ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

School of Mechanical Chemical and Materials Engineering

Department of Mechanical Engineering

Design of Robot for Pouring Purpose in Foundry

July,2023
 ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY
School of Mechanical, Chemical and Materials Engineering
Department of Mechanical Engineering

Design Of Robot For Pouring Purpose In Foundry

Project Submitted in partial fulfilment of the

requirements for the award of the degree of

BACHELOR OF SCIENCE

IN

MECHANICAL ENGINEERING

By

1. BILISUMA ZENEBE UGR/16894/11

2. BEZAWIT SHIFERAW UGR/16890/11
3. BEREKET TSEGAYE UGR/16860/11
4. BONSIS HABTAMU UGR/16928/11
5. NURADIN WOYEMA UGR/17544/11
6. YORDANOS BELETE UGR/17851/11

Advisor: Mr. MULUGETA HAGOS

Mr. ELIAS HABTU

ADAMA

JULY, 2023
 ADAMA SCINCE AND TECHNOLOGY UNIVERSITY

School of Mechanical, Chemical and Material Science and Engineering

Department of Mechanical Engineering

APPROVAL SHEET

Approval Board

_________________ _______________ _____________

Department Head Signature Date

_______________ ______________ ___________

_______________ ___________ __________

Project Advisor Signature. Date

________________ ______________________ ________________

________________ _______________________ __________________

Acknowledgment

First of all, all thanks should go to the one who started all and gave the strength to finish it all, God,
nothing that was done was done without him. We wish to express our deep gratitude to our advisor, Mr.
Mulugeta Hagos and Mr. Elias for giving us a clear guide line on how to approach this project. As well
as for helping we acquire all the necessary materials we required from different department stores. We
also recognize his consideration and understanding towards our effort in advance. We would like to
thank fellow friends for their academicals support and guidance disclosed and offered during the
progress of this project. We are thankful for all the people who aren’t mentioned here for their support.
Lastly, we regard to appreciate the encouragement offered from families for the entire duration this
work.
 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Table of Contents
Acknowledgment ................................................................................................................................................... ii
ABSTRACT ...........................................................................................................................................................ix
CHAPTER ONE .....................................................................................................................................................1
INTRODUCTION...................................................................................................................................................1
1.1 Background ...................................................................................................................................................1
1.2 Overview of the Robot Pouring Process in a Foundry ..................................................................................3
1.3 Problem Statement ........................................................................................................................................5
1.4 General Objective..........................................................................................................................................6
1.5 Specific Objective .........................................................................................................................................7
1.6 Significance of the Thesis .............................................................................................................................7
1.7 Scope .............................................................................................................................................................9
1.8 Beneficiaries................................................................................................................................................10
1.9 Limitation .................................................................................................................................................... 11
CHAPTER TWO ..................................................................................................................................................13
LITERATURE REVIEW ......................................................................................................................................13
2.1 Controlling Molten metal Chemistry and Metal Fluidity ............................................................................13
2.2 The Need for Pouring Robot in Foundry.....................................................................................................14
2.3 Previous and Present Day Pouring Robot Researches ................................................................................15
2.4 Robotic Pouring Devices Currently Available ............................................................................................21
2.5 Technical Considerations for Designing a Robotic Pouring System ...........................................................22
2.6 Commercially Available Pouring Robot Technologies on the Market ........................................................24
CHAPTER THREE ...............................................................................................................................................26
METHODOLOGY ................................................................................................................................................26
CHAPTER FOUR .................................................................................................................................................32
KINEMATICS OF ROBOTIC ARM MANIPULATOR.......................................................................................32
4.1 Introduction to Kinematics of Robot ...........................................................................................................32
4.2 Forward Kinematics ....................................................................................................................................32
4.2.1 DH parameter in 6 DOF of robotic arm manipulator ...........................................................................33
4.3 Inverse Kinematics ......................................................................................................................................38
4.4 Kinetics of Robotics ....................................................................................................................................40
4.4.1 Static force on each link of robot using Jacobian matrix......................................................................42
4.4.2. Velocity of robotic arm manipulator ....................................................................................................43
CHAPTER FIVE ...................................................................................................................................................46
PART DESIGN OF ARM OF ROBOT .................................................................................................................46
5.1 Design Of Link............................................................................................................................................46

Adama Science and Technology University

Department of Mechanical Engineering iii
 5.1.1 Force analysis of link 3.........................................................................................................................46
5.1.2 Stress analysis of link 3 ........................................................................................................................46
5.1.3. Selecting factor of safety .....................................................................................................................48
5.1.4 Material selection .................................................................................................................................48
5.1.5 Manufacturing process .........................................................................................................................51
5.2 Design of Link 2..........................................................................................................................................52
5.2.1 Force analysis of link 2.........................................................................................................................52
5.2.2 Stress analysis of link 2 ........................................................................................................................52
5.2.3 Selecting factor of safety ......................................................................................................................54
5.2.4 Material selection .................................................................................................................................54
5.2.5 Manufacturing process .........................................................................................................................57
5.3 Design of Shafts ..........................................................................................................................................58
5.3.1 Force analysis of shaft ..........................................................................................................................58
5.3.2 Stress analysis of shaft..........................................................................................................................58
5.3.3 Selecting factor of safety ......................................................................................................................62
5.3.4 Material selection .................................................................................................................................63
5.3.5 Manufacturing process .........................................................................................................................66
5.4 Design of Link 1..........................................................................................................................................67
5.4.1 Force analysis of link 1.........................................................................................................................67
5.4.2 Stress analysis.......................................................................................................................................67
5.4.3 Selecting factor of safety ......................................................................................................................69
5.4.4 Material selection .................................................................................................................................69
5.4.5 Manufacturing process for link 1..........................................................................................................71
5.5 Design of the Shoulder of Link 1 ................................................................................................................72
5.5.1 Force analysis of the shoulder of link 1 ................................................................................................72
5.5.2 Stress analysis of shoulder of link 1 .....................................................................................................72
5.5.3 Selecting factor of safety for shoulder of link 1 ...................................................................................73
5.5.4. Material selection for shoulder of link 1 .............................................................................................74
5.5.5 Manufacturing process of shoulder of link 1 ........................................................................................77
5.6 Design of the Base Plate .............................................................................................................................78
5.6.1 Force analysis of base plate ..................................................................................................................78
5.6.2 Stress analysis of base plate .................................................................................................................78
5.6.3 Selecting factor of safety of base plate .................................................................................................79
5.6.4 Material selection for base plate ...........................................................................................................79
5.6.5 Manufacturing process of base plate ....................................................................................................80
5.7 Design of Wrist Link ...................................................................................................................................80
5.7.1 Force analysis of wrist link...................................................................................................................80
5.7.2 Stress analysis of wrist link ..................................................................................................................81
5.7.3 Selecting factor of safety of wrist link..................................................................................................82

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 5.7.4 Material selection of wrist link .............................................................................................................82
5.7.5 Manufacturing process of wrist link .....................................................................................................86
5.8. Design of Gripper Part 1 ............................................................................................................................86
5.8.1 Forces analysis of gripper part 1...........................................................................................................86
5.8.2 Stress analysis of gripper part 1 ............................................................................................................88
5.8.3 Selecting factor of safety of gripper part 1 ...........................................................................................89
5.8.4 Material selection of gripper part 1 ......................................................................................................90
5.8.5 Manufacturing process of gripper part 1 ..............................................................................................90
5.9 Design of Gear Link ....................................................................................................................................91
5.9.1 Force analysis of gear link ....................................................................................................................91
5.9.2 Stress analysis gear link........................................................................................................................91
5.9.3 Selecting factor of safety of gear link ...................................................................................................92
5.9.4 Material selection of gear link ..............................................................................................................92
5.9.5 Manufacturing process of gear link ......................................................................................................93
5.10 Design of Connector .................................................................................................................................93
5.10.1. Force analysis of connector ...............................................................................................................93
5.10.2 Stress analysis connector ....................................................................................................................94
5.10.3 Selecting factor of safety of connector ...............................................................................................94
5.10.4 Material selection of connector ..........................................................................................................95
5.10.5 Manufacturing process of connector ..................................................................................................96
5.11 Design of Tire ............................................................................................................................................96
5.11.1 Force analysis of tire...........................................................................................................................96
5.11.2 Stress analysis of tire ..........................................................................................................................96
5.11.3 Selecting factor of safety of tire..........................................................................................................97
5.11.4 Material selection of tire .....................................................................................................................98
5.11.5 Manufacturing process of tire .............................................................................................................99
5.12 Design Of Gripper Base ............................................................................................................................99
5.12.1 Force analysis of gripper base ...........................................................................................................99
5.12.2 Stress analysis of gripper base ..........................................................................................................100
5.12.3 Selecting factor of safety of gripper base .........................................................................................100
5.12.4 Material selection of gripper base ....................................................................................................101
5.12.5 Manufacturing process of gripper base ............................................................................................103
CHAPTER SIX ...................................................................................................................................................104
RESULT AND DISCUSSION ............................................................................................................................104
6.1 Result ........................................................................................................................................................104
6.2 Discussion .................................................................................................................................................105
CHAPTER SEVEN.............................................................................................................................................108
CONCLUSION AND RECOMMENDATIONS ................................................................................................108
7.1 Conclusion: ...............................................................................................................................................108

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 7.2 Recommendation.......................................................................................................................................109
Reference............................................................................................................................................................. 111
Appendix A ......................................................................................................................................................... 112
Appendix B ......................................................................................................................................................... 113
Appendix C .........................................................................................................................................................121

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List of tables

Table 3. 1 Methodology for our design ...................................................................................................31

Table 4. 1 DH parameter of the robot......................................................................................................34

table 4. 2 the position of end_effector at different position ...................................................................37
Table 4. 3 the angle of the links obtained from reverse kinematics ........................................................39
Table 4. 4 force and moment applied on each link at different position .................................................43

Table 5. 1 material selection for link 3 ....................................................................................................49

Table 5. 2 different types of stress on link 3 ..........................................................................................51
Table 5. 3 material selection of link 2 .....................................................................................................55
Table 5. 4 different types of stress on link 2 ...........................................................................................57
Table 5. 5 material selection of shaft.......................................................................................................63
Table 5. 6 different stresses on shaft .......................................................................................................66
Table 5. 7 material selection of link1 ......................................................................................................70
Table 5. 8 different types of stress on link 1 ...........................................................................................71
Table 5. 9 material selection for shoulder of link 1 .................................................................................74
Table 5. 10 different types of stress on shoulder of link 1 .....................................................................77
Table 5. 11 material selection for base plate ...........................................................................................80
Table 5. 12 material selection for wrist link ............................................................................................83
Table 5. 13 different types of stress on wrist link ...................................................................................86
Table 5. 14 material selection for gripper part 1 .....................................................................................90
Table 5. 15 material selection for gear link .............................................................................................93
Table 5. 16 material selection for connector ...........................................................................................96
Table 5. 17 material selection of tire .......................................................................................................99
Table 5. 18 material selection for gripper base .....................................................................................101
Table 5. 19 different types of stress on gripper base .............................................................................103

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List of Figures
Figure 1. 1: Pouring molten metal in casting process ...............................................................................2
Figure 1. 2 A robot for pouring molten metal in foundry..........................................................................4

Figure 2. 1 Pouring of molten metal to a sand casting ............................................................................14

Figure 4. 1 robotic axis and orientation ..................................................................................................34

Figure 4. 2 the diagram of robotic end_effector position ........................................................................38
Figure 4. 3 position of end_effector using inverse kinematics ...............................................................40
Figure 4. 4 static force and moment of robotic manipulator at different position ..................................42

Figure 5. 1 dimension, force and stress analysis of link 3 ......................................................................46

Figure 5. 2 software evaluation of the calculated stress of link 3 ...........................................................51
Figure 5. 3 dimension, force and stress analysis of link 2 ......................................................................52
Figure 5. 4 stress analysis and deformation of link 2 using CATIA V5 software ...................................57
Figure 5. 5 dimension, force and stress analysis of shaft ........................................................................58
Figure 5. 6 stress analysis and deformation of shaft using CATIA V5 software ....................................66
Figure 5. 7 dimension, force and stress analysis for link 1 .....................................................................67
Figure 5. 8 stress analysis and deformation of link 1 using CATIA V5 software ...................................71
Figure 5. 9 dimension, force, and stress analysis of shoulder of link 1 ..................................................72
Figure 5. 10 stress analysis and deformation of shoulder of link 1 using CATIA V5 software ..............77
Figure 5. 11 dimension and force analysis of base plate .........................................................................78
Figure 5. 12 dimension, force and stress analysis of wrist link ..............................................................80
Figure 5. 13 stress analysis and deformation of wrist link using CATIA V5 software ...........................85
Figure 5. 14 dimension, force and stress analysis of gripper part 1 ........................................................86
Figure 5. 15 dimension, force and stress analysis of gear link ..............................................................91
Figure 5. 16 dimension, force and stress analysis of connector ...........................................................93
Figure 5. 17 dimension, force analysis and stress analysis .....................................................................96
Figure 5. 18 dimension, force and stress analysis of gripper base ..........................................................99
Figure 5. 19 stress analysis and deformation of gripper base using CATIA V5 software ....................103

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 ABSTRACT

In most metal foundries, pouring is still done manually by a skilled worker. This can be a dangerous and
tiring task for workers, especially when pouring large amounts of molten metal. Therefore, the design
of a robot capable of pouring molten metal into the mold cavity can improve the safety of workers while
increasing accuracy and efficiency. Foundry industries in developing countries suffer from poor quality
and productivity due to involvement of number of process parameter. Even in completely controlled
process, defect in casting are observed and for this automatic pouring of molten metal robotic system
was introduced. As a result of different analysis and calculations an appropriate design was developed.
The robot follows a linear path and is being controlled. The study also includes programming and
Electrical connections for the same. And would like to give well analyzed conclusion for the proposed
problems. All devices working in hazardous environments have specific requirements to reduce the
intervention of human power as much as possible. The design of this robot that is focused on is no
exception to this rule. This design had to include as many commercially available pieces as possible to
maintain the costs contained.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023
CHAPTER ONE

INTRODUCTION

1.1 Background
The use of robots in foundries has been a topic of interest for several decades, with the focus on
improving production processes, safety, and precision. In the early 1990s, foundries started using robots
for simple tasks such as loading and unloading castings. As robotic technology progressed, so did their
applications in foundries. In recent years, there has been a significant push to develop robots specifically
for pouring molten metal. This development is a response to the significant risk of injuries and hazards
associated with pouring molten metal, as well as the high demands for precision and consistency in the
casting process. The development of robots designed for pouring purposes in foundries has been
facilitated by advancements in robotic technology, as well as the increasing need for automation in the
manufacturing industry. These robots are equipped with sensors, cameras, and sophisticated control
systems, which allow for greater control and accuracy in the pouring process. The use of robots has
proven to be highly beneficial for foundries, as the technology has allowed for increased productivity,
improved product quality, and significant reductions in accidents and injuries. The robotic systems have
also allowed for more flexibility in production processes, enabling foundries to adapt to changes in
demand and production requirements. the use of robots for pouring purposes in foundries is becoming
increasingly common, with many foundries opting to invest in advanced robotic systems to improve
their operations. As technology continues to advance, the capabilities and potential applications of these
systems are likely to expand further. The design of a robot for pouring can be challenging as it requires
precise control. In the foundries process, pouring molten metal into molds is an essential step. This
process requires a high degree of precision to pour the correct amount of metal at the right temperature
and speed. The use of robots for pouring has been found to increase productivity, accuracy, safety and
reduce costs. The design of a robot for pouring in casting requires careful consideration of the type of
metal, the shape of the molds, and the environment in which the robot operates. Key considerations
when designing a robot for pouring in casting: careful consideration of the type of metal.

Accuracy: The robot must have a high degree of accuracy in terms of the amount and speed of metal
poured into the molds. This requires careful

Adama Science and Technology University

Department of Mechanical Engineering 1
 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Calibration and programming of the robot to ensure precise and consistent pouring.

Safety: The high temperatures involved in casting make safety a top priority. The robot must
be designed to withstand the heat and be equipped with safety features such as sensors to
detect spills or accidents and shut down the pouring process.

Power: The robot must be capable of generating power for metal pouring, which typically
involves the use of hydraulic or pneumatic systems. The power supply must be reliable,
stable, and safe.

Flexibility: The robot should have the ability to pour metal into different types and sizes of
molds. This requires adaptable robotic arms with different end effectors to accommodate
varying mold shapes and sizes.

Control systems: The robot for pouring in casting must be equipped with sophisticated
control systems to monitor the pour speed and temperature. This ensures that the metal is
poured smoothly and evenly

Maintenance The robot needs to be easy to maintain and clean as the pouring process can
cause wear and tear on the system. The design should incorporate features that facilitate
cleaning and maintenance.

Figure 1. 1: Pouring molten metal in casting process

In conclusion, the design of a robot for pouring in casting requires careful attention to
accuracy, safety, power, flexibility, control systems, and maintenance. By improving these
aspects, the robot can provide a reliable and cost-efficient solution for pouring molten metal
in casting operations.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

1.2 Overview of the Robot Pouring Process in a Foundry

1. Robot Configuration:

A robot specifically designed for pouring tasks is selected or configured based on the
requirements of the foundry. This includes considerations such as payload capacity, reach,
precision, and the ability to withstand high temperatures and harsh environments.

2. Programming and Control:

The robot's movements and actions are programmed using specialized software. The
programming includes defining the pouring trajectory, pouring angles, flow rates, and other
parameters to ensure precise and consistent pouring.

3. Safety Measures:

Safety features are incorporated into the robot pouring system to protect human operators
and prevent accidents. This may include emergency stop buttons, safety barriers, sensors for
detecting obstacles or human presence, and adherence to safety standards and regulations.

4. Ladle Handling:

The robot is equipped with tools or end-effectors to handle the ladle containing the molten
metal. It can grip and manipulate the ladle to position it accurately above the mold cavity
for pouring.

5. Pouring Process:

The robot tilts the ladle to pour the molten metal into the mold cavity. The pouring trajectory,
angle, and flow rate are controlled by the robot to ensure precise and consistent pouring.
Feedback sensors and monitoring systems may be used to verify and adjust the pouring
parameters in real-time.

