dp = 166 mm
do = 226 mm
t = 13 mm
D = 20mm
t = 10 mm.
t = 8mm
Standard
D = 72mm
N= 6, M16
Flange
2
3
4
5
Piston road
piston
Piston ring
Joint
Dimension
(4.8
grade)
4.1.4. Design of the return spring
December 2014
Page 37
Factor of Safety
Remarks
Satisfactory
1.5
1.5
-
Satisfactory
Satisfactory
Satisfactory
3 3.4 6, it is
satisfactory
spacing.
Satisfactory

Since the gripper cylinder is single acting it needs a return spring, so the following prior decisions are
taken,
The type of spring used is helical spring (compressed)

Loading fatigue loading
Since the gripper is normally closed the spring must be initial compressed to apply the pre load force for
the gripper and bottle the pre load has no way of calculation but to avoid bottle breakage due to over
pressure it is adopted as 10 N for each bottle gripper the totally for the 24 bottle 240 N Therefore the pre
load is to be =240 Mpa
Spring material music wire ASIM A 228 having SAE1085 G=11.8Gpa the temperature range of 0 oc to
120oC
Tensile Strength, Sut = Adb
Where: b= -0.16 and A=21535 Mpa
Shear strength Suc = 0.67Sut (4.14)
From list of preferred wire diameter correspondingly the selected material by assuming the geometrical
contrite it is taken as d = 6 mm
A) Spring index: as standard it is diameter should be less than the cylinder bore diameter i.e. D=80 mm
to avoid friction between the cylinder wall and the spring. So for this reason the mean diameter of the
sprig D = 70 mm is taken
The spring index
C=
D
=11.667
d
B) Spring rate is given by the formula
K=
AF
D 4G
=
..(4.15)
B 8 D3 Na
AF=F finalF
Ffinal it is the minimum force of the spring
December 2014
Page 38

After deflection from initial position for the gripping purpose by air pressure so it should be equal to the
pressure face by the air applied for operating the gripper
2
Fmes = 0.1 MPa
80
4
=502.38 N
From the gripper analysis of the gripper the required amount of deflection is for opening is 5 mm
K=
502.38240
0.5
= 52.5 N/mm
To achieve this spring rate in the number of active spring coils N o must be
D4 G
6 4 80.8 GPa
No= 8 D 3 K = 8 703 52.5
= 1 turn
Assuming squared and ground end in both sides for the purpose of stable total turn be
Nt = No+2=3 turn
compressed length can be determined

Lc= d Nt = 63=18 mm
The initial defalcation to meet the requirement load that is 240 N
Lin=
Fins
K
240
= 52.5
= 4.57 mm
Total length of the spring

L = Lc+ Lin + Lcl + Lworking , Lworking = 5mm
Giving clashing allowance to avoid the reach of the length compression it adopted 15 %
Lcl = 0.155 = 0.75 mm
L = 18+4.57+5+0.75 = 28.32 mm
December 2014
Page 39

C) The strength of the spring checked from fatigue loading;
Fmax = 502.5N and Fmin = 240 N
Fmean =
F maxF min
= 131 N
2
Faver =
F max+ F min
2
= 371.25N
Direct shear stress factor [Ks] which is given in equation 4.8
1+0.5
K s=
(4.16)
c
1+0.5
c 11.67 = 1.0428
Mean shear stress will be see equation 4.9
m=
Ks 8 Fave D
(4.17)
D3
1.04 8 371.25 0
=147.1 MPa
63
wahl facter, Kw can be calculated using equation 4.10
4 C1
Kw = 4 C4 +
0.615
(4.18)
c
4 11.61
= 4 11.64
0.615
11.6 =1.128
Alternative shear stress [a] will be
December 2014
Page 40

Kw 8 Fc D
1.125 8 131 78
3
a=
=
D
63
= 121.7 MPa
Ultimate shear strength [Sut] will be

Sut = Adb = 2153.5*6-0.1625 = 1609.5 MPa
Tensile yield strength Syt be
Syt =
0.60 Sut=0.6 1609.5=965.7 MPa
Tensile endurance limit from table for peened spring

