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Materials Today: Proceedings 4 (2017) 2403–2410 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

A Vibration Analysis of a 6 Axis Industrial Robot

Using FEA
Supriya Sahua, B.B.Choudhury, B.B.Biswal
a,b
Department of Mechanical Engineering ,I.G.I.T, Sarang, Dhenkanal, Odisha, India
C
Department of Industrial Design, NIT Rourkela

Abstract

Robotic Manipulators are widely used in different fields of industries and with different applications. They are used for the
purpose of saving time, effort, and sometimes save the life of the human being. The current paper shows a vibration analysis of
frequencies of robot. The different modes of frequencies for the robot having crack and without having crack based are analyzed
on the finite element method (FEM). In order to improve the efficiency of an industrial robot, a finite element model of the robot
is established by utilizing the software of ANSYS Workbench. Where the model is designed in CATIA V5 with crack and
without crack and the frequencies at three different modes are obtained. Finally, the weak parts of the robot arm are found out
and relative improving suggestion is put forward, which laid foundation for the optimized design.

©2017 Published by Elsevier Ltd.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).

Keywords:Finite Element; Industrial Robot; Mode shapes; soloid model; vibration

* Corresponding author.
E-mail address:supriyaigit24@gmail.com

2214-7853©2017 Published by Elsevier Ltd.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
2404 Supriya Sahu et al. / Materials Today: Proceedings 4 (2017) 2403–2410

1. Introduction

Industrial Robot is man-made mechanical devices that can move by themselves, whose motion must be modeled,
planned, sensed, actuated and controlled, and whose motion behavior can be controlled by programming. An
Industrial robot is defined by ISO as an automatically controlled, reprogrammable, multipurpose manipulator
programmable in three or more axes. An Aristo robot is a 6 axis Articulated robot. Articulated robots are powered
by a variety of means and can be used to lift parts with great accuracy. They are often used for tasks such as
welding, painting, and assembly. The field of robotics may be more practically defined as the study, design and use
of robot systems for manufacturing.

Finite element techniques of analysis and simulation of mechanical systems is used to build mathematical models
and to analyze the static and dynamic behavior of the structural elements directly on the computer. The methods of
domain discretization supported by the Finite Element Method are popular due to its practicality and versatility
which can also be used to find out the natural frequencies of a cracked structural element. FEM tools are necessary
for modeling and analysis of multi-axes positioning of robots. Multi-axis positioning meant is the different
movements of a point, or a structure in different directions.

Hardeman et al. [1] have used nonlinear finite element based method to derive the dynamic equations of motion in a
form suitable for both simulation and identification. Huang et al. [2] utilized finite element analyzing method to
conduct analog simulation experiment, and finite element model of flexible tactile sensor sensitive unit is
established. Nonlinear analyzing technique of ANSYS software is used to analyze sensitive unit structure. Ghiorghe
[3] showed a methodology to determine the optimum values for the design parameters considering the criteria of
reducing the material used to build the structure of industrial robot, using a structural optimization and topology
algorithm. Alin Ristea [4] presented the overall difference between using a composite material and the traditional
aluminum for the design of the robot elements. Doukas et al. [5] investigated the structural behavior of industrial
robots and developed a model, capable of predicting the robot’s accuracy, under certain arm positions and loading
conditions using Finite Element Method (FEM). Gasparetto et al. [6] considered an effective method for
modeling spatial lightweight industrial robots based on an Equivalent RigidLink System approach from an
experimental validation perspective. Ashwani Kumar et al. [7] analysed the natural frequencies, natural vibration
modes and identify the fracture location of the bone through the computer simulation based on the FEA. They also
used the Solid Edge software for the design and the model is imported in ANSYS R 14.5 for the free vibration
analysis. Ramu I et al.[8] presented the modal analysis of a functionally graded material (FGM) plate to determine
its natural frequencies and mode shapes by using Finite Element Method (FEM). They employed finite element code
to compute the natural frequencies and mode shapes of the FGM plate with different boundary conditions. Chen et
al.[9] used a six-axis force/torque sensor as a component for the large manipulator in the space station. In order to
obtain the large measurement range of force/torques, an elastic body based on cross-beam with anti-overloading
capability is designed, and the size is optimized by using FEA.

2. Experimental Section

2.1 Development of Model in CATIA V5

Solid Model of robot have been developed by using CATIA V5 and analysis is done with crack and without crack.
The 6 axis industrial robot model geometry consists of motion subassembly which is shown in Fig.1.
 Supriya Sahu et al. / Materials Today: Proceedings 4 (2017) 2403–2410 2405

Fig.1. The 6 axis industrial robot model geometry

2.2 The finite element model analysis by ANSYS

FEA is a numerical method for solving engineering problem and physics, or a method to computationally model
reality in a mathematical form. The first step of FEM is to build of a model for the complete structure of the robot.
The model geometry of robot manipulators is imported from CATIA into finite element environment for physical
analysis. Although ANSYS Workbench had a very powerful function in the finite element calculation but its
function in the aspect of modeling are not strong. Therefore, the CATIA V5 software is used to establish a three-
dimensional entity model of robot arm and then data exchange of the model could be imported into ANSYS
Workbench through software interface