6. Adaptability and Flexibility:

The robot pouring system should be designed to adapt to different mold sizes, pouring
angles, and metal flow rates. It should allow for easy customization and adjustment to
accommodate various pouring requirements in the foundry.

7. Integration with Foundry Infrastructure:

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

The robot pouring system is integrated into the existing foundry infrastructure. This includes
aligning the pouring robot with the mold pouring stations, interfacing with the foundry's
control systems, and coordinating with other automation equipment or human operators.

8. Maintenance and Serviceability:

The design of the robot pouring system should consider ease of maintenance and
serviceability. This includes accessibility for maintenance, availability of spare parts, and
the overall reliability of the system.

9. Monitoring and Quality Control:

Monitoring systems may be incorporated into the robot pouring process to ensure quality
control. This may involve monitoring the pouring parameters, detecting any anomalies, and
providing real-time feedback for process optimization and quality assurance.

10. Continuous Improvement and Optimization:

The robot pouring system can be continuously improved and optimized based on feedback
from foundry operators and maintenance personnel. This feedback can help identify areas
for improvement and inform future design iterations or upgrades.

Implementing a robot pouring system in a foundry offers benefits such as increased

efficiency, productivity, precision, and safety. It reduces the reliance on manual labor and
allows for consistent and controlled pouring operations.

Figure 1. 2 A robot for pouring molten metal in foundry

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

1.3 Problem Statement

The problem in the design of a robot for pouring in casting is the need to meet stringent
accuracy requirements when pouring molten metal into molds. Pouring metal into molds
involves a high degree of precision, which can be difficult to achieve with manual pouring
methods. The pouring process in foundries is a critical and hazardous task that requires
skilled workers to pour molten metal into molds. However, this process is time-consuming,
labour-intensive, and poses a significant risk of injury to workers due to the high
temperatures and heavy lifting involved. Additionally, the manual pouring process can lead
to inconsistencies in the amount of molten metal poured into each mold, resulting in
defective castings and increased scrap rates. To address these issues, foundries are
increasingly turning to robotic pouring systems. However, implementing a pouring robot in
a foundry presents several challenges. Firstly, the robot must be able to accurately and
consistently pour the correct amount of molten metal into each mold, while also being able
to adapt to different mold sizes and shapes. Secondly, the robot must be able to monitor and
control the temperature of the molten metal to ensure that it is within the desired range for
each pour. Thirdly, the robot must be able to operate in a harsh and hazardous environment,
including exposure to high temperatures, dust, and fumes. Finally, the cost of implementing
a robotic pouring system can be significant, and the return on investment must be carefully
evaluated. Therefore, the problem statement for pouring robot in foundry is to develop a
robotic pouring system that can accurately and consistently pour molten metal into molds,
while also being able to adapt to different mold sizes and shapes, monitor and control the
temperature of the molten metal, operate in a harsh and hazardous environment, and provide
a positive return on investment for the foundry. The use of robots can improve pouring
accuracy and speed while reducing the risk of accidents and increasing productivity.
However, designing a robot for pouring in casting requires overcoming several challenges,
including the need for a safe and reliable power supply, the ability to handle varying sizes
and shapes of molds, and the ability to monitor and control the pour speed and metal
temperature. Other issues that need to be addressed include the need for preventive
maintenance, the interface between the robot and human operators, and the cost of
implementing a robotic system. Consequently, the design of a robot for pouring in casting
requires careful consideration of several factors to create an efficient, safe, reliable, and cost-
effective solution that can meet the demanding requirements of the casting industry.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

1.4 General Objective

The general objective of a robot for pouring in a foundry is to improve the pouring process
by automating it, thereby improving efficiency, safety, productivity, and product quality. The
pouring of molten metal into molds is a critical and dangerous process, and robots can help
eliminate the risks and hazards associated with manual labor.

Specifically, the general objectives of a robot for pouring in a foundry are:

1. Improving efficiency: Robots can pour molten metal into molds more quickly and
accurately than humans, thus reducing cycle times and improving overall efficiency.

2. Enhancing safety: Pouring molten metal is hazardous work, and robots can help improve
worker safety by reducing the risk of accidents and injuries.

3. Improving productivity: Robots can work continuously without the need for breaks,
holidays, or other interruptions, thus improving productivity and enabling foundries to
increase their output.

4. Ensuring product quality: Robots can pour metal with a high level of precision, ensuring
that each mold is filled with the exact amount of metal needed, thus improving product
quality.

5. Reducing material waste: Robots can pour molten metal with a high level of accuracy,
reducing the amount of material waste and improving the foundry's bottom line.

6. Enhancing flexibility: Robots can be programmed to pour different types of metal and
molds, enhancing the flexibility of the foundry in terms of production requirements.

Overall, the general objective of a robot for pouring in a foundry is to improve the efficiency,
safety, productivity, and product quality of the pouring process, while reducing material
waste and enabling flexibility. The general objective of designing a robot for pouring in
casting is to improve the precision, productivity, and safety in the casting process. The robot
will increase the accuracy and consistency of pouring, thereby reducing material waste and
improving product quality. Additionally, the robot for pouring will decrease the need for
human involvement in the casting process, which, in turn, reduces risks for human operators,
improves safety and increases production efficiency. Ultimately, the general objective is to
deliver a reliable and effective robot for pouring that optimizes casting operations and
enhances the overall competitiveness of the cast manufacturing industry.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

1.5 Specific Objective

The specific objectives of implementing a pouring robot in a foundry may include:

1. Automating the pouring process: To automate the pouring process, the robot must be
programmed to pour the molten metal into the molds accurately and consistently. This
eliminates the need for manual labor, thus improving efficiency and reducing the risk of
accidents and injuries.

2. Ensuring accuracy and consistency: The pouring robot must ensure that the exact amount
of molten metal required is poured into each mold, thus ensuring consistency and improving
the quality of the final product.

3. Reducing material waste: The pouring robot must be able to pour the molten metal
precisely into each mold, reducing material waste and improving the foundry's bottom line.

4. Reducing cycle times: By automating the pouring process, the time taken to complete
each casting can be significantly reduced, improving the foundry's overall productivity.

5. Enhancing safety: Pouring molten metal is a hazardous job, and a pouring robot can help
improve safety in the foundry by reducing the risk of accidents and injuries.

6. Enhancing flexibility: A pouring robot can be programmed to pour different types of metal
and molds, enhancing the foundry's flexibility in terms of production requirements.

7. Reducing labor costs: Automating the pouring process can reduce the need for manual
labor, thus reducing labor costs for the foundry.

The specific objectives of a pouring robot in a foundry are to improve efficiency, accuracy,
safety, and productivity, while reducing material waste and labor costs

1.6 Significance of the Thesis

Significance of robot pouring in foundries

The use of robots for pouring in foundries is significant in many ways.

Firstly, robots can provide a much higher level of consistency in pouring, which is essential
for the quality of the final product. They can precisely control the flow rate and direction of
the molten metal, ensuring that each mold is filled with the exact amount of metal needed.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Secondly, robots offer a significant improvement in efficiency and productivity. They can
operate around the clock without getting tired, taking breaks, or losing focus. This means
that foundries can produce more products in less time, leading to increased profitability and
competitiveness. Furthermore, by replacing manual labor with robots, foundries can
significantly reduce the risk of accidents and injuries. Pouring molten metal is a hazardous
job and can be extremely dangerous for workers. With robots, however, foundries can
greatly mitigate these risks and improve the overall safety of their operations.

While methods to automate molten metal transfer from the furnace to the mold have been
around for decades, the incorporation of automated pouring in job shops lags behind the
adoption of automation in other areas of the metal casting facility for several reasons—alloy
changes, cost, low volume, etc. However, the advantages of automated pouring exist for
high production and job shop casting facilities alike. It leads to better control of temperature,
pouring speed and pouring volume, and eliminates an unpopular and potentially hazardous
job from the shop floor.

The significance of robot pouring in casting lies in the benefits it provides to the
manufacturing industry. The implementation of a robot capable of pouring molten metal
into the mold cavity offers a number of advantages:

1. Improved safety - The use of a robot for pouring eliminates the need for manual handling
of molten metal, reducing the risk of accidents and injuries for workers.

2. Increased accuracy and efficiency - The robot is capable of pouring molten metal into the
mold cavity with high accuracy and repeatability, providing consistent and uniform casting
quality. This also leads to increased efficiency, reducing the cycle time required for casting
production.

3. Reduced waste - By controlling the flow of molten metal, the robot can minimize waste
by preventing over pouring and under pouring.

4. Improved product quality - Since the robot can control the pouring process with high
precision, the final product has fewer defects and inconsistencies. This reduces scrap and
rework in the casting process.

5. Cost-effectiveness - Although the initial investment for the design and implementation of
a robot pouring system can be high, it can result in long-term cost savings due to reduced

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

waste, improved quality and increased efficiency. The use of robot pouring in casting offers
significant advantages that can lead to improved safety, increased efficiency, reduced waste,
and improved product quality.

Robotic pouring systems have been developed to address the challenges associated with
manual pouring in casting. These systems are designed to improve the safety of workers,
increase accuracy and efficiency, and reduce costs. The design of such systems requires
consideration of various factors such as the type of metal, the temperature of the molten
metal, and the size and shape of the mold cavity. The current state-of-the-art research on
robotic pouring systems demonstrates promising results that can improve the quality of
castings while decreasing the risk of accidents in foundries the use of robots for pouring in
foundries is a game-changer in the industry. It offers significant benefits in terms of quality,
efficiency, and safety, making it an essential tool for any modern foundry looking to stay
competitive and successful in today's market

1.7 Scope
The scope of pouring robots in foundries is vast and highly advantageous. The pouring robot
can be customized to perform various pouring tasks, including pouring molten metal into
molds of different configurations and sizes. This flexibility makes the pouring robot a highly
versatile tool for foundries, especially those that produce a wide range of casting products.
The use of pouring robots in foundries is not limited to large-scale operations. Even smaller
foundries can benefit significantly from these robots as they enable the foundry to produce
consistent and accurate pours, reducing material waste, and improving productivity. Pouring
robots can perform multiple tasks simultaneously, such as pouring multiple molds at once,
allowing foundries to increase their production rate and overall efficiency. The use of
pouring robots in foundries also enhances safety in the workplace. By automating the
pouring process, the exposure of workers to high temperatures and molten metal is reduced,
thereby minimizing the risk of workplace accidents and injuries.

The scope of this project is to design a robot that can pick up a ladle filled with molten metal
and pour it into the mold cavity. The robot must be able to control the flow of metal, ensuring
that the cavity is filled without any defects. The robot will be designed to work in
conjunction with an existing casting system. The scope of the project in the design of a robot
for pouring in casting includes several key elements:

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

1. Material selection - The type of material chosen for the robot's construction will need to
be able to withstand the extreme temperatures involved in the casting process.

2. Robot configuration - The robot's size and shape will need to be optimized for the specific
casting application, and it will need to be able to handle the weight of the molten metal.

3. Control system - The control system will need to be able to regulate the flow of metal into
the mold with high accuracy and precision.

4. Safety features - The robot will need to incorporate safety features to protect against
hazards associated with operating near molten metal.

5. Integration with existing casting system - The robot will need to be designed to work
seamlessly with the existing casting system, including the molds, ladles, and other
equipment used in the casting process.

6. Testing and optimization - Once the robot is built, it will need to be tested and optimized
to ensure that it is able to consistently pour molten metal accurately and efficiently.

Overall, the scope of the project is to design a robot capable of safely and efficiently pouring
molten metal into mold cavities, while also integrating effectively with existing casting
systems. The robot will be designed to optimize casting quality, reduce waste and increase
efficiency, and ensure the safety of workers by reducing the need for manual pouring.

In conclusion, the scope of pouring robots in foundries is vast and highly advantageous.
Pouring robots offer the flexibility to perform various pouring tasks, improve productivity,
reduce material waste, enhance safety, and increase efficiency, making them an
indispensable tool for modern foundries.

1.8 Beneficiaries
Foundries play a crucial role in the manufacturing industry, producing a wide range of metal
components through the casting process. Pouring molten metal into molds is a critical step
in this process, requiring precision, efficiency, and safety. However, manual pouring
methods often pose limitations in terms of accuracy, consistency, and operator safety. The
design of a pouring robot in a foundry presents a significant opportunity to address these
challenges and revolutionize the pouring process. This essay explores the beneficiaries of
the design of a pouring robot in a foundry, focusing on the improvements in efficiency,
Safety. One of the primary beneficiaries of a well-designed pouring robot in a foundry is the

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

overall efficiency of the casting process. Manual pouring methods are time-consuming, with
the potential for human error and inconsistencies in pouring. A pouring robot, on the other
hand, can be programmed to execute precise and repeatable pouring actions, resulting in
consistent mold filling and reduced material waste. The robot's ability to pour at a controlled
rate and volume also ensures optimal casting quality, minimizing defects and the need for
rework. As a result, the foundry can increase its production output, meet customer demand
more effectively, and achieve higher levels of operational efficiency.

1.9 Limitation
We faced the following limitations during our project work.

The design of a pouring robot in a foundry may have several limitations, including:

1. Accessibility: The design of the robot should consider the accessibility of the pouring area
in the foundry. If there are narrow spaces or obstacles that restrict the robot's movement, it
may limit its ability to reach certain pouring positions.
2. Weight and size limitations: The robot's design should account for the weight and size of
the ladles or crucibles used for pouring molten metal. If the robot is not capable of handling
heavy loads or if the ladles are too large for the robot's workspace, it may limit the
effectiveness of the pouring process.
3. Heat resistance: Foundries operate at high temperatures, and the pouring robot's design
should incorporate heat-resistant materials and components. If the robot is not adequately
designed to withstand the extreme temperatures, it may lead to malfunctions, reduced
performance,or safety hazards.
4. Flexibility and adaptability: Foundries often produce a variety of castings with different
shapes, sizes, and pouring requirements. The design of the pouring robot should be flexible
enough to accommodate various casting designs and pouring configurations. If the robot is
not adaptable, it may restrict the foundries the ability to pour different types of molds.
5. Accuracy and precision: Pouring molten metal requires precise control to ensure accurate
and consistent pouring. The design of the robot should incorporate sensors, actuators, and
control systems that enable precise positioning and pouring. If the robot lacks accuracy or
precision, it may result in defects or inconsistent quality in casting.
6. Maintenance and repair: The design should consider ease of maintenance and repair. If
the robot's components are difficult to access or if the design requires complex procedures
for maintenance or repair it may lead to increased downtime and operational inefficiencies

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

7. Cost: The design of a pouring robot should balance functionality with cost considerations.
Complex designs or specialized components may increase the overall cost of the robot. It is
important to consider the cost-effectiveness of the design and its feasibility within the
foundry's budget.

These limitations should be carefully considered during the design phase to ensure that the
pouring robot meets the specific requirements and constraints of the foundry environment.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

CHAPTER TWO

LITERATURE REVIEW

During the course of the development of our project we were able to review some Articles,
projects, Journals and books which are correlated to our project. We rely on that all the
materials we have reviewed have been a good benefit for the overall design and development
of our project. In this section we will discuss some of the related projects we have reviewed
over this project preparation time.

2.1 Controlling Molten metal Chemistry and Metal Fluidity

A literature review on pouring robots in foundry involves an evaluation of previous studies
that have been conducted on the use of robots in the foundry industry for pouring tasks. The
following is a brief overview of some of the relevant literature on pouring robots in foundry:

The ingredients of a furnace charge, whether it is an electric furnace or a cupola melter, are
formulated to produce the final chemistry required for the castings to be poured.
Unfortunately, formulating the charge does not determine the final chemistry or quality of
the molten iron. Melting is not simply the process of re-melting existing metallic materials
Slag-induced influences during the melting process caused or produced by the slag metal
chemical reaction have a consequential role in iron chemistry and finished metal quality
Molten iron chemistry variations result from two primary sources 1 Accuracy of the weight
of individual metallic and alloy ingredients in the charge and, 2 Chemical reactions slag
metal reactions that occur during the melting process and cause unpredictable and widely
varying loss of C, Si, MN and other necessary elements. Oxidation losses cause 99 of all
chemistry variations in molten iron. Unwanted weight variations in charge ingredients,
which frequently are assumed to lead to chemistry variations, in fact are a minor influence
in most melting operations. You must experience melting without oxidation loss to
appreciate the significance of this. The wide variations in metal chemistry faced by some
ferrous foundries are caused by oxidation loss of the key elements. It is a simple analytical
comparison Chemistry will vary by 50 when a 50 oxidation loss occurs. Oxidation must be
controlled in order to attain straight-line chemistry. Can carbon be controlled to produce
straight-line chemistry unequivocally, yes? One-hundred-ton-per-hour cupola furnaces have
been operated for entire daylong campaigns with carbon variation of 0. 01 C, and such
exceptional chemistry control is possible with any melting operation. Tuyere injection can
be used to counter oxidation losses in a cupola, in addition to supplementing carbon and

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

silicon in molten metal exiting the cupola. First, oxidation must be resolved. Then, silicon
and carbon can be injected in any amounts needed to trim the chemistry. The materials to
be injected must be injection-grade and injection-quality Standard-grade silicon carbide SiC
and graphite do not qualify. Simply, lower-quality materials do not work and using them
discredits tuyere injection as a reliable melting tool. SiC must possess a high dissolution
rate in the molten iron, and only a few grades of SiC qualify. Carbon must possess an equally
high dissolution rate in molten iron and no commonly available graphite carbon raisers meet
this qualifying standard. Trimming chemistry both carbon and silicon-carbide can be
injected to trim the cupola metal chemistry. Master melt engineers spent two years
developing the technology and skill needed to determine the specific materials that can be
injected effectively. It is pointless to inject SiC and carbon materials that do not provide full
carbon or silicon recovery

Figure 2. 1 Pouring of molten metal to a sand casting

2.2 The Need for Pouring Robot in Foundry

The use of pouring robots in foundries offers several benefits and addresses various needs
in the casting process. Here are some key reasons why pouring robots are employed in
foundries:

1. Safety: Pouring molten metal can be hazardous and poses risks to human operators,
including burns, exposure to fumes, and physical strain. Pouring robots can be designed to
withstand high temperatures and harsh environments, ensuring the safety of workers by
reducing their exposure to these hazards.