Sew= 465 Mpa
The shear endurance limit will be
SewSus
Ses = 0.5 Sus0.5 Sew (4.19)
465 1078.37
= 0.5
1078.350.5 465
= 296.4 MPa
Now let us check for factor of safety of the wire
Ses (Suse)
Nfs = Ses ( me ) + Sus a
(4.20)
296 (1078.38206.5)
= 296 ( 147.1206.5 ) +1078.38 121.7 =2.27 This shows design is safe
D) Check for buckling
To check the buckling if the spring is first let the ratio of Lf to D be calculate as follows
December 2014
Page 41

Lf
28.32
D = 70 = 0.405
Ymax
Yintial +Ywork
5+ 4.87
=
=
Lf
Lf
28.32
= 0.338
Now by taking these two values plot their coordinates on critical buckling curve adopted by. Check
whether it is in safe zones that are against buckling. Therefore (0.405, 0.338) is the stable zone,
generally the springs is safe and satisfactory
4.2. Design of structure (beams horizontal and vertical)

The structure is the help to carries the whole gantry system in giving stability and strength the system and
there are four vertical beams which are identical and two horizontal beam to carry the vertical cylinder. In
this section design of this toe beams are addressed.
4.2.1) Design of Horizontal Beam

This beam is subjected to bending moment in addition it has some friction wear during slide of the
cylinder on it.
The type of cross section is C section this is for the purpose of easy assembling. The maximum bending
moment will occur when the load is at either the picking or placing position. And the maximum bending
occurs at the end of the beam.
A)
Material selection: the selected material for this beam is have KSPI (Kalitey steel product
industry) standard for the purpose of the possibility to be manufactured using domestic available
material, and to improve the structural stability during bending loading, standard C channel having
dimension of 100 43 mm selected form the standard see fig 4.4 Having stress value S y= 200 Mpa, Sut
275 Mpa Elongation of = 31%.
As it shown in the Force analysis in chapter three
P = 354.375 N but since the load is divided in to two beams the load on each will be =177.187 N
MA = MB = 177.18 N1275 mm
The dimension for the C channel is as follows
December 2014
Page 42
Fig 4.4: C section of the horizontal beam

Form KSPI catalogue the project adopt C10328 is selected for the purpose of assembling and for
supporting sliding member in the slot.
B) The strength of this selected cross section will be checked by bending moment;
The critical point of stress occur at the end of beam so that the design is based on this section
Mmax=197 N
Sb=
M
197 102/2
R=
=5.26 MPa
Ixx
1.91 ( 10 )6
Ixx=1.91 106 mm4

R =102/2
The factor of safety will be
F . S=
Sut 275
=
=52.2
Sb 5.26
It is very large and expensive but for the purpose of technological defects considerations this value is
adopted.
4.2.2) Design of Vertical Beam

This vertical beam is subjected to compression force and the maximum compression which is 125.5 N
and the minimum compression force which is 32 N. as a result the beam is subjected to fluctuating load in
which the design is based.
A) Material selection; like that of horizontal beam the material selected have a standard of KSPI
(Kalitey steel product industry) which is hot rolled steel having stress value of; yield stress is 200 MPa,
December 2014
Page 43

tensile stress 275 MPa and elongation of 31 % and the factor of safety for this beam is to be 1.5 because
of there is no fear of failure because the load is too small.
B) Determine the type of cross-section for this beam is for the purpose of assembling, to avoid
eccentricity therefore L section having equal legs are selected. See fig 4.5
6t
t
6t
Fig 4.5: L section of vertical beam
C) Design consideration
To design the beam strength analysis it is to be done in addition it is cheeked for buckling.
For the fluctuating loading the Fmax =125.5 N and Fmin=32 N
The design then should be the equations of Goodman equation see equation 4.5 which is
Sv Sm
1
+
=
Se Suct F . S
Where: Sv is variable stress , Se is the endurance limit, Sm is mean stress, Suct is ultimate compression
stress
Then the above parameters are determined as follows;
Fmax Fmin
1. Fvar.=
2
2. Fmean =
Fmax + Fmin
2
125.532
=
2
= 46.75 N
125.5+32
2
= 78.75 N
3. The area of the L section is
December 2014
A=(t 6 t)+(t 5 t)=11 t 2
Page 44