(a) (b)

(c) (d)

Fig.2 (a). Imported Geometry; (b) Selection of body Parts; (c) The finite element mesh ; (d) Base as fixed support
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Before the model is analyzed in ANSYS Workbench, first of all, the materials need to be selected, therefore the
“Engineer data” module of the ANSYS Workbench was chosen the default “Structural Steel.
After developing the model of robot, it is imported in the ANSYS R14.5 shown in Fig.2(a) with different boundary
condition is applied by selecting fixed support to calculate first three natural frequencies and mode shapes. All the
parts of robot are selected in Fig.2(b). The mesh size is taken as 0.01 in order to define six axes in the manipulators
shown in Fig.2(c). As this type of robot has to be fixed on the floor, when in use and the robot is of six-degree-
freedom structure, it required the fixed constraints on the base surface as shown in Fig.2(d). All nodes at the base
were constrained in all directions. Here the weight factor, mesh design and an appropriate material model are taken
into consideration for finite element modeling and analysis.

3. Results and interpretations

The occurrence of crack or damage in any engineering structure, rotating machines leads to operational problem as
well as premature failure. Due to presence of cracks the dynamic characteristics of structure changes. The change in
dynamic behavior has been utilized as one of the criteria of fault diagnosis for structures. Most important features of
the structure which undergo alteration due to existence of crack are; natural frequencies, the amplitude responses
due to vibration and the mode shapes.In this present research a systematic effort has been made to explore the
dynamic behavior of cracked robot. Finite element analysis has been done to obtain the vibration characteristics of
the robot such as natural frequency and mode shapes.

The model developed in CATIA V5 is imported in ANSYS Work bench to find out natural frequencies and mode
shapes.The output frequencies of generated mode shapes at three different modes for robot were obtained. The
generated three mode shapes for robot without crack are presented in Fig.3, Fig.4 and Fig.5 respectively.The dialog
box at the left side contains explicit values of deformations.The lowest value of the deformation was found at the
bottom of the robot ( Dark blue colour in Fig.3,4 and 5) while the maximum (Red colour in Fig 3,4 and 5) is at the
top of it near the gipper.The first three natural frequencies were obtained in the form of tables.

Fig.3. Generated First Mode Shape for Robot without Crack

 Supriya Sahu et al. / Materials Today: Proceedings 4 (2017) 2403–2410 2407

Fig.4. Generated Second Mode Shape For Robot Without Crack

Fig.5. Generated Third Mode Shape for Robot without Crack

From these figures it can be observed that there are significant variations in mode shapes.The first three natural
frequencies were noted down.The generated three mode shapes of robot for first, second and third with crack are
shown in Fig.6,Fig.7and Fig.8 respectively.

From these it has been noticed that crack had a great influence on mode shapes. In the dynamic structures,
occurrence of crack not only cause a variation in local stiffness but also it affect the mechanical behaviour of whole
structure. So the identification of cracks in the structures is a relevant issue.Output frequencies of ANSYS
workbench for the robot with crack and without crack have been given in the Table.1 and it is found that due the
presence of crack the frequencies for the three different modes slightly increases.
2408 Supriya Sahu et al. / Materials Today: Proceedings 4 (2017) 2403–2410

Fig.6. Generated First Mode Shape For Robot With Crack

Fig.7. Generated Second Mode Shape For Robot With Crack

Fig.8. Generated Third Mode Shape for Robot with Crack

 Supriya Sahu et al. / Materials Today: Proceedings 4 (2017) 2403–2410 2409

Table.1. Frequencies for different mode shapes without and with crack

Mode Frequency without crack Frequency with crack

1 51.123 52.528
2 137.22 139.7
3 159.62 161.06

Taking these output values of frequencies, graphs have been plotted by taking mode in x-axis and frequency in y-
axis and is shown in fig.9.The blue colour indicates the frequencies without crack and the red colour which is above
the blue line indicates the frequencies with crack for three different modes of 1,2 and 3 as presented in graph.

Fig.9. Graphical Presentation of Mode Vs Frequency (Hz)

From Fig.9 it can be noticed that with the presence of crack, frequency of vibration increases for first mode, second
mode and also for the third mode of vibration and it is observed that there are significant variations in mode shapes
due to presence of crack.

4. Conclusions

• There is a deviation in the natural frequencies for the crack has been received with the comparison of uncracked
robot during the vibration analysis. It has beenobserved that the natural frequency increases with crack in the
robot. So it is concluded that the deviations in the natural frequencies can be used effectively to predict crack
parameters in robot structures.
• An improvement of the static behaviour of the elements of the structure led to find a constructive solution for
robot design. The creation and implementation of an FE based model can accurately simulate the behavior of a
typical industrial robot, as long as the necessary requirements (accurate CAD designs, material properties and
loading conditions) are available, but the model can be fine-tuned to further improve the accuracy of simulation.
Finite element and Experimental results show the efficiency of the proposed method for the identification of
damage.
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