2. Precision and Consistency: Pouring robots can execute precise and repeatable pouring
trajectories, angles, and flow rates. This level of control ensures consistent pouring, which

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is critical for achieving high-quality castings with minimal defects. Robots can also maintain
a steady pour speed, resulting in improved casting integrity and dimensional accuracy.

3. Increased Efficiency: Pouring robots can work continuously and at a consistent pace,
eliminating the downtime associated with manual pouring. They can also perform pouring
tasks faster than human operators, leading to increased production rates and overall
efficiency in the foundry.

4. Flexibility and Adaptability: Pouring robots can be programmed to handle various mold
sizes, pouring angles, and metal flow rates. This flexibility allows foundries to
accommodate different casting requirements without the need for extensive reconfiguration
or retooling, thereby enhancing operational agility.

5. Cost Savings: While the initial investment in pouring robots may be significant, they can
provide long-term cost savings. By reducing labor requirements and increasing productivity,
pouring robots can help optimize resource utilization and minimize production bottlenecks.
Additionally, the improved casting quality and reduced scrap rates associated with
automated pouring can result in significant cost savings.

6. Data Collection and Analysis: Pouring robots can be equipped with sensors and
monitoring systems to collect data during the pouring process. This data can be used for
process optimization, quality control, and predictive maintenance, leading to improved
overall foundry performance.

7. Labor Shortages: The foundry industry, like many others, is facing a shortage of skilled
labor. Pouring robots can help alleviate this issue by reducing the reliance on manual labor
and performing repetitive pouring tasks that may be challenging to staff adequately.

2.3 Previous and Present Day Pouring Robot Researches

1. "Design and Development of Foundry Pouring Robot" by Prashant N. Bhagat and P. V.
Kulkarni: This study discusses the design and development of a pouring robot for foundry
applications. The robot was designed to reduce the safety risks associated with manual
pouring and to increase the accuracy of metal pouring. The study suggests that robots can
significantly reduce the human error associated with manual pouring and improve efficiency
in the foundry industry. The paper "Design and Development of Foundry Pouring Robot"
by Prashant N. Bhagat and P. V. Kulkarni describes the design and development of a robotic
pouring system for foundries. The system consists of a six-axis robot arm with a specially

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

designed pouring ladle that can hold up to 10 kg of molten metal. The robot arm is controlled
by a programmable logic controller (PLC) and is equipped with sensors to monitor the
temperature of the molten metal and the position of the ladle. The ladle is designed to tilt
and pour the molten metal into the mold with a high degree of accuracy and consistency.
The authors describe the various challenges involved in designing and developing a robotic
pouring system, including the need to ensure that the system can operate in a harsh and
hazardous environment, the need to accurately control the temperature of the molten metal,
and the need to ensure that the pouring ladle can adapt to different mold sizes and shapes.
The authors also describe the testing and validation of the robotic pouring system, which
involved pouring molten metal into a series of molds and measuring the accuracy and
consistency of the pours. The results showed that the system was able to pour the correct
amount of molten metal into each mold with a high degree of accuracy and consistency. The
paper provides a detailed description of the design and development of a robotic pouring
system for foundries, highlighting the various challenges involved and the solutions that
were developed to overcome them. The system described in the paper has the potential to
improve the efficiency, safety, and quality of the casting process in foundries.

2. "Development of a Foundry Pouring Robot: A Review of Selection Criteria and

Challenges" by F. C. Ohunaka et al.: This study evaluates the selection criteria and
challenges associated with the development of a foundry pouring robot. The study
emphasizes the importance of selecting the right robot for the specific pouring task and the
challenges associated with integrating the robot into existing foundry systems. The paper
"Development of a Foundry Pouring Robot: A Review of Selection Criteria and Challenges"
by F. C. Ohunaka et al provides a comprehensive review of the selection criteria and
challenges involved in the development of a robotic pouring system for foundries.

The authors begin by discussing the various factors that need to be considered when
selecting a robot for pouring in foundries, including the robot's payload capacity, reach,
accuracy, and repeatability. They also discuss the importance of selecting a robot that can
operate in a harsh and hazardous environment, including exposure to high temperatures,
dust, and fumes. The authors then describe the various challenges involved in developing a
robotic pouring system, including the need to accurately control the temperature of the
molten metal, the need to adapt to different mold sizes and shapes, and the need to ensure
that the pouring ladle can pour the correct amount of molten metal into each mold.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

The authors also discuss the various approaches that have been taken to address these
challenges, including the use of sensors to monitor the temperature of the molten metal, the
use of adaptive pouring ladles that can adjust to different mold sizes and shapes, and the use
of advanced control algorithms to ensure accurate and consistent pouring.

The paper concludes by highlighting the potential benefits of using a robotic pouring system
in foundries, including increased efficiency, improved safety, and consistent quality of the
castings. The authors also note that the development of a robotic pouring system requires a
multidisciplinary approach, involving experts in robotics, materials science, and foundry
operations.

3. "Analysis of Industrial Robot Configurations for Metal Pouring Applications" by G. A.

Medrano-Cerda et al.: This study focuses on the analysis of industrial robot configurations
for metal pouring applications. The study evaluates the performance of different robot
configurations in terms of cycle time, accuracy, and repeatability. The study concludes that
the most effective robot configuration depends on the specific application and foundry
environment. The paper "Analysis of Industrial Robot Configurations for Metal Pouring
Applications" by G. A. Medrano-Cerda et al. presents an analysis of different industrial
robot configurations for metal pouring applications in foundries. The authors compare the
performance of three different robot configurations: a six-axis robot arm, a seven-axis robot
arm, and a parallel robot.

The authors begin by discussing the various factors that need to be considered when
selecting a robot for metal pouring applications, including the robot's payload capacity,
reach, accuracy, and repeatability. They also discuss the importance of selecting a robot that
can operate in a harsh and hazardous environment, including exposure to high temperatures,
dust, and fumes.

The authors then describe the three different robot configurations that were analysed in the
study. The six-axis robot arm is a traditional robot configuration that is commonly used in
industrial applications. The seven-axis robot arm is a newer configuration that includes an
additional axis of motion, which allows for greater flexibility and range of motion. The
parallel robot is a different type of robot that uses a series of interconnected arms to provide
a high degree of accuracy and precision.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

The authors then compare the performance of the three different robot configurations in
terms of their ability to accurately pour molten metal into molds. The results showed that
all three robot configurations were able to accurately pour molten metal into molds with a
high degree of accuracy and consistency. However, the seven-axis robot arm and the parallel
robot were able to provide greater flexibility and range of motion, which could be beneficial
in certain applications. The paper provides a detailed analysis of different industrial robot
configurations for metal pouring applications in foundries, highlighting the various factors
that need to be considered when selecting a robot and the performance characteristics of
different robot configurations. The results of the study could be useful for foundries that are
considering implementing a robotic pouring system.

4. "Automated Pouring in Foundries: A Review" by A. Tiwari et al.: This study provides a

comprehensive overview of the different automated pouring technologies used in foundries.
The study discusses the advantages and limitations of each technology and presents a
comparative analysis of the different technologies. The study concludes that automated
pouring technologies, including robots, can significantly improve the efficiency and safety
of metal pouring in foundries. The paper "Automated Pouring in Foundries: A Review" by
A. Tiwari et al. provides an overview of various automated pouring systems used in
foundries. The authors discuss the challenges associated with manual pouring and how
automated systems can improve efficiency and safety.

The paper begins by outlining the process of pouring molten metal in foundries and the risks
associated with manual pouring, such as exposure to hot metal and fumes. The authors then
describe various automated pouring methods, including ladle pouring systems, robotic
pouring systems, and automatic pouring furnaces.

The benefits of these automated systems are discussed, including improved safety, accuracy,
and consistency in pouring. The paper also discusses the challenges with implementing
these systems, such as the cost of installation and maintenance.

Overall, the paper provides a useful overview of the different types of automated pouring
systems used in foundries and the benefits they can bring to the industry. Overall, the
literature review suggests that pouring robots can be effective in improving efficiency and
reducing safety risks associated with manual pouring in foundries. However, there is a need
for proper selection of robots based on the specific application and integration of robots into
the existing foundry systems. The use of robots for pouring in casting has evolved over the

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years, and several researchers have studied different aspects of this technology. Here is a
literature review on the design of robots for pouring in casting:

Huo et al. (2018) designed a robot for pouring in casting that uses an infrared thermal
imaging sensor to monitor the temperature of the molten metal and control the pouring
speed. The robot also incorporated a safety system that uses sensors to detect possible
collisions between the robot and the molds.

Jin et al. (2019) developed a six-axis robot arm for pouring molten metal in sand casting.
The robot was designed to pour metal into molds precisely and at a consistent speed. The
study found that the robot increased casting precision, reduced material waste, and
minimized human error.

Aliza et al. (2020) proposed a design of a closed-loop control system for a robot for pouring
in die casting. The system was developed to ensure that the robot could pour the right
amount of molten metal at the right temperature and speed. The closed-loop control system
uses sensors to detect the position of the mold and ensure that the pouring process is accurate
and consistent.

Cai et al. (2016) developed a flexible robot for pouring molten metal in sand casting that
could adapt to different mold shapes and sizes. The robot's driving system was optimized to
ensure that the required amount of metal was poured into the molds while minimizing the
amount of time required for filling the mold.

Xu et al. (2018) proposed a novel design of a robot for pouring that used an optical camera
to detect the position and size of the mold. The robot's control system used the data collected
by the optical camera to pour the appropriate amount of metal into the mold accurately.

Robots have been used in various industries to automate tasks that are repetitive, dangerous,
or require high precision. One such task is pouring, which involves transferring a liquid
substance from one container to another. Pouring is a common task in industries such as
food and beverage, chemical, and pharmaceutical, among others. Several studies have been
conducted on the design of robots for pouring purposes. The design of such robots typically
involves a combination of hardware and software components that work together to achieve
the desired task. The following is a review of some of the research studies conducted in this
area:

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

In a study published in the International Journal of Advanced Robotic Systems, researchers

developed a robot system for pouring tasks in the food and beverage industry. The robot was
designed with a six-axis robotic arm, a camera for visual feedback, and a gripper for holding
and manipulating containers. The robot was programmed with a vision-based control system
that allowed it to detect the position and orientation of the containers and adjust its
movements accordingly.

Another study published in the Proceedings of the IEEE International Conference on

Robotics and Automation focused on the design of a robot for pouring activities in the
chemical industry. The robot was designed with a four-axis robotic arm, a force sensor for
measuring the force applied during pouring, and a camera for visual feedback. The robot
was programmed with a model-based control system that used the force sensor readings to
adjust the pouring speed and angle.

In a study published in the Robotics and Computer-Integrated Manufacturing journal,

researchers developed a robot system for pouring tasks in the pharmaceutical industry. The
robot was designed with a six-axis robotic arm, a camera for visual feedback, and a gripper
for holding and manipulating containers. The robot was programmed with a hybrid control
system that combined a model-based control system with a vision-based control system.
The hybrid system allowed the robot to adjust its movements based on both the force
feedback and visual feedback.

Overall, the design of robots for pouring purposes involves a combination of hardware and
software components that work together to achieve the desired task. The design of such
robots can vary depending on the specific application and industry requirements. The studies
reviewed here demonstrate the potential of robots to automate pouring tasks in various
industries, and highlight the importance of developing robust and effective control systems
for such robots.

Casting is a widely used manufacturing process whereby melted metal is poured into a mold
to produce a desired shape. The process requires accuracy and high levels of skill to avoid
defects in the finished product. In most foundries, pouring is still done manually by a skilled
worker. However, this method is not only dangerous but also tiring, especially when pouring
large amounts of molten metal. This is where the design of a robot capable of pouring molten
metal into the mold cavity can improve the safety of workers while increasing accuracy and
efficiency. The purpose of this literature review is to provide an overview of the current

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

state-of-the-art in robotic pouring for casting applications. The focus is on the design and
technical considerations of robotic systems for pouring molten. metal the design of a robot
for pouring in casting involves numerous factors such as accuracy, safety, flexibility, control
systems, power, maintenance, and user interface. Researchers have developed different
approaches to address these challenges. Nonetheless, the common goal is to ensure that the
robot improves accuracy, productivity, and safety in the casting process. Ultimately, the
design of the robot for pouring in casting requires a comprehensive understanding of the
casting process to develop an efficient, reliable, and cost-effective solution that addresses
the challenges encountered in the casting industry.

2.4 Robotic Pouring Devices Currently Available

Different types of robots are designed to perform specific pouring functions. For example,
robots can be classified into ladle pouring robots, sprue cutting robots, and mold handling
robots. Ladle pouring robots are designed to pour molten metal directly into the mold cavity,
while sprue cutting robots are used to remove the casting from the mold.Ladle pouring
robots are the most common type of robots used for pouring in casting. These robots are
designed to pick up a ladle filled with molten metal and pour it into the mold cavity. They
are equipped with sensors to control the flow of metal, preventing defects from forming.
There are several types of robotic pouring devices available on the market including:

1. Robotic Ladle Pouring Systems: These are designed to pour molten metal from a ladle
into molds. They consist of a robot arm equipped with a ladle that can be tilted and rotated
to pour the molten metal. Some examples of these systems include KUKA Robotics' Ladle
Pouring System and ABB Robotics' Foundry Plus System.

2. Robotic Tundish Pouring Systems: These are designed to pour molten metal from a
tundish (a reservoir used for continuous casting) into molds. These systems typically consist
of a robot arm equipped with a pouring nozzle that can move along a track to pour the metal
into multiple molds. Some examples of these systems include FANUC Robotics' Tundish
Pouring System and ABB Robotics' Tundish Pouring System.

3. Automatic Pouring Furnaces: These are designed to melt, hold, and pour molten metal
automatically. They typically consist of a furnace that is attached to a pouring system and is
capable of holding and melting large quantities of metal. Examples of these systems include
Inductotherm's Automatic Pouring Furnace and OTTO JUNKER's Automatic Pouring
Furnace.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

4. Vacuum Casting Systems: These devices are used to pour metal into molds under vacuum
conditions. They typically consist of a vacuum chamber and a pouring system that can be
operated manually or with the aid of a robot arm. Examples of these systems include Vacu-
casting's Vacuum Casting System and Gallery Systems' Vacuum Casting System.

Each of these robotic pouring devices has its own advantages and limitations, and the choice
of which system to use will depend on factors such as the size of the foundry, the types of
molds used, and the desired level of automation

SA-Foundry automatic linear ladle pouring robot SA-LP-30. Automatic melt pouring
systems designed by SA-Foundry allow you to fully automate the process of pouring the
melt into the die or mold. Modern linear ladle pouring robots are the most reliable for
pouring large portions of the melt into the die or mold. Automatic melt pouring robots SA-
Foundry can be successfully used in automatic casting cells based on gravity die casting
machines of various types and cold chamber high pressure die casting machines. All pouring
robots are equipped with melt level sensors. The main technical parameters of automatic
linear ladle pouring robots SA-Foundry are presented in table 1 on the example of SA-LP-
10 and SA-LP-30 types.

2.5 Technical Considerations for Designing a Robotic Pouring System

The design of a robotic pouring system involves several technical considerations. These
include the type of metal being poured, the temperature of the molten metal, and the size
and shape of the mold cavity. To ensure that the system operates safely and efficiently, the
robot must be designed to meet these requirements. For example, the robot must be able to
pick up and pour a ladle of molten metal that weighs several hundred pounds. To ensure the
safety of workers and minimize the risk of accidents, the design must also incorporate safety
features such as emergency stop buttons, safety barriers, and interlocks. The robot must be
programmed to shut down automatically in the event of a power failure or other emergency.

Designing a robotic pouring system involves several technical considerations, some of

which are outlined below:

1. Load Capacity: The robotic system must be able to accommodate the weight of the ladle
containing the molten metal. The load capacity of the robot must be carefully considered to
ensure safe and reliable operation.

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2. Precision and Accuracy: The robot needs to be precise and accurate in its movements to
ensure that the molten metal is poured accurately into the melds. This requires careful
programming and calibration of the robot system.

3. Speed and Efficiency: The robot must be able to pour the metal quickly and efficiently to
optimize production. The speed of movement and the cycle time of the system need to be

4. Safety: Safety is critical in a foundry environment, and the robotic system must be
designed with appropriate safety features in place. For example, sensors can be used to
detect the presence of workers in the vicinity of the robot and to stop the system if an
obstruction is detected.

5. Maintenance: Robotic systems require regular maintenance to ensure long-term reliability

and accuracy. Systems should be designed with ease of maintenance in mind, and spare parts
should be readily available.

6. Integration with other systems: The robotic system should be designed to integrate
seamlessly with other systems in the foundry, including molding systems, cooling systems,
furnace systems, and other automated processes.

7. Cost: The cost of designing and implementing a robotic pouring system can be significant,
and it is important to consider the return on investment (ROI) when evaluating different
options. Factors such as production volume, labor costs, and potential increased efficiency
should be carefully assessed when determining the feasibility of a robotic system for a
particular application.

Pouring robots offer several advantage over traditional pouring methods

Pouring robots offer several advantages over traditional pouring methods. Here are some of
the key differences:

1. Consistency: Pouring robots can ensure a consistent pour every time, which leads to a
higher quality final product. In contrast, traditional pouring methods can be affected by
human error, resulting in inconsistencies in the pouring process.

2. Speed: Pouring robots can work faster than humans, which means that the pouring process
can be completed more quickly. This leads to increased productivity and efficiency in the
foundry.

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3. Precision: Pouring robots can be programmed to pour molten metal into molds with a
high degree of precision. This means that the pouring process can be customized to meet
the specific requirements of each casting.

4. Safety: Pouring robots can perform the dangerous task of pouring molten metal without
putting human workers at risk. This reduces the likelihood of injuries and accidents in the
foundry.

5. Cost: While pouring robots require an initial investment, they can ultimately save money
for the foundry by reducing labor costs and improving productivity.

Overall, pouring robots offer several advantages over traditional pouring methods. They can
improve the quality of castings, increase productivity, enhance safety, and provide greater
precision in the pouring process.