Fv
A
4. Sv =
5. Smean =
46.75
= 11 t t
Fmean
78.75
=
A
11 t t
6. Se is calculated from the following formula

Se=KasKbKcKdKeSuct
Where
Kas is surface factor =58.15Sut-0.79 =1.023

Kb is size factor which is = 1 for axial loading
Kc loading factor then for axial loading =1.23Sut-0.0778 =0.79
Kd is temperature factor since the working condition is at room temperature it. Taken as =1
Ke is miscellaneous factor to take account corrosion and other source of Failure =1.12
Therefore;
Se=1.023 180.79 1 1.12 275 10 6 = 248.9MPa
Then collecting the above all result and using Goodman equation the thickness can be determined as:
46.75
248.78 11 t t
78.75
+ 275 11 t = 1.5
the solving for the thickness
t=0.25 mm
To satisfy the required amount of this thickness the project select L200200mm from KSPI.
D)
Check for this thickness for buckling
To check whether the beam thickness is safe for buckling, it is assumed that the load on each beam is
applied at the central loading.
The critical loading or the minimum load that can buckle calculated from Euler formula for buckling for
the cross section see fig
December 2014
Page 45

C 2 EI
Pcr =
L2
Euler formulae
Where L is length of the rod which is =1600 mm

E is modules of elasticity which is =206 Gpa
C =1.2 recommended value for end condition
A= D
I=
64
D
64
at section of x-x and y-y

Y
X
200
8
200
Fig 4.6 Cross-section of vertical beam

Since the beam have equal length the buckling load in the two axes is equal that is;
Ix-x = Iy-y = 10.67106 mm4
The maximum compression load on each beam is 125.5 N,
Then the Factor of safety for buckling will be =
Pcr =
1.2 2 206.7 10 9 10.67 10 6

1600 1600
125.25
Pcr
Pcr
125.25
1.2 2 206.7 10 9 10.67 106

1600 1600
= 9.561011 N so the
factor of safety will be 7.6109 it is very high and expensive design but to take account the effect of low
grade manufacturing technology it is adopted.
4.3. Gripper Components Design

In this section each part of the gripper is designed and analysis as follows:
December 2014
Page 46

4.3.1.
Design of shaft
This part is subjected to tensile stress and a factor of safety of 2.5 is adopted because it a critical part for
the gripper that help the bottle be grippe by using the actuation from the cylinder. Material selection for
this part having tensile strength of 206 MPa is selected.
Therefore the following governing equation the diameter of the shaft diameter can be determined.
Sy F
=
F .S A
6
206 10 F 43.2 N
=
2
F. S
D
, solving for D,
4
43.22.54
206 106
=2.7 mm
From the minimum diameter of this shaft to avoid sudden failure the diameter of the shaft taken as 8 mm
4.3.2.
Design of pin
On this pin shear stress and crushing stress are the main forces set up on it as a result of it the design is on
the shear stress and checked for crushing stress developed on it see diagram 4.11. Material for this pin is
having designation of AISI 1006 and the strength parameter of 170 MPa yields stress and hot rolled with
factor of safety of 2.5. Then from above figure the minimum shearing area can be calculated as
follows;
The number of shear areas is 2, max the maximum shear = 85 MPa
=
max
F
max
F
2
=
=
=
where A= r
F . S 0.852A F . S 1.7A
Then solving for the diameter of the pin it will be

D=
11.092.54
=4.494 104 mm
1.780 106
December 2014
Page 47

Then the diameter of the pin is taken as D= 3 mm for the purpose of more safety and
manufacturing issue. Check the pin against crushing: for the bearing stress that developed on the
pin is diameter should be checked then
Then,
The length of the pin on the bearing area is = 7 mm
Diameter of the pin =3 mm
Bearing area A= LD =73 =21 mm2
S=
Fn
11.09 n
=170 10 6=
Ab
21 106
Solving for n = 28.33 therefore the pin is safe in crushing stress because the factor of safety is
very safe enough.
Fig 4.7: Connecting Pin

