How can you design a robot's mechanical structure for long-term reliability?

First and foremost, conduct mechanical designing and simulate the design through SOLIDWORKS or CATIA. Select materials for parts and simulate heat and stress analysis for each part. Make sure that joints and connections are designed for longevity and can withstand repeated movements. Recommended usage of high-quality bearings, bushings, and fasteners. Seal and enclose entire electrical and electronic control system based on environment of application. Proper ventilation, cooling systems, thermal insulation and grounding should be prioritized. Prepare proper documentation works for mechanical designs, E&E circuits, addresses and maintenance procedure to avoid mishandling.

Ask what long-term reliability means. Long-term reliability can mean several things- a. easy/inexpensive parts/components replacement & maintanence b. same input-output requirements for x years; reliability = repeatable accuracy c. varying input-output requirements; reliability = versatility. Prioritizing choices a, b and c can lead us to evaluate the trade-offs between prioritizing materials & modular design (helps with choice a), time-tested control system algorithm design (helps with choice b) and environment-sensitive algorithm deployment with better sensors and processing equipment (sensor fusion and GPUs for image processing). More details about the task to be accomplished can fine-tune the kinematics and control systems involved.

When choosing the right material for Robot's mechanical structure one should consider the following factors: 1. Requirements from the structure - If the application is weight intensive and demanding one should use a strong and rigid material. 2. Application - When the robots are used for rough application the material should meet the needs. Ex - In high heat applications using plastic is not advisable. 3. Environmental Conditions - This factor plays a very major role as choosing the right material for environmental factors is going to determine the life of the robot keeping the reliability intact.

Selecting the optimal materials is crucial for a robot's longevity and functionality. Considering specific application needs, a balance between strength, rigidity, and weight is key. Metals offer durability but require considerations for weight and corrosion. Plastics provide a lightweight alternative but may lack temperature resistance and structural integrity. Composites present a superior blend of properties yet pose challenges in manufacturing. Each material choice must align with the robot's intended operational environment and performance requirements. #Robotics

To simulate FEA/DFMEA analysis prior to the physical prototype design and implementing the required sensors at pin points to acquire the feedback timely for taking necessary actions afterwards if required.

Alongside simplicity and modularity, the design should also have points for accessibility. If there are sensors/parts that have to be frequently replaced, having the space accessible will help. A mundane yet important thing, if the design requires fastners (nuts and hex bolts in specific) have enough space to tighten/loosen them, more often than not, we end up camping them up and face diffulty while taking them apart. PS: Please don't use countersunk screws for fastening. Sure, it looks great, but if the head wears out, it's doomed!

In my experience in self balancing robot, dividing the components into sub components and attaching them together to create the desired part is much more easier to debug than doing the whole thing. I love modular design.

When designing robotic mechanical structure simplicity plays a very major role and it helps a long way in determining the reliability. The simpler the design the better it is for application and servicing. One must also keep the design modular in nature as it helps in using the robotic system in multiple configurations and also the maintenance of the system becomes easy.

Designing for simplicity and modularity is paramount for robotic reliability. Streamlining complexity minimizes potential failure points, reducing maintenance and enhancing performance. Modular designs facilitate ease of assembly and maintenance, ensuring quick repairs and part replacements, ultimately saving time and cost. Standardized parts increase the system's adaptability and scalability, making upgrades more efficient. This approach extends the robot's lifecycle and supports sustainability through resource conservation. #RoboticsDesign

The current process vision needs to focus on simplicity, robustness and, above all, flexibility. Processes need to have flexibility to achieve the highest degree of competitiveness in the market.

Un importante factor sobre el entorno recae en los espacios, los diseños funcionales de trayectorias nos pueden ayudar a la hora de situar nuestro robot, pero para personal de mantenimiento esto puede ser un riesgo operacional al no contar con espacio suficiente o de fácil accesibilidad al espacio que se desea intervenir.

Environment and Load are the ones that is directly related to Robot selection and its deployment. And for sure other factors like layout, kinematics, control system will follow and complement for long term reliability.

Considering the environmental factors is not only important for choosing the right material but also important for designing the various components like links, joints and actuators. Understanding the application of the robotic system provides very crucial information regarding selecting the right components. Also when designing the structure not only consider the application environment but also the environment for transportation and various loads and whether conditions that the system will witness in the field.

This is a great design objective. There are many factors that directly and indirectly affect robot structure reliability. If this is a new design, I would suggest comprehensive approach from design, analysis, operation and environmental. Design for rigidity and life cycles taking into account dynamic loading for full operation with safety margin. Static snd dynamic force analysis is good starting phase. Additionally, performing FEA, modal and vibratoion amblysis, fatigue and considering stress concentration and impact. Finally, consider other eliminates such as bearings, couplings, gearboxes and available material, tolerances, and composites. There is a lot to consider, plan and validate. Thank you

Account for the operational environment and anticipated loads during design. Finite Element Analysis (FEA) software like ANSYS can simulate various conditions, ensuring the mechanical structure withstands environmental challenges and anticipated loads. This proactive approach minimizes the risk of structural failures.

A very important point is not to be afraid to innovate, create new layouts, concepts and technological variations. Today there are enough tools to study, test, simulate and validate layouts in different industrial segments and different flows. Engineering teams need to seek differentiated solutions that add value to the customer and their business.

Every robotics system is designed to cater to some needs and while it's in operation it works in a workspace. When designing the mechanical structure the links of the system must be optimised in such a way that it fulfills the needs but at the same time is not subjected to very high stress. Optimization will help in evenly distributing the stress and also works efficiently in the defined workspace.