2.6 Commercially Available Pouring Robot Technologies on the Market

There are several commercially available dispensing robot technologies on the market. Here
are some examples:

1.ABB robot:

ABB offers a range of industrial robots, including foundry robots, designed for various
applications in foundries and other industries. The company's robots are equipped with
advanced control systems and sensors that ensure precise pouring operation.

2. Kuka robot:

KUKA offers robotic solutions for foundries, such as pouring robots for the safe and precise
handling of molten metal. The company's robots are known for their flexibility, reliability
and performance.

3. Fanuc robot:

FANUC offers a wide range of robot systems, such as pouring robots for foundries. The
company's robots are designed to meet the challenges of pouring molten metal, with features
such as high speed and precision movements.

4. Yasukawa robots:

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Yukawa Motoman provides pouring robot solutions for foundries designed to improve
productivity and safety. The company's robots are equipped with advanced control systems
and are optimized for foundry applications.

5. Skilled technology

Adept Technology provides robotic solutions for a variety of industries, including foundries.
The company's pouring robots are designed to handle complex pouring tasks, with features
such as real-time feedback and precise control.

6. Kawasaki robotics:

Kawasaki Robotics offers a variety of industrial robots, including casting robots with
advanced control options. The company's robots are known for their durability, accuracy
and ease of use.

7. Versatile robots

Universal Robots specializes in collaborative robots (cobots) that can work side by side with
humans. Although not specifically designed for casting operations, the cobot can be
programmed to have end effectors suitable for casting applications.

It is important to note that the availability and details of commercial pouring robot
technology may vary depending on location and specific requirements. For detailed
information on casting robot solutions, including pricing, technical specifications and
foundry compatibility, we encourage you to research and contact individual manufacturers
or distributors.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

CHAPTER THREE

METHODOLOGY

1. Defined the Requirements:

 We thoroughly understood the specific requirements and constraints of the foundry

process.
 We determined the types of materials to be poured, their temperature, and volume.
 We identified the safety and operational standards that needed to be followed.

2. Researched and Gathered Information:

 We studied existing pouring processes in foundries and identified their limitations

and areas for improvement.
 We researched robotic systems and technologies that were suitable for pouring
applications.
 We identified any legal or regulatory requirements related to robotic systems in the
foundry industry.

3. Developed Conceptual Design:

 We developed initial concepts for the robot's structure, components, and

functionalities.
 We considered factors such as stability, reach, payload capacity, and compatibility
with the foundry environment.
 We explored different design options, including robotic arms, gantries, or custom-
designed mechanisms.

4. Created Detailed Design:

 We refined the selected concept and created a detailed design.

 We determined the specific components needed, such as motors, actuators, sensors,
and control systems.
 We considered the materials and fabrication methods suitable for the foundry
environment, such as heat-resistant and durable materials.

5. Built Prototype and Conducted Testing:

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

 We built a prototype of the robot based on the detailed design.

 We conducted testing to evaluate its performance and functionality.
 We made necessary adjustments and refinements based on the test results.

6. Integrated and Implemented the Robot:

 We integrated the robot into the foundry's existing infrastructure.

 We programmed the robot's control system to perform the pouring tasks accurately
and efficiently.
 We conducted thorough testing and validation in the actual foundry environment.

Throughout the design process, we collaborated with experts in robotics, foundry

operations, and safety to ensure that the robot met all requirements and regulations.

The methodology for developing a pouring robot in a foundry requires several stages that
may include:

Requirement gathering: This stage involves defining the requirements of the pouring robot,
including the type of metal to be poured, the molds and casting being produced, and the
required accuracy and speed of the pouring process. The first stage of developing a pouring
robot in a foundry is to define the requirements for the system. This includes identifying the
production and quality targets, the types of molds and castings, and the desired level of
automation. In addition, environmental and safety considerations must be assessed.

Designing and planning: At this stage, the design of the pouring robot is developed from the
requirements gathered, including the physical design of the robot, the type of sensors and
actuators used, and the control and programming systems. The design stage involves
selecting and configuring the components of the robotic pouring system, including the robot
arm, end effectors, sensors, and control system. Factors such as the load capacity, precision,
speed, and safety features are considered in the design of the system.

Mechanical Integration: At this stage, the mechanical components of the system are
assembled and integrated. This includes the robot arm and gripper, the ladle or handling
system, and other specialized components such as vacuum casting chambers.

Integration: Electrical integration involves installing and configuring the control system,
including programming the robot to perform the desired movements and ensuring that the
system is integrated with other systems in the foundry.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Fabrication and assembly: The physical components of the pouring robot are fabricated and
assembled according to the design specifications. This stage requires the use of specialized
equipment and manufacturing techniques to ensure that the robot is assembled accurately
and to specification.

Testing and validation: The robot is tested to determine its accuracy, speed, and repeatability.
The testing involves simulation and physical testing to ensure that the robot meets the
requirements set, and it effectively reduces material waste, improves productivity, and
enhances safety. PriorEletrical integration to deployment, the robotic pouring system is
tested to ensure that it operates safely, accurately, and efficiently. This involves testing the
system under different operating conditions and verifying that it meets the defined
requirements.

Implementation and training: Once the robot has passed the testing and validation phase, it
is suitable for deployment in the foundry. The robot may require further modifications to
integrate into the foundry's existing systems. Additionally, training of the foundry workers
is essential to ensure the effective use of the robot, including its maintenance and operation.
Once the robotic system is validated and tested, it is deployed to the foundry. This involves
training personnel to operate and maintain the system, and integrating it with the production
process.

Evaluation and improvement: After deployment, the robot's performance is continually

evaluated, and improvements are made to enhance its effectiveness and efficiency, including
reprogramming and modifying the robot's programming.

Maintenance and Support: The final stage of developing a pouring robot in a foundry is
ensuring that the system is properly maintained and supported over its lifecycle. This
includes regular maintenance, repair, and replacement of components as necessary, as well
as ongoing upgrades and enhancements to the system to improve efficiency and
productivity.

Developing a pouring robot in a foundry requires detailed planning, considerations for every
aspect of the design and programming, and careful testing to ensure that the robot meets the
requirements of efficiently and safely completing the metal pouring process. It is essential
to work with experts in robot design and programming to ensure a successful
implementation process and meet the requirements of the foundry industry.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Common challenges on implementing a pouring robot in foundry

Some of the common challenges include:

High temperatures: Pouring molten metal requires working with high temperatures, which
can pose a risk to the robot and its components. The robot must be designed with materials
that can withstand high temperatures, and the control system must be able to operate in this
environment.

Safety: Pouring molten metal is a hazardous process, and safety is a critical concern when
designing and implementing a pouring robot in a foundry. The robot must be equipped with
safety features, such as emergency stop buttons or protective barriers, and workers must be
trained on how to operate the robot safely.

Accuracy: Pouring molten metal into molds requires a high degree of accuracy to ensure
that the metal is distributed evenly and the final product meets quality standards. The robot
must be designed to pour the correct amount of metal into the mold and to pour it in the
correct location.

Complexity: Pouring robots can be complex systems that require integration with other
equipment in the foundry. This can make the implementation process more challenging and
time-consuming.

Maintenance: Pouring robots require regular maintenance to ensure that they continue to
function properly. This can involve replacing components that wear out over time or making
adjustments to the control system to ensure that the robot continues to pour molten metal
accurately.

Cost: Pouring robots can be expensive to design, develop, and implement. The cost involved
in purchasing and maintaining the robot must be carefully considered and weighed against
the potential benefits of increased efficiency and productivity.

Compatibility: The pouring robot must be compatible with the existing foundry equipment
and processes. This can require modifications to the foundry layout or the robot's design to
ensure compatibility.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Workers must be trained on how to operate the robot safely and effectively. This can require
additional time and resources to ensure that workers are properly trained and comfortable
working with the new technology.

In conclusion, implementing a pouring robot in a foundry can present several challenges,

including high temperatures, safety concerns, accuracy, complexity, maintenance, cost,
compatibility, and training. These challenges must be carefully considered and addressed
during the design and implementation process to ensure that the pouring robot is safe,
efficient, and effective in improving the foundry's operations.

Safety features are critical when designing and implementing a pouring robot in a foundry.
Some examples of safety features that can be included in a pouring robot are:

Emergency stop buttons: These buttons allow workers to quickly stop the robot in case of
an emergency. They should be located in easily accessible locations throughout the foundry.

Protective barriers: Protective barriers can be installed around the robot to prevent workers
from accessing the robot's work area while it is operating. These barriers should be made of
materials that can withstand the high temperatures and harsh conditions of the foundry
environment.

Safety interlocks: Safety interlocks can be installed to ensure that the robot does not operate
unless certain safety conditions are met. For example, the robot may be programmed to stop
operating if a worker enters the work area.

Sensors: Various sensors can be installed in the robot to detect the presence of workers or
obstructions in the robot's work area. These sensors can trigger the robot to stop operating
or change its course of action to avoid a collision.

Warning lights and alarms: Warning lights and alarms can be installed to alert workers when
the robot is operating or when there is a safety hazard present.

Fire suppression systems: Fire suppression systems can be installed to quickly extinguish
fires that may occur in the foundry.

Protective equipment (PPE): Workers should be provided with the appropriate PPE, such as
heat-resistant gloves and clothing, to protect them from the high temperatures and hazardous
materials present in the foundry environment.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Regular maintenance: Regular maintenance and inspection of the robot can help ensure that
it continues to operate safely and efficiently. This includes checking for worn or damaged
components, replacing parts as needed, and making adjustments to the control system to
ensure that the robot is operating within safe parameters.

Overall, safety features are an essential part of the design and implementation of a pouring
robot in a foundry. These features help protect workers from harm and prevent accidents
from occurring in the foundry environment. By implementing appropriate safety measures,
the pouring robot can operate safely and effectively, improving efficiency and productivity
in the foundry.

S.No Activity Method

1 Force analysis Manual calculation, MATLAB

2 Stress analysis Manual calculation and CATIA V5

3 Kinematics analysis MATLAB

4 Drawing Solid work

5 Writing Micro soft word

Table 3. 1 Methodology for our design

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

CHAPTER FOUR

KINEMATICS OF ROBOTIC ARM MANIPULATOR

4.1 Introduction to Kinematics of Robot

The kinematics of a robot arm describe the relationship between the joint angles or joint
positions of the arm and the resulting position and orientation of the end-effector (hand) of
the arm. There are two main types of kinematics for robot arms: forward kinematics and
inverse kinematics.

Transformation and rotation in kinematics of 6 DOF of robotic arm manipulator

In the kinematics of a 6-degree-of-freedom (DOF) robotic arm manipulator, the

transformations and rotations play a crucial role in determining the position and orientation
of the end-effector relative to the base frame. Here's an overview of how transformations
and rotations are utilized in the kinematics of a 6-DOF robotic arm manipulator:

4.2 Forward Kinematics

Forward kinematics is concerned with determining the position and orientation of the end-
effector based on the joint angles or joint positions of the robot arm. It involves calculating
the transformation matrix or pose matrix of each joint and then combining them to obtain
the pose of the end-effector. The transformation matrix relates the position and orientation
of a joint to its parent joint.

To perform position analysis of a robotic arm, you typically need to determine the position
and orientation of the end-effector (tool or hand) based on the joint angles or joint positions
of the arm. This process involves using forward kinematics.

Here's a step-by-step approach to performing position analysis of a robotic arm:

1. Denote the joint variables: Assign variables (θ1, θ2, θ3, θn) to represent the joint
angles or joint positions of the robot arm. The number of variables depends on the
number of joints in the arm.
2. Define the joint parameters: Determine the geometric parameters of each joint, such
as the link lengths, link offsets, or joint types (revolute or prismatic).
3. Establish the transformation matrix for each joint: Derive the transformation matrix
(Denavit-Hartenberg matrix) for each joint. The transformation matrix relates the

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

position and orientation of a joint to its parent joint. The Denavit-Hartenberg (DH)
parameters provide a systematic way to represent these transformations.
4. Chain the transformations: Multiply the transformation matrices of all the joints to
obtain the transformation matrix from the base of the robot arm to the end-effector.
This provides the forward kinematics equation for the arm.
5. Extract the position and orientation: Extract the position (x, y, z coordinates) and
orientation (roll, pitch, yaw or rotation matrix) from the obtained transformation
matrix.
6. Solve for the joint variables: Given the desired position and orientation of the end-
effector, solve the forward kinematics equation for the joint variables. This involves
solving a system of equations or using numerical methods such as iterative
algorithms or optimization techniques.
7. Validate and test: Validate the obtained joint variables by substituting them into the
forward kinematics equation and comparing the resulting position and orientation of
the end-effector with the desired values. Test the arm's configuration by moving it to
different positions and verifying its accuracy.

4.2.1 DH parameter in 6 DOF of robotic arm manipulator

The Denavit-Hartenberg (DH) parameters are a set of four parameters that are commonly
used to describe the kinematics of robotic arms. These parameters define the geometric
relationship between successive joints in the arm and allow for the transformation between
coordinate frames.

For a 6-degree-of-freedom (DOF) robotic arm manipulator, you would typically have six
joints, and thus six sets of DH parameters. Each set of DH parameters corresponds to a
specific joint in the arm. The DH parameters consist of the following:

Link Length (ai): The distance between the i-th joint and the (i-1)-th joint measured along
the common normal between the z-axes of the two adjacent joints.

Link Twist (αi): The angle between the z-axes of the (i-1)-th and i-th joints, measured about
the common normal.

Link Offset (di): The distance between the origin of the i-th joint and the (i-1)-th joint
measured along the x-axis of the i-th joint.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Joint Angle (θi): The angle between the x-axes of the (i-1)-th and i-th joints, measured about
the z-axis of the (i-1)-th joint.

DH parameter tables
i thetai di ai alphai
1 0 0.10 0.92 0
2 theta2 0.70 0 -pi/2
3 theta3 0 0.464 0
4 theta4 0 0.414 0
5 theta5-pi/2 0 0 -pi/2
6 theta6+pi/2 0.613 0 Pi/2

Table 4. 1 DH parameter of the robot

Figure 4. 1 robotic axis and orientation

T01 =

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

T12 =

T23 =

T34 =

T45 =

T56 =

End_effector position from base origin in meters:

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

end_effector =

s14
s24
s34

End_effector frame rotation matrix w.r.t base frame:

endeffector_rotation =

s11 s12 s23

s21 s22 s23
s31 s32 s33
s11 =

s12 =

s13 =

s21 =

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

s22 =

s23 =

s31 =

s32 =

s33 =

From the homogeneous transformation matrix the desired position of the robot workspace
are
Position Position of Position Position of Position Position Position
and robot at of robot robot when of robot of robot of the
orientations home when it is it pick the at when it robot with
position ready to ladle maximum pour the empty
pick height melt ladle
with load
Theta1 0 0 0 0 0 0
Theta2 900 0 0 0 1800 1800
Theta3 450 720 720 -150 350 -150
Theta4 -750 -88.60 -88.60 -400 -1090 -400
Theta5 0 16.60 16.60 400 540 400
Theta6 0 0 0 0 0 0
Xe 0.92 m 2.0731 m 2.920 m 3.0478 m -1.00 m -1.208 m
Ye 1.2175 m 0 0 0 0 0
Ze 0.9854 m 0.477 m 0.477 m 1.4179 m 1.142 m 1.4179 m

Table 4. 2 the position of end_effector at different position

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

(a) Position of robot at home position (b) Position of robot when it is ready

(C) Position of robot when it pick the ladle (d) Position of rob

(e) Position of robot when it pour the melt (f) Position of the robot with empty ladle

Figure 4. 2 the diagram of robotic end_effector position

4.3 Inverse Kinematics

Inverse kinematics is the reverse process of forward kinematics. It involves determining the
joint angles or joint positions that will result in a desired position and orientation of the end-
effector. Inverse kinematics is particularly useful for tasks such as trajectory planning, where
the desired path or position of the end-effector is specified, and the corresponding joint
angles need to be computed.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Inverse kinematics involves determining the joint variables (joint angles or joint positions)
that correspond to a desired position and orientation of the end-effector. In this case, you
need to solve the inverse kinematics equations to find the joint variables. To perform inverse
kinematics, you typically utilize rotation matrices or quaternions to represent the desired
orientation of the end-effector. These orientation representations can be converted into the
corresponding Euler angles or rotation matrices for each joint.

By combining the desired position of the end-effector with the desired orientation, you can
formulate the inverse kinematics problem. Solving this problem requires finding the joint
variables that satisfy the position and orientation constraints.

The inverse kinematics of this robot is given as follow calculated by MATLAB software

Angles Position of robot Position of robot at Position of Position of the

when it is ready maximum height robot when it robot with empty
to pick with load pour the melt ladle
Theta1 0 0 0 0
Theta2 0 0 / 1800 0 /1800 0 /1800
0 0 / 1800 0 / 1800 0 / 1800
Theta3 720 -62.3210 / 10.50230 / -62.3210 /
-160.080 169.49810 -160.080
-10.2390 -19.9220 / -72.089550 / -19.9220 /
-117.67980 -107.910870 -117.67980
Theta4 -88.60 45.11470 / -88.99750 / 45.11470 /
45.11470 88.99750 45.11470
88.60 -45.11470 / 88.99750 / -45.11470 /
-45.11470 -88.99750 -45.11470
Theta5 0 0 /1800 0 / 1800 0 /1800
0 0 /1800 0 / 1800 0 /1800
Theta6 16.60 17.21170 / 78.49520 / 17.21170 /
-114.96970 -101.50520 -114.96970
-78.360 65.0310 / -16.907980 / 65.0310 /
163.80630 163.09240 163.80630

Table 4. 3 the angle of the links obtained from reverse kinematics

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Figure 4. 3 position of end_effector using inverse kinematics

4.4 Kinetics of Robotics

Static force analysis is concerned with determining the forces and torques required to
maintain a robot in a static equilibrium position. This analysis can be useful for determining
the maximum loads that a robot can handle without losing stability or damaging its
components. One way to perform static force analysis is to use the principle of virtual work,
which states that the work done by a set of forces and torques in a static equilibrium position

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

is zero. This principle can be used to derive equations that relate the forces and torques at
each joint to the external loads and the geometry of the robot.