Design of the upper parts supporter
This parts used to support the upper part as a result the force that will propagate are shear stress and
tensile stress since the shearing stress is the critical one the design is bead ion the shearing and it is
cheeked against tensile strength.
43.2 N
Fig 4.8: Section view of upper supporter
Material selected gray cast iron with tensile strength stress of 152 MPa and compressive stress of 570
MPa. The shearing area = Dl = 3010-3 = 94.24710-3 l. Using factor of safety to be F.S =
2.5 as in the above all cases;
December 2014
Page 48

max F 152 106
43.2
= =
=
F.S A
2.5
1.794 .247 103 l
Therefore solving l, l =7.5310-6 m. From manufacturing and related problems, the length taken as 3 mm
Checking for tensile strength
43.2N
Fig 4.9 Upper Supporter
The above fig 4.9 shows the tensile strength set up on the part then is should be checked on tensile
strength then
D
36 10
(3)30 103
( 2d 2) 2
= =3.11 104 m2
4
4
A=
And from the tensile stress formula the factor of safety for this dimension is calculated ad
F . S=
At 152 106 3.11 104

=
=10.9
F
43.2
Therefore the factor of safety is grater than from the assumed then it is safe in tensile stress.
Design of swingier piece
The material for this part is SAC or AISI 1006 having yield strength of 170 MPa with hot rolled and cold
drawn.
Calculating for bending strength
Factor of safety = 2.5
December 2014
Page 49

1 1
4
4
I ( moment of inertia)= (D d ) for quarter circular hollow components
4 64
C distance where maximum bending stress occur.
Bending stress=
Sy Mc
=
n
I
D
170 10 4
MD
=
2.5
1
4
3 4
( D (30 10 ) )
256
1 1
( 4d 4 )
4 16
, Where d=30 mm,
Sy Mc
=
n
C=D
22.253 10 =
Solving for
D
3 4
D (30 10 )
4
, Since
M =30 10 1.4=0.15 Nm
D=30.05 mm and the thickness t=Dd=0.05 mm
Note the thickness t=3mm and D=36 mm are selected for the sake of manufacturability.
Checking for shearing stress
Maximum shear stress
Shear area
max=
t L
Sy 170
=
=85 MPa
2
2
= 810-3t mm2
t
Fig 4.10: Shear area of swingier piece
Then shear stress=
December 2014
max F max
F
= =
=
n
A
n
8 103 t
solving for the thickness t will be
Page 50
and

t=1.84 105 m
For the purpose of manufacturability and machinability t = 3 mm is adopted. With similar the related
subcomponents have been designed and selected. By this we will concluded the manual design of the
components to evaluate the preliminary design will use some CAD and FEA softwares to have further
fined output.
Design Evaluation
In the previous sections we have been trying to determine the possible dimension suitable for the loading
conditions of each component. In this section use the results of the manual design we will evaluate them
and make some amendment.
To do so, first the all the components will be model using one of the CAD softwares, for this project
Solidworks 2014 has been used, then the models will be analyzed using ANSYS 12. The analysis may
vary based on the type of load experienced.
Table 4.3: Conclusion Design Evaluation
No
.
Part Name
Material
Loading
Remarks
Vertical Cylinder
1
ASIM 20
Pressure (Distributed load)
Satisfactor
y
Horizontal Cylinder
Gripper Cylinder
Vertical Piston Rod
AISI1006
Axial fatigue loading (tensile)
Horizontal Piston Rod
AISI1006
Gripper Piston Rod
AISI1006
Horizontal Beams
hot rolled steel
Axial fatigue loading (compression and

tensile)
Axial fatigue loading (compression and
tensile)
Bending loading
Vertical Beams
hot rolled steel
Axial compression load and buckling
Gripper Components
Satisfactor
y
Satisfactor
y
Satisfactor
y
Satisfactor
y
Satisfactor
y
Satisfactor
y
By this we conclude our components design and evaluation section and the results are satisfactory. In the
next chapter we will design the control of the system.
December 2014
Page 51

Chapter Five
Design of Control System
A robot must have a control system to perform its motion cycle and control system is directly
related to robot programming. Control system is therefore defined as a path in space to be
followed by the manipulator combined with peripheral action that support the work cycle. In this
section the most important points and design parameter for the control system are addressed this
are;
1.
2.
3.
4.
Selecting the type of control system to be used

Selecting the types of pneumatic valve to be used
The motion cycle of the gantry system
The speed in flow lines and of air will determined
5.1) Selecting the type of control system to be used