Projetar componentes com geometrias que minimizem pontos de estresse e concentração de tensão, distribuindo uniformemente as cargas ao longo da estrutura. Além disso, é fundamental considerar a ergonomia e a acessibilidade durante o projeto, garantindo que os componentes possam ser facilmente acessados para manutenção e reparo.

Optimizing geometry and layout is crucial for both performance and reliability. Implement topology optimization using software like Altair Inspire to refine the structure based on stress distribution. This aids in reducing unnecessary material, enhancing strength-to-weight ratios, and improving overall reliability.

O uso do design generativo no projeto aprimora a confiabilidade ao eliminar excessos de material, criando geometrias mais eficientes que reduzem o peso sem comprometer a resistência. Essa abordagem otimizada contribui para a durabilidade e eficiência estrutural, reduzindo o desgaste ao longo do tempo. A topologia otimizada oferece benefícios adicionais ao distribuir o estresse de maneira mais equitativa nas peças, minimizando pontos de concentração que poderiam levar a falhas. Portanto, a combinação de design generativo e topologia otimizada promove um projeto robusto e confiável para um desempenho consistente a longo prazo.

Need exact kinematics and Dynamic load analysis first. then we have to do modeling to find stress points and nature of stress. then need to do the design ,( may need to use correct materials to overcome weight issues and added weights and durability)

The robotic system when performing its operation is subjected to many static as well as dynamic loads. Carrying out the kinematics and dynamics analysis will help designing the structure in such a way that the reliability of the system can be maintained for a long life. Various simulation techniques can be implemented for carrying out the kinematics and dynamics analysis which are supported by mathematical models. One can also run some tests on prototype design to verify the efficacy of the structure of robotic system.

Kinematics and dynamics to be calculated and designed to avoid the vibration, easy orientation and reachability. simulation will help for this calculation

Kinematic analysis in robotics, essential for accuracy and efficiency, involves mapping a robot's joint parameters to its end-effector's position and orientation. In our CERBERUS robot, kinematics enables precise control over three independent screwdrivers in a planar space. This control is critical for tasks requiring high precision, like assembly operations, where each movement must be exact. We apply forward and inverse kinematics: forward for predicting end-effector positions based on given joint angles, and inverse for determining necessary joint movements to achieve desired end-effector locations. #Robotics

Kinematics and Dynamics of the system or Robot greatly depends on the structure and vice versa. So generally we should have an idea of the dynamics we want to implement on the robot before we choose a material that can satisfy those conditions. It will be a lot harder if we select a material before knowing the dynamics we want to accomplish. Most likely because the material did not give us what we wanted

Systems need to evolve from simple I/O signal systems to work with process data and create improvements automatically, through algorithms and AI. This is the biggest challenge for engineers in getting ideas off paper and putting technology into machines.

Incorporate feedback and control systems to enhance precision and response. Utilize control theory principles with tools like Simulink for dynamic simulations. Implementing sensors and actuators, along with closed-loop control systems, ensures the robot adapts to changing conditions, enhancing reliability over time.

Estes sistemas permitem monitorar continuamente o desempenho e o estado da estrutura, identificando potenciais problemas antes que causem danos significativos. Sensores de monitoramento de carga, temperatura e vibração podem ser instalados em pontos críticos da estrutura para fornecer dados em tempo real sobre o ambiente operacional e as condições de funcionamento do robô.

Implementando funcionalidad y llevando mas allá el hecho de solo tener una "estructura" podemos conocer nuestro entorno, las fortalezas y debilidades las cuales nos guiaran a un entorno preventivo y predictivo, minimizando potenciales errores los cuales son fatales en la industrial actual,

Closed loop feedback system to be designed with encoders and resolvers to get the accurate feedback in real time to control the position and speed

Un punto que suele pasar desapercibido durante la fase de diseño, suele ser el mantenimiento y la reparación de las posibles averías o incidencias. No sólo hay que pensar en cómo construir. Hay que pensar como se puede mantener y reparar durante su vida útil. Si tienes una máquina que tanto las paradas por mantenimiento como las averías o incidencias son rápidas de solventar, marcará la diferencia.

Building a long-lasting robot is like picking strong materials, keeping it simple, & making sure it can adapt. Consider where it works, how much it carries, & how it moves. First, choose strong materials & make the design simple and easy to change. Use computer analysis & control systems. Think about where the robot will work & what it will carry. Make sure the shape & layout are just right, and check how the parts move & balance. Also, make it easy to fix & understand. Think about its power, cooling, & balance. Plan for updates & think about the environment. Check it can handle changes, won't get tired, & works well with people. Consider extreme conditions & different situations. These steps ensure a reliable, durable robot.

A good mechanical structure also reduces the time we have to spend on noise(error) modeling for robots' motion. For example, a precisely engineered structure can reduce the likelihood of mechanical flexing or backlash in joints, which in turn reduces positional errors.

Ben... il ya un aspect purement marketing... si Elon développe un robot humanoïde, c'est que les clients veulent un droide comme dans les films de science fiction. Techniquement et économiquement c'est probablement pas le meilleur choix c'est sûr.

In addition to the fundamentals, consider the power supply and energy management. Efficient energy use reduces thermal stress, prolonging component life. Also, factor in ease of repair and accessibility of parts. Future-proof your design by anticipating technological advancements; this ensures your robot remains relevant and adaptable. Pay attention to redundancy in critical systems to enhance reliability. Incorporating sensors for real-time diagnostics can preempt failures. Finally, remember that a robot is not just a machine but an integration of engineering and ingenuity, where every detail contributes to its longevity and effectiveness.