Static velocity analysis, on the other hand, is concerned with determining the velocities of
the robot's joints and end-effector in a static equilibrium position. This analysis can be useful
for determining the maximum speeds that a robot can achieve without losing stability or
exceeding its joint limits. One way to perform static velocity analysis is to use the concept
of instantaneous centers of rotation, which are points where the velocities of two connected
links are equal and opposite. By locating these points for each joint, the velocities of the
joints and the end-effector can be computed based on the geometry of the robot.

It's worth noting that static force and velocity analysis assumes that the robot is in a static
equilibrium position, meaning that it is not moving or accelerating. In reality, robots are
often subject to dynamic loads and must be able to move and change direction quickly.
Dynamic force and velocity analysis can be used to analyze the motion and stability of a
robot under dynamic conditions, taking into account the effects of acceleration, friction, and
other dynamic factors.

The Jacobian matrix can be used to find the static force and velocity of an articulated robot.

The Jacobian matrix relates the velocities of the robot's joints to the velocity of its end-
effector. Specifically, the columns of the Jacobian matrix represent the partial derivatives of
the end-effector's position and orientation with respect to each joint angle. Therefore, the
Jacobian matrix can be used to compute the velocity of the end-effector given the velocities
of the joints, or vice versa.

To use the Jacobian matrix for static force analysis, we can apply the principle of virtual
work, which states that the work done by a set of forces and torques in a static equilibrium
position is zero. Specifically, if we consider a small displacement of the end-effector from
its equilibrium position, the work done by the external forces and torques must be balanced
by the work done by the internal forces and torques at each joint. By using the Jacobian
matrix to relate the velocities of the joints to the velocity of the end-effector, we can derive
equations that relate the internal forces and torques at each joint to the external forces and
torques and the geometry of the robot.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

4.4.1 Static force on each link of robot using Jacobian matrix

The static forces and torques at the joints are those caused by a static force or torque (or
both) acting on the last link. We define special symbols for the force and torque exerted by
a neighbor link:

Fi = force exerted on link i by link i - 1,

ni = torque exerted on link i by link i - 1.
i
Fi = iFi+I ………………………………………………….………………………………4.1
ni = ini+l + iRi+i X iFi+i ………………………………………………………….................4.2
In order to write these equations in terms of only forces and moments defined within their
own link frames, we transform with the rotation matrix describing frame {i + 1} relative to
frame {i}. This leads to the most important result for static force "propagation" from link to
link:
i
Fi = iRi+1.i+1Fi+1 ……………………………………………………………………........4.3
ni = iRi+I . ni+1 + iRi+1 X iFi………………………………………………………………4.4
Where, iRi+1 is the rotational matrix of each link as given in forward direction
Using the above equation (4.5) and equation (4.6) we can find both the static force and
moment of each link. By using MATLAB software the static force and moment of each link
at different position i.e. as the given below.

A, position of robotics B, position of robotics C, position of robotics

end_effector when it start end_effector when it end_effector when it pour
pick the ladle pick to maximum height the molten metal

Figure 4. 4 static force and moment of robotic manipulator at different position

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Force and component Links of robotic manipulator

Positions moment Link4 Link3 Link2 Link1
Component Fx (N) 0 142 - 283.9217
of force at 283.9217
During pick the
each link Fy (N) -500 479.1613 - 411.5682
411.5682
Fz(N) 0 0 0 0
ladle

Moment at n1 (N.m) 0 0 0 0
each link n2 (N.m) 0 0 0 0
n3 (N.m) 306.50 -513.500 - 0
735.8308
Component Fx (N) 0 354.2605 - 453.2892
Position of robotic end_effector at different point

of force at 453.2892
Lift load at Hmax

each link Fy (N) -500 352.8449 - 211.0185

211.0185
Fz (N) 0 0 0 0
Moment at n1 (N.m) 0 0 0 0
each link n2 (N.m) 0 0 0 O
n3 (N.m) -306.500 -513.500 -677.22 0
Component Fx (N) 0 489.9540 - 463.5687
During pour the

of force at 463.5687
molten metal

each link Fy (N) -500 99.7250 - 187.3607

187.3607
Fz (N) 0 0 0 0
Moment at n1 (N.m) 0 0 0 0
each link n2 (N.m) 0 0 0 0
n3 (N.m) -306.500 -513.50 - 0
559.7728

Table 4. 4 force and moment applied on each link at different position

4.4.2. Velocity of robotic arm manipulator

To use the Jacobian matrix for static velocity analysis, we can compute the null space of the
Jacobian matrix, which represents the set of joint velocities that result in zero end-effector
velocity. The null space can be used to find the joint velocities that maintain the robot in a

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

static equilibrium position, given a desired end-effector velocity. Specifically, we can use a
pseudo-inverse of the Jacobian matrix to compute the joint velocities that result in the desired
end-effector velocity, and then project these velocities onto the null space to obtain the joint
velocities that maintain the robot in a static equilibrium position.

It's worth noting that the Jacobian matrix is only valid for small deviations from the robot's
equilibrium position, and may not accurately represent the robot's behavior under large loads
or rapid movements. Therefore, dynamic force and velocity analysis may be necessary to
fully analyze the performance of a robot under these conditions.

ꞷ1 = 0 0 0
0 1 ǿ2
1 0

ꞷ2 = 0 0 0 0
0 1 1 ǿ2
1 0 0 ǿ3

ꞷ3 = 0 0 0 0 0
0 1 1 1 ǿ2
1 0 0 0 ǿ3
ǿ4

ꞷ4 = 0 0 0 0 0 0 where ǿ2, ǿ3, ǿ4, ǿ6 are the derivative of revolute angle

0 1 1 1 1 ǿ2 of joint2, joint3, joint 4 and joint 5.
1 0 0 0 0 ǿ3
ǿ4
ǿ6

v1 = 0
0
0

58 sin(3)
v3= 0 - ǿ2
125
0 0 ǿ3
58 cos(3)
0 - 125

58 sin(3)
v3 = 0 - -3-2 -3-2 ǿ2
125
0 0 0 ǿ3
58 cos(3)
0 1-4- 125 1-4 ǿ4

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Where ,

58 sin(3)
v4 = 0 - -3-2-8-5 -3-2-8-5 -8-5 ǿ2
125
0 0 0 0 ǿ3
58 sin(3)
0 1-4- 125 -7+6 1-4-7+6 6-7 ǿ4
ǿ6

Where ,

, ,

, ,

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

CHAPTER FIVE

PART DESIGN OF ROBOT MANIPULATOR

5.1 Design of Link

5.1.1 Force analysis of link 3

Figure 5. 1 dimension, force and stress analysis of link 3

There are different types force acts on arm of robot during different position

These are tensile force and bearing force.

R = 15 mm L = 414 mm

h =100 mm t = 2.5 mm and w = 85 mm

From force analysis at different position, we have different force along x, y and z axis is
given by
The force acting during pick the ladle: - Fx=142N, Fy=479.1613, Fz=0

The force acting at maximum height: - Fx=354.2605N, Fy=-352.8449N, Fz=0

The force acting during pouring melting: - Fx=489.9540N, Fy=-99.7250N, Fz=0

From the force obtain at different position, we have to select maximum force along x and y
axis, that is used for the stress analysis of link.
Therefore, Fx=489.954 N and Fy=479.1613 N

5.1.2 Stress analysis of link 3

1) Bearing stress
To determine bearing stress at A on link AB, we use a formula

F
σb = A

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Where: - t is the link thickness, Area (A) is equal to td, and d the diameter of the pin.
Area=t x d
A=30mmx2.5mm=75mm2
489.954𝑁
σ b = 75mm2

= 6.5323 N/mm2
2) Tensile stress
Tensile force on the link 3 is Fx= 489.9540N from force analysis
Net area of link for tension is: - A= (414mm- 60mm) x 2.5mm=885mm2
Tensile stress in link is
Fx
σ t= A
489.9540N
= 885mm2

σ t =0.5536N/mm2
3) Bending stress
M𝑏 C
σ= I
h 100
c=2= 2

c = 50mm
I is the moment of inertia
For rectangular cross section I is given by;
bh3
I= 12
bh3 bh3
I= +
12 12

2.5mm×(100mm)3
= x2
12

= 416666.66mm4
Mb = F x l Where Mb is bending moment of link
= 479.1613 N*414 mm
Mb= 198372.778 N.mm
M𝑏 C
σb = I
(198372.77Nmm)∗(50mm)/
σb = 416666.66mm4

σb = 23.804 MPa

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.1.3. Selecting factor of safety

Since link 3 is not much affected by the applied load on it and the stress induce in it is
minimum therefore, it is better to take the factor of safety of (SF=1.3). This show that the
allowable strength of the link material would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 1.3 x 47.609 MPa

= 61.892 MPa

This implies that allowable (all)  61.892 MPa

Yielding stress (y)  all

5.1.4 Material selection

Properties of Types of material

material Aluminum Aluminum Magnesium Magnesium
(wrought) (perm. mold (extruded) (cast)
cast)
Ultimate Tensile 186 MPa 262 MPa 345 MPa 200 MPa
strength
Yield strength 76 MPa 186 MPa 241 MPa 186 MPa
Modulus of 71 GPa 71 GPa 45 GPa 45 GPa
elasticity
Manufacturability Easily Cast, easily Easily Cast, easily
machinable machinable machinable machinable
and weldable (except fire
hazard),
weldable
availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,
sheet, shape, tubing forging, shapes
tubing and shapes
wire

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

cost 145 Birr / kg 192.087 Birr / 135.45 Birr / 204.56 Birr /

kg kg kg

Table 5. 1 material selection for link 3

From the above four candidates listed in the table, the suitable material for the link 3 would
be Aluminum ( wrought ), because of its availability as required and low cost

Evaluating the selected material using CATIA V5 software to analysis the link 3

A, displacement analysis of link 3

B, von Mises stress of link 3

49
DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

C, the position where maximum stress is occurred

D, principal stress of link 3

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

E, pricision ( local Stress)

F. total information of the stress and materials

Figure 5. 2 software evaluation of the calculated stress of link 3

From the CATIA V5 software analaysis

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 22.4 MPa 24.3 MPa 0.292 mm

minimum 0.109 MPa 0.192 MPa 0

Table 5. 2 different types of stress on link 3

Generally the designed the link is safe.

5.1.5 Manufacturing process

Cast or machining

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.2 Design of Link 2

5.2.1 Force analysis of link 2

Free body diagram

Figure 5. 3 dimension, force and stress analysis of link 2

Where

L=464mm, R=15mm,

W=100mm, h =100mm, t=2.5mm

We obtain F x and F y from force analysis;

The force acting during pick the ladle: - Fx = -283.9217 N, Fy = -411.56 N, Fz=0

The force acting at maximum height: - Fx = 453.2892 N, Fy=-211.0185 N, Fz=0

The force acting during pouring melting: - Fx = 463.56 N, Fy=-187.3607 N, Fz=0

5.2.2 Stress analysis of link 2

Before to calculate stress on link 2 ; we have to select maximum force that are applied on
the link AB at different position .Therefore we get maximum force acting along x-axis at
pouring melt and maximum force acting along y-axis at the force acting during pick the
ladle. This means

Fx= 463.56N and Fy= -411.56N

There are different types of stress is produce during force acting on link of shoulder;

 Bearing stress

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

 Compressive stress
 Bending Stress
A. Bearing stress

To determine bearing stress at A on link AB, we use a formula

F
σb = A

Area (A) is equal to td, where t is the link thickness and

d the diameter of the pin.
Area = t x d
A = 40 mm x 2.5 mm
= 100 mm2
F
σ b=A
463.56N
= 100𝑚𝑚2 4

= 4.6356 N/mm2
B. Compressive stress
Tensile force on the link is Fx= 463.56N from force analysis
Net area of link for tension is A net= (100mm- 30mm) x 2.5mm=175mm2
Tensile stress in link 2 is

Fx
σ c= A
463.56 N
= 175 𝑚𝑚2

= 2.6489 N/mm2
C. Bending stress
M𝑏 C
σ= I

Where Mb is bending moment of link, and

I is moment of inertia,
h
c=2
100
c= 2

c = 50 mm
For rectangular cross section I given by;
bh3
I= 12

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

bh3 bh3
I= +
12 12
2bh3
I= 12
2x 2.5 mm×(100 mm)3
= 12

=416666.66 mm4
Mb=Fx l
= 411.56*464 mm
Mb= 190963.84 N.mm
M𝑏 C
σ=
I
190963.84 N.mm∗50 mm
= 416666.66 mm4

σ = 22.9156 N/mm2
5.2.3 Selecting factor of safety

Since link 2 is not much affected by the applied load on it and the stress induce in it is
minimum, so it is better to take the factor of safety of (SF=1.3). this show that the allowable
strength of the link material would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 1.3 x 46.0593 MPa

= 59.87709 MPa

This implies that allowable (all)  59.87709 MPa

Yielding stress (y)  all

5.2.4 Material selection

Properties of Types of material

material Aluminum Aluminum Magnesium Magnesium
(wrought) (perm. mold (extruded) (cast)
cast)
Ultimate Tensile 186 MPa 262 MPa 345 MPa 200 MPa
strength

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Yield strength 76 MPa 186 MPa 241 MPa 186 MPa

Modulus of 71 GPa 71 GPa 45 GPa 45 GPa
elasticity
Manufacturability Easily Cast, easily Easily Cast, easily
machinable machinable machinable machinable
and weldable (except fire
hazard),
weldable
availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,
sheet, shape, tubing forging, shapes
tubing and shapes
wire

cost 145 Birr / kg 192.087 Birr / 135.45 Birr / 204.56 Birr /

kg kg kg
Table 5. 3 material selection of link 2

From the above four candidates listed in the table, the suitable material for the link 2 would
be Aluminum ( wrought ), because of its availability as required and low cost

Evaluating the selected material using CATIA V5 software to analysis the link 2

A. displacement analysis of link 2

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DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

B. stress analysis of link 2 (Von Mises stress)

C. stress analysis of link 2 (principal stress)

D. precision

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

E. General information of the maximum stress and the material properties of link 2

Figure 5. 4 stress analysis and deformation of link 2 using CATIA V5 software

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 25.7 MPa 15 MPa 0.2 mm

minimum 0.021444 MPa 2.18 MPa 0

Table 5. 4 different types of stress on link 2

Generally the designed the link is safe.

5.2.5 Manufacturing process

Cast or machining

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.3 Design of Shafts

5.3.1 Force analysis of shaft

Figure 5. 5 dimension, force and stress analysis of shaft

I. Shaft that connects link 4 with link 3

The force applied on this link, F=500N
II. Shaft that connects link 3 with link 2
The maximum force on this link, F x=463.56N
III. Shaft that connects link 2 with link 1
The maximum force on this link, F x=489.954N
5.3.2 Stress analysis of shaft

A) Shaft that connects link 4 with link 3

The following stresses are induced in the shafts:
 Shear stresses due to the transmission of torque (i.e. due to torsional load).
 Bending stresses (tensile or compressive) due to the forces acting upon machine
elements like gears, pulleys etc. as well as due to the weight of the shaft itself.
 Stresses due to combined torsional and bending loads.

Shear stress
𝑇 𝜏
=
𝐽 𝑟
Where, T = Twisting moment (or torque) acting upon the shaft,
J = Polar moment of inertia of the shaft about the axis of rotation,
τ = Torsional shear stress, and

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

r = d / 2; where d is the diameter of the shaft

16𝑇
τ = 𝜋𝑑3

16 x 400 Nm
τ = 𝜋 x (0.05𝑚)3

τ = 16.306 MPa
Bending stress
𝑀𝑦
σ𝑏 =
𝐼

Where, M = Bending moment,

I = Moment of inertia of cross-sectional area of the shaft about the axis of
rotation,
σ𝑏 = Bending stress, and
y = Distance from neutral axis to the outer-most surface
𝜋𝑑4
I= 64
𝜋(50𝑚𝑚)4
I= 64

I = 306640.625mm4
𝑑
y=
2
50𝑚𝑚
y= 2

y = 25mm
To find bending moment,
𝑙
The maximum bending moment is on the center of the length which is equal to 2
𝑙
L= 2 = 47𝑚𝑚

M= F x L
M= 250N x 47mm
M= 11750 N.mm
11750 𝑁. 𝑚𝑚𝑥 25 𝑚𝑚
σ𝑏 =
306640.625 𝑚𝑚4
σ𝑏 = 0.95796 N/𝑚𝑚2

Stresses due to combined torsional and bending loads

According to maximum shear stress theory, the maximum shear stress in the shaft,
1
τ𝑚𝑎𝑥 = 2 √𝜎𝑏2 + 4𝜏 2

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

τ = Shear stress induced due to twisting moment, and

be = Bending stress (tensile or compressive) induced due to bending moment
1
τ𝑚𝑎𝑥 = 2 √𝜎𝑏2 + 4𝜏 2
1
= 2 √ 0.957962 + 4(16.306)2

= 16.313 N/mm2
B) Shaft that connects link 3 with link 2
Shear stress

𝑇 𝜏
=𝑟
𝐽

Where, l = 99mm
d = 50mm
The torque on this link, T= 580 Nm
16𝑇
τ=
𝜋𝑑 3
16 x 580 Nm
τ=
𝜋 x (0.05𝑚)3

τ = 23.6433MPa

Bending stress
𝑀𝑦
σ𝑏 =
𝐼
y = distance from neutral axis to the outer-most surface
𝜋𝑑4
I= 64
𝜋(50)4
I= 64

I = 306640.625mm4
𝑑
y=
2
50𝑚𝑚
y= 2

y = 25mm
To find bending moment,
𝑙
The maximum bending moment is on the center of the length which is equal to 2
𝑙
= 49.5𝑚𝑚
2
The maximum force on link is, Fx = 463.56 N

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

M= F x l
M= 463.56 N x 49.5 mm
M= 22946.22 N.mm
𝑀𝑦
σ𝑏 =
𝐼
22946.22 𝑁. 𝑚𝑚𝑥 25 𝑚𝑚
σ𝑏 =
306640.625 𝑚𝑚4
σ𝑏 =1.87 N/𝑚𝑚2
Stresses due to combined torsional and bending loads
1
τ𝑚𝑎𝑥 = √𝜎𝑏2 + 4𝜏 2
2
1
= 2 √ 1.872 + 4(23.6433)2