The type of control is the main governing factor for the robot in its complexity, cost and technology level
therefore selecting a proper type of control system is then a big deal then from various type of controlling
system available today for this robot manual set up programming is selected this is because of the
whole gantry system have linear and limited sequence of motion.
Manual set up programming is among the simplest type of robot programming mostly uses mechanical
limiting switch and mostly applicable in gantry system in picking placing robot which have limited in
motion. Therefore to achieve this limiting switch is used to control over position and actions of the
cylinder in sequence.
5.2) Selecting the type of valve to be used

In the electricity we use a lamp to stabbing a switch. It is also natural that we in the pneumatics
"something" to enable the cylinders to switch. In the pneumatics valves, as in the different types of power
switches, depending on the application, as will also the various types of valves are pneumatics. This may
differ from construction of the valve to the type of operation.
So for the controlling purpose the following two things are addressed
1) The control system will be using pilot valves to control the pressure The actuating valves are 3/2
way spool valve
December 2014
Page 52

2) The system has 5/2 way valve to control the vertical and horizontal cylinders.
5.2.1) Pilot valve
Pilot valves are ports through which compressed air travels when actuating the pilot portion of a pilot
operated valve and A pilot valve is a small valve that controls a limited-flow control feed to a separate
piloted valve. Typically, this valve controls a high pressure or high flow feed. Pilot valves are useful
because they allow a small and easily operated feed to control a much higher pressure or higher flow feed,
which would otherwise require a much larger force to operate; indeed, this is even useful when a solenoid
is used to operate the valve.
Pilot valves are often used in critical applications (i.e., emergency and safety controls) and are human
operated. They can be set up as a push-to-activate
More generally pilot valves have the following categories
1. INTERNALLY PILOTED SOLENOID VALVES
With direct-acting valves, the static pressure forces increase with increasing orifice diameter which means
that the magnetic forces required overcoming the pressure forces, become correspondingly larger.
Internally piloted solenoid valves are therefore employed for switching higher pressures in conjunction
with larger orifice sizes; in this case, the differential fluid pressure performs the main work in opening
and closing the valve.
2. INTERNALLY PILOTED 2-WAY VALVES
Internally piloted solenoid valves are fitted with either a 2- or 3-way pilot solenoid valve. A diaphragm or
a piston provides the seal for the main valve seat. When the pilot valve is closed, the fluid pressure builds
up on both sides of the diaphragm via a bleed orifice. As long as there is a pressure differential between
the inlet and outlet ports, a shut-off force is available by virtue of the larger effective area on the top of
the diaphragm. When the pilot valve is opened, the pressure is relieved from the upper side of the
diaphragm. The greater effective net pressure force from below now raises the diaphragm and opens the
valve. In general, internally piloted valves require a minimum pressure differential to ensure satisfactory
opening and closing.
3. INTERNALLY PILOTED MULTI-WAY SOLENOID VALVES
Internally piloted 4-way solenoid valves are used mainly in hydraulic and pneumatic applications to
actuate double-acting cylinders. These valves have four port connections: a pressure inlet P, two cylinder
December 2014
Page 53

port connections A and B, and one exhaust port connection R. An internally piloted 5/2-way poppet valve
when de-energized, the pilot valve opens at the connection from the pressure inlet to the pilot channel.
Both puppets in the main valve are now pressurized and switch over. Now port connection P is connected
to A, and B can exhaust via a second restrictor through R.
4. EXTERNALLY PILOTED VALVES
With these types an independent pilot medium is used to actuate the valve.. When the solenoid valve is
energized, the piston is raised against the action of the spring and the valve opens. A normally-open valve
version can be obtained if the spring is placed on the opposite side of the actuator piston. In these cases,
the independent pilot medium is connected to the top of the actuator. Double-acting versions controlled
by 5/2-way valves do not contain any spring.
Therefore external pilot valve are selected from standard of FESTO and t the pilot have the following
symbol;
Fig 5.1: External Pilot
5.2.2) 3/2 and 5/2 valve selection:
A valve has a body, an outer shell and a bottom board. The outer shell contains a membrane and internal
and external sliding bases with abutting stubs pressing the membrane. Channels are defined in the body
and the sliding bases. The bottom board fits inside a rear of the body and has multiple apertures rotatable
aligning the channels in the body to change 5-way, 2-position or 3-way, 2-position operation modes.
Moreover, an electromagnetic valve with a shaft is installed inside the valve and cooperates with the
movement of the sliding bases to selectively open or close the channels
3/2 way valve see fig 5.2 is used to actuate the gripper cylinder and the mechanical limits switch and 5/2
see fig 5.3 way valve used for the vertical and horizontal cylinders
Therefore from standards of FESTO for the working pressure of 0.1 MPa pressure and the load the
following standard is selected from fest for the 3/2 way valve having code of VL/0-312 and for 5/2
way valve CPE10-M1BH-5JS-M7 are selected from FESTO standards
Fig 5.2: 3/2 way valves