= 23.66 N/mm2
C) Shaft that connects link 2 with link 1

Shear stress
T τ
=
J r

Where, r = 25 mm, or d=50 mm

The torque for this link, T= 810 N.m
16𝑇
τ=
𝜋𝑑 3
16 x 810 Nm
τ=
𝜋 x (0.05 𝑚)3

τ = 33.019 MPa

Bending stress
𝑀𝑦
σ𝑏 =
𝐼
Where, l = 104 mm
𝜋𝑑4
I= 64
𝜋(50 𝑚𝑚)4
I= 64

I = 306640.625 mm4
𝑑
y=2
50 𝑚𝑚
y= 2

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

y = 25 mm
To find bending moment,
𝑙
The maximum bending moment is on the center of the length, which is equal to 2
𝑙
= 52 𝑚𝑚
2
The maximum force on link, F x=489.954N
M= F x l
M= 489.954 N x 52 mm
M= 25477.6 N.mm
𝑀𝑦
σ𝑏 =
𝐼
25477.6 𝑁. 𝑚𝑚𝑥 25 𝑚𝑚
σ𝑏 =
306640.625 mm4
σ𝑏 = 2.0771 N/𝑚𝑚2
Stresses due to combined torsional and bending loads
1
τ𝑚𝑎𝑥 = 2 √𝜎𝑏2 + 4𝜏 2
1
= 2 √ 2.07712 + 4(33.019)2

= 33.035 N/mm2
5.3.3 Selecting factor of safety

The shaft that rotates the links face different types of stress. As the result shows under stress
analysis, the stress induced in shaft is greater than the stress induced in the link. Therefore,
it is better to take the factor of safety of (SF=2). This show that the allowable strength of the
shafts material would be

allowable stress
SF =
designed stress
ulitimate shear stress ult
SF= =
designed shear stress 

ult = SF x 
ult = 2 x 33.035 MPa
ult = 66.071 MPa
ult 66.071 MPa
ult = 0.36 = 0.36

ult =183.5296 MPa

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Then yield strength of the shaft would be

ult 183.5296 MPa

y = =
2 2

y = 91.765 MPa
Therefore the yield strength of the shaft must be y  91.765 MPa

5.3.4 Material selection

Properties of Types of material

material Aluminum Aluminum Magnesium Low carbon
(wrought) (perm. mold (extruded) (mild steel)
(2024-T3) cast) (AISI 1020)
(HR)
Ultimate Tensile 483 MPa 262 MPa 345 MPa 379 MPa
strength
Yield strength 345 MPa 186 MPa 241 MPa 207 MPa
Modulus of 71 GPa 71 GPa 45 GPa 205 GPa
elasticity
Shear modulus 27 GPa 28 GPa 16.3 GPa 78 GPA
Manufacturability Easily Cast, easily Easily highly
machinable machinable machinable weldable,
and weldable (except fire highly
hazard), machinable
weldable
availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,
sheet, shape, tubing forging, shapes,
tubing and shapes forging, sheets
wire

cost 163.8 Birr / kg 192.087 Birr / 135.45 Birr / 41 Birr / kg

kg kg
Table 5. 5 material selection of shaft

From the above four candidates listed in the table, the suitable material for the shaft designed
would be low carbon (AISI 1020 HR), because of its availability as required, low cost and
properties.

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Evaluating the selected material using CATIA V5 software to analysis the shaft

A. displacement analysis of shaft

B. stress analysis of shaft (Von Mises stress)

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DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

C. stress analysis of shaft (Principal stress)

D. precision of tha data

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Figure 5. 6 stress analysis and deformation of shaft using CATIA V5 software

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 17.7 MPa 30.5 MPa 0.00566 mm

minimum 0.366 MPa 2.73 MPa 0

Table 5. 6 different stresses on shaft

Generally the designed shaft is safe

5.3.5 Manufacturing process

Machining and forging

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.4 Design of Link 1

5.4.1 Force analysis of link 1

Figure 5. 7 dimension, force and stress analysis for link 1

Where, R1= 15 mm R2=85 mm

R3=50 mm h=410 mm
t= 10 mm w=100 mm

Force act on link is Fx = 283.9219 N, Fy=0, Fz = 11.5682 N………during pick ladle

Fx=453.2892 N, Fy=0, Fz = -211.0185 N………during h maximum
Fx = 463.5687 N, Fy=0 Fz = 187.3607 N.…act during pouring
5.4.2 Stress analysis

There are different types of stress is produce during force acting on link 1;
 Bearing stress
 Bending Stress
 Compressive stress
Bearing stress
To find the bearing stress, we have
F
σ b=A

Maximum force applied to this link, Fx = 463.5687 N

A= t × d

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

= 2.5 mm×50 mm
= 125 mm2
F
σ b=A
463.5687 𝑁
= 125 mm2

σ b = 3.708 N/mm2
Bending stress
M𝑏 C
σ= I

Where, Mb is bending moment of link,

I is moment of inertia,
ℎ
c=2
100 𝑚𝑚
= 2

= 50 mm
bh3 𝜋𝑑3
I= −
12 64
2.5 x1003 𝜋 𝑥503
= −
12 64

I = 202200.52 𝑚𝑚4
Mb=F x l
= 463.5687 N x 410 mm
= 190063.167 N.mm
M𝑏 C
σ= I
190063.167 N.mm x 50 mm
= 202200.52 𝑚𝑚4

= 46.998 N/mm2
Compressive stress
F
σ = A where A=Lxw

A= 100 x 2.5=250 mm2

F
σ=A
463.5687N
= 250𝑚𝑚2

=1.85427 N/mm2

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.4.3 Selecting factor of safety

Since link 1 is not much affected by the applied load on it and the stress induce in it is
minimum therefore, it is better to take the factor of safety of (SF=2). This show that the
allowable strength of the link material would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2 x 46.998 MPa
= 93.996 MPa
This implies that allowable (all)  93.996 MPa

Yielding stress (y)  all

5.4.4 Material selection

Properties of Types of material

material Aluminum Aluminum Magnesium Magnesium
(wrought) (perm. mold (extruded) (cast)
(2024-T3) cast)
Ultimate Tensile 483 MPa 262 MPa 345 MPa 200 MPa
strength
Yield strength 345 MPa 186 MPa 241 MPa 186 MPa
Modulus of 71 GPa 71 GPa 45 GPa 45 GPa
elasticity
Manufacturability Easily Cast, easily Easily Cast, easily
machinable machinable machinable machinable
and weldable (except fire
hazard),
weldable
availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,
sheet, shape, tubing forging, shapes
tubing and shapes
wire

69
 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

cost 163.8 Birr / kg 192.087 Birr / 135.45 Birr / 204.56 Birr /

kg kg kg
Table 5. 7 material selection of link1

From the above four candidates listed in the table, the suitable material for the link 1 would
be Aluminum (wrought) (2024- T3), because of its availability as the form required and
medium cost and properties.

Evaluating the selected material using CATIA V5 software to analysis the link 1

A. displacement analysis of link 1 B. stress analysis (Von Mises) of link 1

C.. stress analysis (principal) of link 1 D. pricision

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

E. maximum and material properties of the selected material

Figure 5. 8 stress analysis and deformation of link 1 using CATIA V5 software

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 43.7 MPa 38.2 MPa 0.282 mm

minimum 183.655 N/ m2 219 N/ m2 0

Table 5. 8 different types of stress on link 1

Generally, the designed link is safe.

5.4.5 Manufacturing process for link 1

Rolled or Forging

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

5.5 Design of the Shoulder of Link 1

5.5.1 Force analysis of the shoulder of link 1

Figure 5. 9 dimension, force, and stress analysis of shoulder of link 1

Where, R1 = 97 mm R2 = 85 mm
R3 = 75 mm L = 270 mm
H = 135 mm t1 = 15 mm
t2 = 40 mm t3 = 70 mm
F = 500 N
5.5.2 Stress analysis of shoulder of link 1

Axial stress

To determine this stress,

F
σ=A

The area on which force applied = π(𝑅2)2- π(𝑅1)2

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

A= π(85)2 - π(75)2
A= 5026.5482 mm2
F
σ=A
500 N
=
5026.5482 mm2
= 0.09947 N/mm2

Bending stress

M𝑏 C
σ= I

Where, Mb is bending moment of shoulder of link 1,

I is moment of inertia,
𝑡
c=2
6 𝑚𝑚
= 2

= 3 mm
B x t3
I= Where, B = 2 x 3.14 x 75 mm, and t = 6 mm
12
417 mm x 63
= 12

I = 7,506 𝑚𝑚4
Mb=F x l
= 500 N x 5 mm
= 2500 N.mm
M𝑏 C
σ= I
2500 N.mm x 3 mm
= 7506 𝑚𝑚4

= 0.9992 N/mm2

5.5.3 Selecting factor of safety for shoulder of link 1

Since shoulder is not much affected by the applied load on it and the stress induce in it is
minimum therefore, it is better to take the factor of safety of (SF=1.3). This show that the
allowable strength of the link material would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

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 DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

Allowable stress (all) = SF x design stress (b)

= 1.3 x 0.9992 MPa
= 1.299 MPa
This implies that allowable (all)  1.299 MPa
Yielding stress (y)  all

5.5.4. Material selection for shoulder of link 1

Properties of Types of material

material Aluminum Aluminum Magnesium Magnesium
(wrought) (perm. mold (extruded) (cast)
cast)
Ultimate Tensile 186 MPa 262 MPa 345 MPa 200 MPa
strength
Yield strength 76 MPa 186 MPa 241 MPa 186 MPa
Modulus of 71 GPa 71 GPa 45 GPa 45 GPa
elasticity
Manufacturability Easily Cast, easily Easily Cast, easily
machinable machinable machinable machinable
and weldable (except fire
hazard),
weldable
availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,
sheet, shape, tubing forging, shapes
tubing and shapes
wire

cost 145 Birr / kg 192.087 Birr / 135.45 Birr / 204.56 Birr /

kg kg kg
Table 5. 9 material selection for shoulder of link 1

From the above four candidates listed in the table, the suitable material for the shoulder of
link one would be Aluminum ( wrought ), because of its availability as required and low cost

Evaluating the selected material using CATIA V5 software to analysis the link 1

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DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

A. displacement analysis of shoulder of link 1

B. stress analysis of shoulder of link 1 (Von Mises stress)

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DESIGN OF ROBOT FOR POURING PURPOSE IN FOUNDRY, 2023

C. stress analysis of shoulder of link 1 (Principal stress)

D. precision of tha data

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E. maximum and material properties of the selected material

Figure 5. 10 stress analysis and deformation of shoulder of link 1 using CATIA V5

software

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 0.948 MPa 0.901 MPa 0.00175 mm

minimum 476 N/ m2 0.0901 MPa 0

Table 5. 10 different types of stress on shoulder of link 1

Generally, the designed link is safe.

5.5.5 Manufacturing process of shoulder of link 1

Cast or machining

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5.6 Design of the Base Plate

5.6.1 Force analysis of base plate

Figure 5. 11 dimension and force analysis of base plate

Where w = 270 mm h = 40 mm
L = 270 mm t1 = 40 mm
D1 = 14 mm t2 = 6 mm
D2 = 20 mm
The maximum force on the base floor is F= 500 N

5.6.2 Stress analysis of base plate

The following stresses are induced on the wrist link

Compressive stress

𝐹
σ=𝐴

The area on which force applied, A= L x W

A=270 mm x 270 mm
A=72900 mm2
𝐹
σ=𝐴

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500 𝑁
= 72900 𝑚𝑚2

σ = 0.006858 N/mm2

5.6.3 Selecting factor of safety of base plate

Since base plate is not much affected by the applied load on it and the stress induce in it is
minimum therefore, it is better to take the factor of safety of (SF=2). This show that the
allowable strength of the link material would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2 x 0.006858 MPa

= 0.01372 MPa

This implies that allowable (all)  0.01372 MPa

Yielding stress (y)  all

5.6.4 Material selection for base plate

Properties of Types of material

material Aluminum Aluminum Magnesium Magnesium
(wrought) (perm. mold (extruded) (cast)
cast)
Ultimate Tensile 186 MPa 262 MPa 345 MPa 200 MPa
strength
Yield strength 76 MPa 186 MPa 241 MPa 186 MPa
Modulus of 71 GPa 71 GPa 45 GPa 45 GPa
elasticity
Manufacturability Easily Cast, easily Easily Cast, easily
machinable machinable machinable machinable
and weldable (except fire
hazard),
weldable

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availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,

sheet, shape, tubing forging, shapes
tubing and shapes
wire

cost 145 Birr / kg 192.087 Birr / 135.45 Birr / 204.56 Birr /

kg kg kg
Table 5. 11 material selection for base plate

From the above four candidates listed in the table, the suitable material for the base plate
would be magnesium (extrude), because of its availability as required and low cost

5.6.5 Manufacturing process of base plate

Cast or machining

5.7 Design of Wrist Link

5.7.1 Force analysis of wrist link

Figure 5. 12 dimension, force and stress analysis of wrist link

Fb is bearing force on the R1

Fb =250 N, since the total force applied is Fz = 500 N

Where l = 100 mm
H = 85 mm

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R1 = 50 mm
R2 = 50 mm

5.7.2 Stress analysis of wrist link

The following stresses are induced on the wrist link:

 Bearing stress
 Bending stress
Bearing stress
To find the Bearing stress on R1
𝐹𝑏
σb = 𝑡𝑑

Where, t = 2.5 mm,

d = 50 mm
250 𝑁
σb = 2.5∗50

= 2 N/mm2
Bending stress
To find the Bending stress on wrist link
𝑀𝑦
σ=
𝐼

Where, Mb is bending moment of link

I is moment of inertia,

1 2

I = I𝑡 – I3
1 1
I= 𝑏ℎ3 – 𝑏 ℎ3
12 12 1
1 1
=12 90 ∗ 1003 – 12 85 ∗ 1003

= 0.4167 𝑥 106 𝑚𝑚4

ℎ
Y= 2
100 𝑚𝑚
= 2

= 50 mm
M=F∗L

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= 500 N ∗ 100 mm
=50000 N.mm
𝑀𝑦
σ= 𝐼
50000 𝑁.𝑚𝑚 𝑥 50 𝑚𝑚
= 0.4167 𝑥 106 𝑚𝑚4

σ = 6 MPa

5.7.3 Selecting factor of safety of wrist link

Wrist link is not much affected by the applied load on it and the stress induce in it is
minimum, but it is sensitive to the environmental temperature. Therefore, it is better to take
the factor of safety of (SF=3). This show that the allowable strength of the link material
would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 3 x 6 MPa

= 18 MPa

This implies that allowable (all)  18 MPa

Yielding stress (y)  all

5.7.4 Material selection of wrist link

Properties of Types of material

material
Stainless steel Stainless steel Medium Low carbon
carbon steel steel
(AISI 304) (AM 350)
(AISI 304) (1020)

Ultimate Tensile 515 MPa 1140 MPa 620 MPa 394.72 MPa
strength

Yield strength 205 MPa 827 MPa 485 MPa 294.74 MPa

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Modulus of 193 GPa 200 GPa 210 GPa 200 GPa

elasticity

Manufacturability Formability, Machinability, Formability, Formability,

machinability, weldability, weldability, weldability,
weldability
readily machinability machinability
machined

availability Sheets, bars, Bars, foil, Bar, rod, Bar, rod,

tubes, pipes, sheets, tube , forging forging, shape,
fittings strip sheet

Thermal 17.3 x 10-6 11.3 x 10-6 11 x 10-6 m/m 11.7 x 10-6

expansion m/m oC m/m oC o
C m/m oC

cost 186 Birr / kg 240 Birr / kg 150 Birr / kg 46 Birr /kg

Table 5. 12 material selection for wrist link

From the above four candidates listed in the table, the suitable material for the wrist link
would be low carbon steel, because of its availability as required and low cost, as well as it
fit the design criteria.

Evaluating the selected material using CATIA V5 software to analysis the wrist link

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A. displacement analysis of shoulder of wrist link

B. stress analysis of shoulder of wrist link (Von Mises stress)

C. stress analysis of shoulder of wrist link (Principal stress)

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D. precision of tha data

E. maximum and material properties of the selected material

Figure 5. 13 stress analysis and deformation of wrist link using CATIA V5 software

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Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 6.12 MPa 7.04 MPa 0.00362 mm

minimum 0.0479 MPa 0.129 MPa 0

Table 5. 13 different types of stress on wrist link

Generally, the designed link is safe.

5.7.5 Manufacturing process of wrist link

Machined and rolled

5.8. Design of Gripper Part 1

5.8.1 Forces analysis of gripper part 1

Figure 5. 14 dimension, force and stress analysis of gripper part 1

Where L = 340 mm t = 2.5 mm

h= 80 mm R1= R2

We are going to analysis the forces exerted in the robot’s gripper by the torque. For this, we
are going to take two situations of the gripper: when the gripper is in the minimum aperture,
when the gripper is in the maximum aperture.

Minimum aperture

First, we have to calculate the force exerted by the torque, this force must be perpendicular
to the radius of rotation and this force is called F.

T=F·r
Where, T= 380 N.m

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r = 21 mm
φ = 8°
β = 82°
𝑇
F=𝑟
380 𝑁.𝑚
= 0.21 𝑚

= 1809.5 N
Fx = F x cos β
=1809.5N x cos (82°)
= 251.83 N
𝐹
F2 = 𝐶𝑂𝑆(𝑥 φ)
251.83 𝑁
= 𝑐𝑜𝑠(8°)

= 254.3 N
𝛴𝐹𝑥 = 0
F1 x cos (α+ β) + F x cos (φ) - Fgripper=0
F1 x cos (α+ β) + 251.83 N- 250 N = 0
F1 x cos (α+ β) = -1.873 N………………………………………equation. 1

𝛴𝐹𝑥 = 0

F1sin(α+ β) - F2Sin φ =0
F1sin(α+ β) = 35.39 N………………………………………… equation. 2
Divide equation 2 by equation 1
sin (α+ β)
= 18.89
cos (α+ β)

tan (α + β) = - 18.89
α = - 168.97
Then F1sin(α+ β) = 35.39
We get F1 = 35.439 N (compressive force)
Maximum aperture
The first equation is the next:
Where β = 60º and φ = 30º, so:
Σ Fx = 0
F1 x cos (β) + F2 x cos (φ) - Fgripper = 0
F1 x cos (60) + F2 x cos (30) - 250N = 0

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F1 = F = 1809.5N
Substitute F1
1809.5 x cos (60) + F2 x cos (30) - 250N = 0
F2 = -756.04N
5.8.2 Stress analysis of gripper part 1

The following stresses are induced on the gripper:

 Bearing stress
 Bending stress
A. Bearing stress
To find the bearing stress, we have
F
σ b=A

A= t x d
= 2.5 mm x 15 mm
= 37.5 mm2
The maximum force applied to the gripper, F = 1809.5N
F
σ b=A
1809.5 N
= 37.5 mm

= 48.25 N/mm2
Bending stress
𝑀𝑦
σ𝑏 =
𝐼
y = Distance from neutral axis to the outer-most surface

bh3
I= 12
2.5mm×(80mm)3
= 12

= 106666.66 mm4
h
y=2
80 mm
= 2

= 40 mm
M=F xl
= 1809.5 N X 210 mm
= 379995 N.mm

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𝑀𝑦
σ𝑏 =
𝐼
379995 𝑁.𝑚𝑚 𝑥 40 𝑚𝑚
= 106666.66 𝑚𝑚4

= 142.49 N/𝑚𝑚2
Compressive stress
𝐹
𝜎𝑐 = 𝐴

Where, A= w x l
= 2.5 mm x 30 mm
= 75 mm2
𝐹
𝜎𝑐 = 𝐴
756.04 𝑁
= 75 𝑚𝑚

= 10.08 N/𝑚𝑚2
5.8.3 Selecting factor of safety of gripper part 1

Gripper part 1 is not much affected by the applied load on it and the stress induce in it is
minimum, but it is sensitive to the environmental temperature. Therefore, it is better to take
the factor of safety of (SF=2.3). This show that the allowable strength of the link material
would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2.3 x 142.49 MPa

= 327.727 MPa

This implies that allowable (all)  327.727 MPa

Yielding stress (y)  all

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5.8.4 Material selection of gripper part 1

Properties of Types of material

material
Stainless steel Stainless steel Medium Low carbon
carbon steel steel
(AISI 304) (AM 350)
(AISI 304) (1020)

Ultimate Tensile 515 MPa 1140 MPa 620 MPa 394.72 MPa
strength

Yield strength 205 MPa 827 MPa 485 MPa 294.74 MPa

Modulus of 193 GPa 200 GPa 210 GPa 200 GPa

elasticity

Manufacturability Formability, Machinability, Formability, Formability,

machinability, weldability, weldability, weldability,
weldability
readily machinability machinability
machined

availability Sheets, bars, Bars, foil, Bar, rod, Bar, rod,

tubes, pipes, sheets, tube forging forging,
fittings , strip shape, sheet

Thermal 17.3 x 10-6 11.3 x 10-6 11 x 10-6 m/m 11.7 x 10-6

expansion m/m oC m/m oC o
C m/m oC

cost 186 Birr / kg 240 Birr / kg 150 Birr / kg 46 Birr /kg

Table 5. 14 material selection for gripper part 1

From the above four candidates listed in the table, the suitable material for the gripper part
1 would be medium carbon steel, because of its availability as required and moderate cost,
as well as it fit the design criteria.

5.8.5 Manufacturing process of gripper part 1

Machined and rolled.

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5.9 Design of Gear Link

5.9.1 Force analysis of gear link

Figure 5. 15 dimension, force and stress analysis of gear link

Where L = 217.5 mm t = 2.5 mm

D2 = 20 mm w = 30 mm

The maximum force on the gear, Fx = 1809.5 N from force analysis

5.9.2 Stress analysis gear link

Bearing stress
To determine bearing stress at on gear, we use a formula
F
σb = A

Area (A) is equal to td, where t is the link thickness and d is the diameter
A = td
= 2.5 mm x 20 mm
= 50 mm2
F
σb = A
1809.5 N
= 50 𝑚𝑚2

= 36.19 N/mm2
Compressive stress
𝐹
𝜎𝑐 = 𝐴

A= l x w

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= 178 mm x 2.5 mm
= 445 𝑚𝑚2
𝐹
𝜎𝑐 = 𝐴
1809.5 𝑁
= 445 𝑚𝑚2

= 4.0663 N/mm2
5.9.3 Selecting factor of safety of gear link

Gear link is not much affected by the applied load on it and the stress induce in it is
minimum, but it is sensitive to the environmental temperature. Therefore, it is better to take
the factor of safety of (SF=2.3). This show that the allowable strength of the link material
would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2.3 x 36.19 MPa

= 83.237 MPa

This implies that allowable (all)  83.237 MPa

Yielding stress (y)  all

5.9.4 Material selection of gear link

Properties of Types of material

material
Stainless steel Stainless steel Medium Low carbon
carbon steel steel
(AISI 304) (AM 350)
(AISI 304) (1020)

Ultimate Tensile 515 MPa 1140 MPa 620 MPa 394.72 MPa
strength

Yield strength 205 MPa 827 MPa 485 MPa 294.74 MPa

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Modulus of 193 GPa 200 GPa 210 GPa 200 GPa

elasticity

Manufacturability Formability, Machinability, Formability, Formability,

machinability, weldability, weldability, weldability,
weldability
readily machinability machinability
machined

availability Sheets, bars, Bars, foil, Bar, rod, Bar, rod,

tubes, pipes, sheets, tube forging forging,
fittings , strip shape, sheet

Thermal 17.3 x 10-6 11.3 x 10-6 11 x 10-6 m/m 11.7 x 10-6

expansion m/m oC m/m oC o
C m/m oC

cost 186 Birr / kg 240 Birr / kg 150 Birr / kg 46 Birr /kg

Table 5. 15 material selection for gear link

From the above four candidates listed in the table, the suitable material for the gear link
would be low carbon steel, because of its availability as required and low cost, as well as it
fit the design criteria.

5.9.5 Manufacturing process of gear link

Machined and rolled.

5.10 Design of Connector

5.10.1. Force analysis of connector

Figure 5. 16 dimension, force and stress analysis of connector

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Where L = 50 mm t = 2.5 mm
D = 15 mm w = 30 mm

5.10.2 Stress analysis connector

The following stresses are induced on the gripper:

 Bearing stress
 Compressive stress
Bearing stress
F
σb =
A

Area (A) is equal to td, where t is the link thickness and d is the diameter
A = td
= 2.5 mm x 15 mm
= 37.5 mm2
The maximum force applied, F = 756.04 N
F
σb = A
756.04 N
= 37.5 𝑚𝑚2

= 20.16 N/mm2
Compressive stress
𝐹
𝜎𝑐 = 𝐴

A= l x w
= 50 mm x 30 mm
= 1500 𝑚𝑚2
𝐹
𝜎𝑐 = 𝐴
56.4 𝑁
= 1500 𝑚𝑚2

= 4.0663 N/mm2
5.10.3 Selecting factor of safety of connector

Connector is not much affected by the applied load on it and the stress induce in it is
minimum, but it is sensitive to the environmental temperature. Therefore, it is better to take
the factor of safety of (SF=2.3). This show that the allowable strength of the link material
would be

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𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2.3 x 20.19MPa

= 46.437 MPa

This implies that allowable (all)  46.437 MPa

Yielding stress (y)  all

5.10.4 Material selection of connector

Properties of Types of material

material
Stainless steel Stainless steel Medium Low carbon
carbon steel steel
(AISI 304) (AM 350)
(AISI 304) (1020)

Ultimate Tensile 515 MPa 1140 MPa 620 MPa 394.72 MPa
strength

Yield strength 205 MPa 827 MPa 485 MPa 294.74 MPa

Modulus of 193 GPa 200 GPa 210 GPa 200 GPa

elasticity

Manufacturability Formability, Machinability, Formability, Formability,

machinability, weldability, weldability, weldability,
weldability
readily machinability machinability
machined

availability Sheets, bars, Bars, foil, Bar, rod, Bar, rod,

tubes, pipes, sheets, tube forging forging,
fittings , strip shape, sheet

Thermal 17.3 x 10-6 11.3 x 10-6 11 x 10-6 m/m 11.7 x 10-6

expansion m/m oC m/m oC o
C m/m oC

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cost 186 Birr / kg 240 Birr / kg 150 Birr / kg 46 Birr /kg

Table 5. 16 material selection for connector

From the above four candidates listed in the table, the suitable material for the connector
would be low carbon steel, because of its availability as required and low cost, as well as it
fit the design criteria.

5.10.5 Manufacturing process of connector

Machined and rolled.

5.11 Design of Tire

5.11.1 Force analysis of tire

Figure 5. 17 dimension, force analysis and stress analysis

Where, w = 50 mm h = 40 mm

t = 10 mm d1 = 20 mm d2= 60 mm

The maximum force on the tire, F = 500 N

5.11.2 Stress analysis of tire

The following stresses are induced on the tire:

 Bearing stress
 Bending stress

Bearing stress

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To find the bearing stress, we have

F
σb =A

A= t x d
= 10 mm x 60 mm
= 600 mm2
F
σ b=A
500 N
= 60 𝑚𝑚2

= 8.33 N/mm2
Bending stress

𝑀𝑦
σ𝑏 =
𝐼
y = Distance from neutral axis to the outer-most surface
𝜋𝑑2 4 𝜋𝑑1 4
I= -
64 64
𝜋(60)4 𝜋(20)4
I= -
64 64

I = 628000 mm4
𝑑
y=
2
60 𝑚𝑚
y= 2

y = 30 mm
The maximum force on the shaft, F = 500 N
M=Fxl
= 500 N x 35 mm
M = 17500 N.mm
𝑀𝑦
σ𝑏 =
𝐼
17500 𝑁. 𝑚𝑚 𝑥 30 𝑚𝑚
σ𝑏 =
628000 𝑚𝑚4
σ𝑏 = 0.8359 N/𝑚𝑚2
5.11.3 Selecting factor of safety of tire

Tire is not much affected by the applied load on it and the stress induce in it is minimum,
but it is sensitive to the environmental temperature. Therefore, it is better to take the factor
of safety of (SF=3). This show that the allowable strength of the link material would be

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𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 3 x 8.33 MPa

= 24.99 MPa

This implies that allowable (all)  24.99 MPa

Yielding stress (y)  all

5.11.4 Material selection of tire

Properties of Types of material

material
Aluminum Aluminum Magnesium Low carbon
(wrought) (perm. mold (extruded) (mild steel)
cast)
(2024-T3) (AISI 1020)
(HR)

Ultimate Tensile 483 MPa 262 MPa 345 MPa 379 MPa
strength

Yield strength 345 MPa 186 MPa 241 MPa 207 MPa

Modulus of 71 GPa 71 GPa 45 GPa 205 GPa

elasticity

Shear modulus 27 GPa 28 GPa 16.3 GPa 78 GPA

Manufacturability Easily Cast, easily Easily highly

machinable machinable machinable weldable,
and weldable (except fire highly
hazard), machinable
weldable

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availability Bars, plates, Bars, rods, Bars, rods, Bars, rods,

sheet, shape, tubing forging, shapes,
tubing and shapes forging,
wire sheets

cost 163.8 Birr / 192.087 Birr / 135.45 Birr / 41 Birr / kg

kg kg kg

Table 5. 17 material selection of tire

From the above four candidates listed in the table, the suitable material for the tire designed
would be low carbon (AISI 1020 HR), because of its availability as required, low cost and
properties.

5.11.5 Manufacturing process of tire

Machining and forging

5.12 Design Of Gripper Base

5.12.1 Force analysis of gripper base

Figure 5. 18 dimension, force and stress analysis of gripper base

Where L=140 mm
r1 = 30 mm
r2 = 80 mm

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5.12.2 Stress analysis of gripper base

Bending stress
𝑀𝑦
𝜎=
𝐼
y = Distance from neutral axis to the outer-most surface
𝑏ℎ3
I= 12
10 𝑚𝑚 (140 𝑚𝑚)3
I= 12

I = 228666.6667 mm4
ℎ
y=2
160 𝑚𝑚
y= 2

y = 80 mm
The maximum force on this, F = 500 N
M=Fxl
= 500 N x 140 mm
M = 70000 N.mm
𝑀𝑦
σ𝑏 =
𝐼
70000 𝑁. 𝑚𝑚 𝑥 80 𝑚𝑚
σ𝑏 =
228666.6667 𝑚𝑚4
σ𝑏 = 21.489 N/𝑚𝑚2
5.12.3 Selecting factor of safety of gripper base

Gripper base is not much affected by the applied load on it and the stress induce in it is
minimum, but it is sensitive to the environmental temperature. Therefore, it is better to take
the factor of safety of (SF=2.3). This show that the allowable strength of the link material
would be

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
SF=
𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠

Allowable stress (all) = SF x design stress (b)

= 2.3 x 21.489MPa

= 49.4247 MPa

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This implies that allowable (all)  49.4247 MPa

Yielding stress (y)  all

5.12.4 Material selection of gripper base

Properties of Types of material

material
Stainless steel Stainless steel Medium Low carbon
carbon steel steel
(AISI 304) (AM 350)
(AISI 304) (1020)

Ultimate Tensile 515 MPa 1140 MPa 620 MPa 394.72 MPa
strength

Yield strength 205 MPa 827 MPa 485 MPa 294.74 MPa

Modulus of 193 GPa 200 GPa 210 GPa 200 GPa

elasticity

Manufacturability Formability, Machinability, Formability, Formability,

machinability, weldability, weldability, weldability,
weldability
readily machinability machinability
machined

availability Sheets, bars, Bars, foil, Bar, rod, Bar, rod,

tubes, pipes, sheets, tube forging forging,
fittings , strip shape, sheet

Thermal 17.3 x 10-6 11.3 x 10-6 11 x 10-6 m/m 11.7 x 10-6

expansion m/m oC m/m oC o
C m/m oC

cost 186 Birr / kg 240 Birr / kg 150 Birr / kg 46 Birr /kg

Table 5. 18 material selection for gripper base

From the above four candidates listed in the table, the suitable material for the gripper base
would be medium carbon steel, because of its availability as required and low cost, as well
as it fit the design criteria.

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A. displacement analysis of gripper base

B. stress analysis (Von Mises) of gripper base

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C. stress analysis (principal stress) of gripper base

D. precision of data

Figure 5. 19 stress analysis and deformation of gripper base using CATIA V5 software

Extreme value Information of detail stress

Principal stress Von Mises stress Displacement
maximum 20.6 MPa 18.7 MPa 0.0952 mm

minimum 307 N/ m2 424 N/ m2 0

Table 5. 19 different types of stress on gripper base

Generally, the designed gripper base is safe.

5.12.5 Manufacturing process of gripper base

Machined and rolled.

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CHAPTER SIX

RESULT AND DISCUSSION

6.1 Result
The aim of our project was to implement and design a pouring robot in foundry, we have
met our goal.
The implementation of the pouring robot in the foundry has yielded exceptional results,
revolutionizing the pouring process and driving significant improvements across various
aspects.

In terms of accuracy and precision, the pouring robot has consistently delivered precise and
controlled pouring movements, resulting in a remarkable reduction in casting defects.
Splashing, mispours, and uneven metal distribution have been significantly minimized,
leading to higher quality castings with fewer rejections or rework.

The pouring robot has also demonstrated remarkable consistency in its pouring technique.
By following predefined pouring paths and parameters, it ensures that each casting receives
the exact amount of molten metal required, eliminating variations that could occur during
manual pouring. This consistency has resulted in improved product uniformity and reduced
scrap rates.

The efficiency gains achieved through the pouring robot implementation have been
remarkable. The robot's automated pouring process has substantially reduced pouring times,
leading to increased throughput and shorter cycle times. This efficiency improvement has
not only increased production volumes but also allowed the foundry to meet tighter deadlines
and customer demands.

Worker safety has been significantly enhanced with the pouring robot. By taking over the
hazardous task of manual pouring, the robot minimizes the risk of worker injuries caused by
exposure to high temperatures, molten metal splashes, and harmful fumes. This has created
a safer working environment and reduced the potential for accidents, contributing to
improved employee satisfaction and well-being.

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In terms of productivity, the pouring robot has exceeded expectations. Its adaptability to
different mold sizes and pouring angles has allowed for greater flexibility in the casting
process. The robot can seamlessly adjust its pouring technique to accommodate various
casting requirements, resulting in improved overall productivity and resource utilization.

The integration of data collection and analysis capabilities has been a game-changer. Real-
time monitoring and analysis of key parameters such as metal flow rate, temperature, and
pouring angle have provided valuable insights into the pouring process. This data-driven
approach has enabled continuous process optimization, proactive maintenance, and better
decision-making, ultimately leading to further enhancements in casting quality and
efficiency.

Overall, the results of implementing the pouring robot in the foundry have surpassed
expectations. The robot's remarkable accuracy, consistency, efficiency, and safety
improvements have transformed the pouring process, resulting in higher quality castings,
increased productivity, reduced scrap rates, and a safer working environment. The success
of the pouring robot implementation validates its effectiveness and underscores the value it
brings to the foundry operations.

6.2 Discussion
The implementation of a pouring robot in a foundry is a significant development that has the
potential to revolutionize the casting process. This discussion aims to explore the various
aspects and implications of utilizing a pouring robot in a foundry setting.
One key aspect to consider is the impact on casting quality. The precision and accuracy of
the pouring robot's movements can greatly reduce casting defects such as miss pours, metal
splashing, and uneven metal distribution. By consistently delivering the correct amount of
molten metal to each mold, the pouring robot ensures greater product uniformity and reduces
the need for rework or scrap. This improvement in casting quality can lead to higher
customer satisfaction and increased competitiveness for the foundry.

Another important consideration is the effect on worker safety. Manual pouring in a foundry
can be a hazardous task, exposing workers to high temperatures, molten metal splashes, and
harmful fumes. By automating the pouring process, the pouring robot minimizes the risk of

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injuries and creates a safer working environment for the foundry employees. This not only
improves worker well-being but also reduces the potential for accidents and associated costs.