December 2014
Fig 5.3: 5/2 way valve

Page 54

Table 5.1: Valve specification for the 3/2 and 5/2 way valves
Valve function
3/2-way valve, closed + open, 5/2-way valve
Design
Pilot actuated piston spool valve with cartridge seal
Nominal size [mm]
Standard nominal flow rate [l/min]
200
Operating pressure range [bar]
-0.9 ... 8 (with external auxiliary pilot suitable for vacuum

operation)
Response time [ms] on/off
12/10
Ambient temperature [C]
-5 ... +50
Width [mm]
10 or 12
5.2.3) Description of limit switch:

The limit switches are switches that detect the presence or absence of an object by physically touching it.
Limit switches have a variety of actuators that come into contact with an object therefore the limit switch
which is used have 3/2 way normally open valve that is it have a pressure source and to be actuated by a
roller attached to it see the fig5.4 below
Fig 5.4: a 3/2 way roller limit switch

The limit switch have 3/2 way normally close valve which is the same as the valve used in the cylinder
and the second part that help to actuate and controlee position are roller type and the standard is selected
from the Festo catalogue for all specification. Then Festo code of ASL -02 is selected
5.3) Motion cycle of the gantry system

The robots have the following cycle of motion on its three cylinders. The names of each cylinder are
giving as Cylinder A (vertical cylinder), Cylinder B (horizontal cylinder), and Cylinder C (gripper
cylinder). And also + sign used for extend movement of the cylinder and used for retraction of cylinder
December 2014
Page 55

Description of one cycle motion of the gantry
1. First to start the robotics all the pressure lines should be open, then since cylinder A is at the
picking position when it gets pressure it move down extend A+, after it reaches at the bottle it
actuated the mechanical switch at the gripper.
2.
The limit switch at the gripper then will action at the spring retract cylinder to extend C+, in this
stage both cylinder A and C are in still extending until the bottle are gripped this will achieved
because the stork length of cylinder C . Then after cylinder C fully extend it will actuate the other
limit switch located at the gripper.
3. In the third movement the actuate limit switch at the gripper will in turn actuate the 5/2 way
normally closed valve to retract the cylinder A A- this helps the gripped bottle to be move up
warred or to be picked then when the cylinder A fully retracts and it will actuate the limit switch
which is located at this position.
4. The cylinder B now get to be extend B+ to move the bottle horizontally up to placing position
after cylinder B fully extend it will actuate the other limit switch located at the placing position to
side.
5. The cylinder A now get to be extend A+ to move the bottle down to place the bottle, after
cylinder A fully extend it will actuate the other limit switch located at the placing position
(bottom limit switch.)
6. The limit switch at the gripper then will action at the spring retract cylinder to extend C+, in this
stage both cylinder A and C are in still extending until the bottle are placed in the box this will
achieved because the stork length of cylinder C . Then after cylinder C fully extend it will actuate
the other limit switch located at the gripper
7. In this stage the actuate limit switch at the gripper will in turn actuate the 5/2 way normally
closed valve to retract the cylinder A A- this helps the gantry to be move up warred then when the
cylinder A fully retracts and it will actuate the limit switch which is located at this position.
8. Finally The cylinder B now get to be retract B- to move the gantry horizontally up to placing
position after cylinder B fully extend the one cycle journey of the whole system will be end her.
Therefore from above all the data required are determined therefore using Automation studio V 5.0 which
a pneumatic circuit maker and simulator the circuit diagram are accomplished generally the circuit
December 2014
Page 56

diagram have done at the position that is at the picking and placing position the following two diagram
shows the picking and placing position pneumatic circuit diagram in fig 5.5 and fig 5.6
Fig 5.5: Pneumatic circuit diagram at the picking position
Fig 5.6 Pneumatic circuit diagram at the placing position
Table 5.2: The pneumatic circuit parts