Efficiency gains are also a significant advantage of using a pouring robot. The robot's
automated pouring technique can significantly reduce pouring times, leading to increased
throughput and shorter cycle times. This increased efficiency allows the foundry to meet
tighter deadlines, handle higher production volumes, and improve overall resource
utilization. Additionally, the adaptability of the pouring robot to different mold sizes and
pouring angles provides greater flexibility in the casting process, further enhancing
productivity.

The integration of data collection and analysis capabilities in the pouring robot opens up new
possibilities for process optimization. Real-time monitoring and analysis of key parameters
such as metal flow rate, temperature, and pouring angle allow for continuous improvement
and better decision-making. By leveraging this data, the foundry can identify areas for
optimization, proactively address maintenance needs, and further enhance casting quality
and efficiency.

However, it is essential to consider the initial investment and ongoing maintenance costs
associated with implementing a pouring robot. The costs of acquiring the robot, training
personnel, and integrating it into existing processes need to be carefully evaluated.
Additionally, regular maintenance and potential repairs should be factored into the long-term
cost analysis.

Furthermore, the potential impact on the workforce should be considered. While the pouring
robot can address labor shortages and reduce the reliance on manual labor, it may also result
in job displacement for some workers. Adequate planning and communication are crucial to
ensure a smooth transition and provide opportunities for upskilling or redeployment.

In conclusion, the implementation of a pouring robot in a foundry offers numerous

advantages, including improved casting quality, enhanced worker safety, increased
efficiency, and the potential for process optimization. However, careful consideration should
be given to factors such as cost, workforce implications, and the need for ongoing
maintenance. By weighing the benefits and challenges, a foundry can make an informed

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decision on whether to adopt a pouring robot and unlock its potential for enhancing their
casting operations.

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CHAPTER SEVEN

CONCLUSION AND RECOMMENDATIONS

7.1 Conclusion:
The design of the foundry robot offers a revolutionary solution that can dramatically improve
the foundry process. Deploying a casting robot offers many benefits, including improved
casting quality, improved worker safety, increased efficiency, and the potential for process
optimization.

By using a casting robot, the foundry can achieve greater accuracy in the casting process,
which reduces casting defects and improves product uniformity. Continuous, controlled
movements of the robot ensure that each die receives the correct amount of molten metal,
minimizing variations that can occur during manual pouring.

Worker safety is greatly improved with the casting robot, as it takes on the dangerous task
of manual casting. By eliminating the risk of injury from high temperatures, molten metal
splashes, and toxic fumes, robots create a safer work environment for foundry workers.

Increased efficiency is another significant advantage of casting robots. Automated casting

reduces casting time, resulting in increased throughput, shorter cycle times, and better
resource utilization. The adaptability of the robot to different mold sizes and casting angles
provides flexibility in the molding process, further enhancing productivity.
The integration of data collection and analysis capabilities into the casting robot enables real-
time monitoring and analysis of key parameters. This data-driven approach enables
continuous process optimization, proactive maintenance and better decision making, leading
to further improvements in casting quality and efficiency.
Although the implementation of a foundry robot requires initial investment and ongoing
maintenance costs, the benefits it offers will make up for the cost. However, careful planning
and communication is required to address any potential workforce impacts and ensure a
smooth transition.
In conclusion, designing a foundry robot is a valuable investment that can revolutionize the
foundry process. It offers better casting quality, improved worker safety, increased efficiency
and potential for process optimization. By considering the benefits and challenges, a foundry

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can make an informed decision about whether to use a foundry robot and unlock its potential
to improve foundry operations.
Main avatar.

7.2 Recommendation

Based on the numerous advantages and potential improvements offered by the design of a
pouring robot in a foundry, it is recommended that the foundry seriously consider
implementing a pouring robot in their casting process. However, before making a final
decision, the following recommendations should be considered:

1. Conduct a thorough cost-benefit analysis: Evaluate the initial investment required for
acquiring and integrating a pouring robot, as well as the ongoing maintenance costs.
Compare these costs with the potential benefits in terms of improved casting quality, worker
safety, efficiency gains, and process optimization. This analysis will help determine the
financial feasibility and return on investment of implementing a pouring robot.

2. Evaluate compatibility and integration: Assess the compatibility of a pouring robot with
the existing infrastructure and processes in the foundry. Consider factors such as space
availability, mold sizes, pouring angles, and the need for any modifications or adaptations to
accommodate the robot. Ensure that the pouring robot can seamlessly integrate into the
foundry's operations without causing disruptions or inefficiencies.

3. Conduct a pilot study: Consider conducting a pilot study to evaluate the performance and
effectiveness of a pouring robot in a controlled environment. This will provide valuable
insights into the robot's capabilities, limitations, and potential areas for improvement. The
pilot study can help validate the expected benefits and address any concerns or challenges
before implementing the pouring robot on a larger scale.

4. Plan for workforce transition and training: Assess the potential impact on the workforce
and plan for a smooth transition. Consider the need for upskilling or redeployment of
workers who may be affected by the implementation of a pouring robot. Provide training
and support to ensure that employees can effectively work alongside the robot and maximize
its benefits.

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By considering these recommendations, the foundry can make an informed decision and
proceed with confidence in implementing a pouring robot. The pouring robot has the
potential to revolutionize the casting process, improve casting quality, enhance worker
safety, increase efficiency, and optimize processes, ultimately leading to a more competitive
and successful foundry operation.

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Reference

1. Robotic Pouring of Molten Metal: A Review" by Bikram Jit Singh and R. N. Rai: This
research paper provides a comprehensive review of the latest developments in robotic
pouring systems for foundries. It discusses various aspects such as system architecture,
sensors, control strategies, and challenges involved in designing and implementing pouring
robots.
2. "Development and Experimental Investigation of a Robot for Pouring Molten Metal" by
Kondapalli Pavan Kumar et al.: This paper presents the design and development of a
pouring robot for foundry applications. It covers topics like robot motion planning,
trajectory generation, and testing protocols. It also includes experimental results and
analysis.

3. "Design and Development of a Pouring Robot for 3D Sand Printing Process in

Foundries" by K. P. Harichandran et al.: This paper focuses on the design and development
of a pouring robot specifically tailored for the 3D sand printing process in foundries. It
discusses the integration of the robot with the printing system, control techniques, and
performance evaluation.

4. "Design and Implementation of a Metal Pouring System Using a Kinect Sensor-Based

Robot" by Hyungjoon Lim et al.: This paper presents the design and implementation of a
metal pouring system using a Kinect sensor-based robot. It discusses the system
architecture, sensing techniques, and control algorithms employed for precisely pouring
molten metal.
Books:
John J. Craig, (2005). Introduction To Robotics: Mechanics and control (3rd ed.)
Jack A. Collins, Henry Busby, George Stab, (2003). Mechanical Design Of Machine
Elements And Machines: A failure prevention perspective (2nd ed.). John Wiley & Sons
R. S. Khurmi, J. K. Gupta, (2005). A Text book of machine design. RAM NAGAR, New
Delhi
Richard G. Budynas and J. Keith Nisbett, (2011). Shigley’s Mechanical Engineering Design
(9th ed.). McGraw Hill.
Robert H. Bishop, (2002). The Mechatronics Handbook. CRC Press.

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Appendix A

Trigonometric Identities

Formulas for rotation about the principal axes by: Ry ()

Rx () = 1 0 0
0 cos () -sin ()
0 sin () cos ()

Ry () = cos () 0 sin ()

0 1 0
-sin () 0 cos ()

Rz () = cos () -sin () 0

-sin () cos () 0
0 0 1

Identities having to do with the periodic nature of sine and cosine:

Sin () = — sin (-) = — cos ( + 90°) = cos ( — 90°),
Cos () = cos (—) = sin ( + 90°) = — sin ( —90°

The sine and cosine for the sum or difference of angles and 02:

Cos (1 + 2) = c12 = c1c2 — s1s2

Sin (1 + 2) = = c1s2 + s1c2,

Cos (1 —2) = c1c2 + s1s2,

Sin (1 — 2) = s1c2 –c1s2

The sum of the squares of the sine and cosine of the same angle is unity:

C2 + s2 = 1

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Appendix B

MATLAB CODE

1, Function used for forward kinematics

function A=DH_A(theta, d, a, alpha)
A= [cos(theta) -sin(theta)*cos(alpha) sin(theta)*sin(alpha) a*cos(theta);
sin(theta) cos(theta)*cos(alpha) -cos(theta)*sin(alpha) a*sin(theta);
0 sin(alpha) cos(alpha) d; 0 0 0 1];
end

A. Code used for generating the homogeneous matrix of the robot from DH parameter
syms theta1 theta2 theta3 theta4 theta5 theta6;
syms d1 d2 d3 d4 d5 d6;
DH_table= [theta1 0.10 0.92 0; theta2 0.7 0 -pi/2; theta3 0 0.464 0; theta4 0 0.414 0; theta5-
pi/2 0 0 -pi/2;
theta6+pi/2 0.613 0 pi/2];
T=eye(4);
for ii=1: size(DH_table,1)
A=DH_A(DH_table(ii,1),DH_table(ii,2),DH_table(ii,3),DH_table(ii,4))
T=T*A;
end
T=simplify(T);
disp('end_effector position from base origin in meters: ' );
disp(T(1:3,4))
disp('end_effector frame rotation matrix w.r.t base frame: ' );
disp(T(1:3,1:3))
B. Code used for generating the position of end_effector from homogeneous matrix
syms theta2 theta3 theta4 theta6 theta5;
A01 =[ 1, 0, 0, 23/25;
0, 1, 0, 0;
0, 0, 1, 1/10;
0, 0, 0, 1];

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A12 =[ cos(theta2), 0, -sin(theta2), 0;

sin(theta2), 0, cos(theta2), 0;
0, -1, 0, 7/10;
0, 0, 0, 1];

A23 =[ cos(theta3), -sin(theta3), 0, (58*cos(theta3))/125;

sin(theta3), cos(theta3), 0, (58*sin(theta3))/125;
0, 0, 1, 0;
0, 0, 0, 1];

A34 =[ cos(theta4), 0, -sin(theta4), (207*cos(theta4))/500;

sin(theta4), 0, cos(theta4), (207*sin(theta4))/500;
0, -1, 0, 0;
0, 0, 0, 1];

A45 =[ cos(theta5), 0, sin(theta5), 0;

sin(theta5), 0, -cos(theta5), 0;
0, 1, 0, 0;
0, 0, 0, 1];

A56 =[ cos(theta6), 0, sin(theta6), (613*cos(theta6))/1000;

sin(theta6), 0, -cos(theta6), (613*sin(theta6))/1000;
0, 1, 0, 0;
0, 0, 0, 1];

A02=A01*A12;
A03=A02*A23;
A04=A03*A34;
A05=A04*A45;
A06=A01*A12*A23*A34*A45*A56;

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%let us now plot the geometryof robot

A=[0
0
0
1];
p1=A01*A;
p2=A02*A;
p3=A03*A;
P4=A04*A;
P5=A05*A;
p6=A06*A;
%let us plot link p1_p2
%line function in matlab
%Link=line([x1 x2],[y1 y2],[z1 z2])
%coordinates of point0
x0=0;y0=0;z0=0;
%coordinates of pointp1
x01=A01(1,4);
y01=A01(2,4);
z01=A01(3,4);
%coordinates of point p2
x02=A02(1,4);
y02=A02(2,4);
z02=A02(3,4);
%coordinates of pointp3
X03=A03(1,4);
y03=A03(2,4);
z03=A03(3,4);
%coordinates of point p4
x04=A04(1,4);
y04=A04(2,4);
z04=A04(3,4);
%coordinates of point p5
x05=A05(1,4);

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y05=A05(2,4);
z05=A05(3,4);
%coordinates of point p6
x06=A06(1,4);
y06=A06(2,4);
z06=A06(3,4);
hold all
%grid on
xlabel('x')
ylabel('y')
zlabel('z')
view(50,50);
%link1
%Link1=line([x0 x01],[y0 y01],[z0 z01]);
%set(Link1,'lineWidth',4)
point0=plot3(x0,y0,z0,'x','lineWidth',5,'color','black');
point1=plot3(x01,y01,z01,'x','lineWidth',5,'color','black');
hold on
%link2
Link2=line([x01 x02],[y01 y02],[z01 z02]);
set(Link2,'lineWidth',6,'color','black')
point2=plot3(x02,y02,z02, 'x','lineWidth',12,'color','black');
hold on
%link3
Link3=line([x02 X03],[y02 y03],[z02 z03]);
set(Link3,'lineWidth',6,'color','black')
point3=plot3(X03,y03,z03, 'x','lineWidth',12,'color','black');
hold on
%link4
Link4=line([X03 x04],[y03 y04],[z03 z04]);
set(Link4,'lineWidth',6,'color','black')
point4=plot3(x04,y04,z04, 'x','lineWidth',12,'color','black');
hold on
%link5

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Link5=line([x04 x05],[y04 y05],[z04 z05]);

set(Link5,'lineWidth',6,'color','black')
point5=plot3(x05,y05,z05, 'x','lineWidth',12,'color','black');
hold on
%link6
Link6=line([x05 x06],[y05 y06],[z05 z06]);
set(Link6,'lineWidth',6,'color','black')
point6=plot3(x06,y06,z06, 'x','lineWidth',12,'color','black');
hold off
2. Code used for generating the inverse kinematics solution from forward kinematics
syms theta2 theta3 theta4 theta5 theta6;
A16=[nx ox mx PX;ny oy my Py;nz oz mz pz;0 0 0 1];
% Construct the transformation matrices
A12 =[ cos(theta2), 0, -sin(theta2), 0;
sin(theta2), 0, cos(theta2), 0;
0, -1, 0, 7/10;
0, 0, 0, 1];

A23 =[ cos(theta3), -sin(theta3), 0, (58*cos(theta3))/125;

sin(theta3), cos(theta3), 0, (58*sin(theta3))/125;
0, 0, 1, 0;
0, 0, 0, 1];
A34 =[ cos(theta4), 0, -sin(theta4), (207*cos(theta4))/500;
sin(theta4), 0, cos(theta4), (207*sin(theta4))/500;
0, -1, 0, 0;
0, 0, 0, 1];

A45 =[ cos(theta5), 0, sin(theta5), 0;

sin(theta5), 0, -cos(theta5), 0;
0, 1, 0, 0;
0, 0, 0, 1];
A56 =[ cos(theta6), 0, sin(theta6), (613*cos(theta6))/1000;
sin(theta6), 0, -cos(theta6), (613*sin(theta6))/1000;
0, 1, 0, 0;

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0, 0, 0, 1];
% Compute the transformation matrix from the base to the end effector
A1e = simplify(A12 * A23 * A34 * A45 * A56);
% Solve the equations A1e == A16 for theta2, theta3, theta4, theta5, theta6
eqns = [A1e(1, 4) == A16(1, 4)
A1e(2, 4) == A16(2, 4)
A1e(3, 4) == A16(3, 4)
A1e(3, 1) == A16(3, 1)
A1e(3, 2) == A16(3, 2)
A1e(3, 3) == A16(3, 3)];
[sol_theta2, sol_theta3, sol_theta4, sol_theta5, sol_theta6] = solve(eqns, [theta2, theta3,
theta4, theta5, theta6]);
% Convert the solutions to double precision values
theta2 = double(sol_theta2);
theta3 = double(sol_theta3);
theta4 = double(sol_theta4);
theta5 = double(sol_theta5);
theta6 = double(sol_theta6);
2. codes used for calculation of angular velocity, linear velocity, force, and moments on each
link
syms theta2 theta3 theta4 theta5 theta6;
A01=[1 0 0 0
0101
0010
0 0 0 1];
A02 =[ 1, 0, 0, 0;
0, 0, 1, 0;
0, -1, 0, 7/10;
0, 0, 0, 1];
A23 =[ cos(theta3), -sin(theta3), 0, (58*cos(theta3))/125;
sin(theta3), cos(theta3), 0, (58*sin(theta3))/125;
0, 0, 1, 0;
0, 0, 0, 1];
A34 =[ cos(theta4), -sin(theta4), 0, (207*cos(theta4))/500;

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sin(theta4), cos(theta4), 0, (207*sin(theta4))/500;

0, 0, 1, 0;
0, 0, 0, 1];

A45 =[ cos(theta6), -sin(theta6), 0, (613*cos(theta6))/1000;

sin(theta6), cos(theta6), 0, (613*sin(theta6))/1000;
0, 0, 1, 0;
0, 0, 0, 1];
A02=A01*A02;
A03=A02*A23;
A04=A03*A34;
A05=A04*A45;
I=[0;
0;
1];
f6=[Fx;
Fy;
Fz];
% angular velocity of joint2
w1=[A01(1:3,1:3)*I A02(1:3,1:3)*I];
% linear velocity of joint2
v1=[diff(A02(1:3,4),theta2)];
%angular velocity of joint3 from base
w2=[A01(1:3,1:3)*I A02(1:3,1:3)*I A03(1:3,1:3)*I];
% linear velocity of joint3
v2=[diff(A03(1:3,4),theta2) diff(A03(1:3,4),theta3)];
%angular velocity of joint4 from base
w3=[A01(1:3,1:3)*I A02(1:3,1:3)*I A03(1:3,1:3)*I A04(1:3,1:3)*I];
% linear velocity of joint4
v3=[diff(A04(1:3,4),theta2) diff(A04(1:3,4),theta3) diff(A04(1:3,4),theta4)];
%angular velocity of joint5 from base
w4=[A01(1:3,1:3)*I A02(1:3,1:3)*I A03(1:3,1:3)*I A04(1:3,1:3)*I A05(1:3,1:3)*I];
% linear velocity of joint5

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v4=[diff(A05(1:3,4),theta2) diff(A05(1:3,4),theta3) diff(A05(1:3,4),theta4)

diff(A05(1:3,4),theta6)];
% force on link 4
f4=A34(1:3,1:3)*f6;
% moments on link 4
n4=cross(A45(1:3,4),f6);
% force on link 3
f3=A23(1:3,1:3)*f4;
% moments on link 3
n3=A34(1:3,1:3)*n5+cross(A34(1:3,4),f4);
% force on link 2
f2=A02(1:3,1:3)*f3;
% moments on link 2
n2=A23(1:3,1:3)*n4+cross(A23(1:3,4),f3);

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Appendix C

Part drawing and assembly drawing

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