No.
1
2
3
4
5
6
7
8
9
December 2014
Part Name
Customized valve
Exhaust valve
Pressure line
Single-Acting Cylinder with Spring Return
Roller
Pneumatic pressure source (compressor)
Double acting cylinder
External Pneumatic Pilot
Spring return
Page 57
Quantity
8
9
13
1
5
9
2
5
6

5.4 The speed and flow rate calculation
The flow is the main factors from the speed of the robot and then the response time. In order to get fast
response time it necessary to apply high flow rate in the cylinder with the some restricting factors such as
pipe diameter, compressibility of the air , pressure of flow and other environmental condition.
As already stated the working pressure for each is 0.1 MPa and because of the restriction of pipe diameter
and pipe material which is selected from standards the flow rate allowed for this standard pipes is
200L/min this standard plastic made pipe for the purpose of flexibility so only it will used from the
branch up to the part of the cylinder for the rest selection metallic pipe will in to consideration
A) Assumption
The type of air flow between the FLR up to the cylinder is assumed as incompressible flow with some
accuracy because of the following reason
Since the cylinder are double acting (vertical, horizontal) as the fluid applied at the one part it
will vent as the other port there is no oxygen compression of air

The gripper cylinder is actually single acting but it will used on from open the gripper so it
actuations type is very small and the stroke length is 5 mm

To minimize design effort compressibility flow and the project will taken in to account this effect
in the flow and calculation is based on the following equation 5.1
Q=Q 1+Q 2+Q 3 .(5.1)
But,
Q1=Q2=Q 3=200 L/min , Then Q = 600 L/min
Therefore the required moment of the air flow from the compressor should be 600 L/mm and having the
pressure 0.1 MPa if the flow rate and pressure supply by the compressor as above the indicated limit the
regulator can reduce it in to the required level.
B) Speed calculation the speed is calculated for the three cylinders as follows see parameters in fig 5.7
Speed of vertical cylinder
Flow rate supplied Q = 200 L/min = 3.3210-3 m3/sec
December 2014
Page 58

D2
The cross sectional area of the cylinder =
4
802
4
= 5.026510-3 mm2
The speed if the piston can be the calculated as follows
Q
Vp = A
3.33 103
5.026 103
= 0.66 m/sec
But to take account the compressibility and frictional losses 0.9 the speed to be
Vp = Vp
0.9 = 0.66 0.9, Then the velocity of the vertical cylinder Vp = 0.462 m/sec
The total time required to complete single stroke is calculated as flows
strokelength
Ts =
Vp
0.88
= 0.462
Then the cylinder will take 1.255 sec to complete one stroke of its movement
Gripper cylinder
Since the cross section of this cylinder is equal that of the vertical cylinder the speed of the piston is Vp =
0.462 m/sec . From the stork length the time taken can be calculated as follows
strokelength
Ts =
Vp
0.005
= 0.462
= 0.0108 sec
Horizontal cylinder
Flow rate supplied Q =200 L/mm=3.3210-3 m3/sec
D2
The cross sectional area of the cylinder =
4
502
4
The speed if the piston can be the calculated as follows
December 2014
Page 59
=1.96310-3 mm2

Q
Vp = A
3.33 103
1.963 103
= 1.697 m/sec
But to take account the compressibility and frictional losses 0.7 the speed to be Vp = Vp 0.7 =1.6979
0.7
Then the velocity of the vertical cylinder Vp =1.188 m/sec
Then, the total time required to complete single stroke is calculated as flows
Ts =
strokelength
Vp
0.95
= 1.1188
then the cylinder will take 0.799 sec to complete one stroke of its
movement.
C) Total speed of the robot
The time required to complete single cycle of the gantry system is the sum of each cylinder time then
Ttotal = 4Tvs+2THs+2Tgr = 41.288+ 20.799+20.0108 = 6.639 sec

Therefore the total time require to complete its cycle with in 6.639sec which is fast and satisfactory as
compared to the manual operation of handling bottles.
December 2014
Page 60
Fig 5.7 Pneumatic circuit and flow rate Q
Conclusion and Recommendation

The use of automated system over the manual operation has got many merits and has been discussed in
the first chapter of this report. Considering so a gantry robot has been design for coca cola bottle
transportation. The design considers the current plant condition and specifications, the resources available
and other constrained.
The gantry robot with pneumatic power supply having three degrees of freedom has been design. The
robot has two main cylinders for vertical and horizontal motions and one gripper cylinder to operate the
grippers. The basic advantage of this system it utilized the compressed air produced for other operation so
it does not need additional compressor.
December 2014
Page 61

The design process starts selection of the suitable type of automated system. Then in the preceding
section conceptual design, force analysis, design of components and then finally design of control system
has been discussed. The mechanical components design has been done in to steps once the preliminary
dimensions are determined based on manual design process the components will be modeled using
Solidworks and analyzed using either ANSYS or COSMOS, to evaluate the design and make some
amendments.
To finalize the report; Highly, low operating cost, maintenance cost products are a result of not only good
designer but also right interaction and relation between the designer and the manufacturer and also the
customers. The manufacturing of the components need high pressure specially the pneumatic and control
components. Therefore, rather than manufacturing in domestic it is preferable to import from experienced
companies this problem is account during design as it stated this components are standards.
After properly assembled, the product is at the hand of the customers and they should take the following
cares: To avoid the wear of the bracket duet to over wear of the bushing, the customers should replace the
bushing when the wear of the bushing is above 2mm. Lubrication for sliding contact between the bushing
and the horizontal beams is necessary and oil lubrication is recommended because of the speed the robot.
Air supply for the actuation form the compressor should be as indicated (i.e. because of the regulator the
pressure can vary from 1-6bar and flow rate above 600litter/minute.). Periodic maintenance for the
robot must be held per six month. The main specifications of this robot are conveyor speed and dimension
and the customer must use the following type:
Specification
Type of conveyor
Speed of supply
Bottle conveyor
Roller conveyor
3.615bottle/sec
Box conveyor
Roller conveyor
1box/6.693sec
Bibliography
1. Design
for
manufacturing
:structural
approach/Corrado
Poli
P.cm,
ISBN
0-7506-
7341.9(alk.papers)2001 by butter Worth -Heinemann

2. Automation production system and computer integrated manufacturing ,Grover,Mikell.p,
revised edition,
ISBN 0-13-054652-6
3. Hydraulic and pneumatics ,Parr Andrew,g21.51,ISBN 07506 07939
4. Air logic system/Rudy G.Wojetecki,P.cm
,ISBN 084943 20577(alk Paper)
5. Mechanical engineering design Shigely joseph Edward
(joesph Edward shigely Charles ,mischke 6th edition
December 2014
Page 62
6.
7.
8.
9.
p.cm
ISBIN 0-07-365939-8 (alk paper
Robotics principles and practice K.C jain L N Aggrawe 3rd edtion Delhi 2002
K.S Vision C inteligenu Mc Graw Hill Madrid 1998
Robotics control detection Ray Dained L.Robotics simulation Londen CDC 1994
Robotics Technology Michel pernt and Claude London kogan C 1993Morries N.m Control
engineering McGraw Hill 1968

10. Design of Machine elements Faires Virgil Moring 3rd edition NY 1995
11. Design of Machinery Norton Robert L McGraw Hill 2nd edition 1999
12. Introduction result to mechanical vibration,luel fissha ass.prof. of mechanical engineering
AAU,AA
Appendix
CAD Results
Vertical Cylinder
Factor of safety result
December 2014
Page 63

Displacement result
Horizontal Cylinder
Factor of safety
December 2014
Page 64

Stain result
Horizontal Cylinder Head (at the base)

December 2014
Page 65
Displacement result
Horizontal Cylinder Head (at the end)

December 2014
Page 66
Strain result
Vertical Cylinder Piston Rod Integral
December 2014
Page 67

Vertical Beam
December 2014
Page 68

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