Tightening Torques Required on Pins

At all of the pin positions, there are nyloc nuts that are used to compress the plates against the
nylon bushings. Based on the list of COTS fasteners needed for the robot structure, there are
M5 and M8 nuts being used to provide the necessary clamping force on the plate links.

𝐹𝑖 = 𝑘𝑖 𝐴𝑡 𝑆𝑝

For the M5 x 0.8 nyloc nuts and accompanying pins:

The assumption is made that the fastener initially tightened with a tightening constant ki of 0.9
(according to Juvinall and Marshek). The stressed tensile area is taken from Juvinall and
Marshek and is 14.20 mm2 for M5 ISO series fasteners. The proof strength Sp is taken from
Juvinall and Marshek and is 310 MPa for SAE class 4.8 fasteners.

𝐹𝑖 = 𝑘𝑖 𝐴𝑡 𝑆𝑝

𝐹𝑖 = 0.9 × 14.20 × 310 = 3961.8 𝑁

𝑀𝑡 = 0.20𝐹𝑖 𝑑

𝑀𝑡 = 0.20 × 3961.8 × 0.005 = 3.96 𝑁𝑚

For the M8 x 1.25 nyloc nuts and accompanying threaded pins:

The same assumption is made that the fastener initially tightened with a tightening constant ki
of 0.9 (according to Juvinall and Marshek). The stressed tensile area is taken from Juvinall and
Marshek and is 36.60 mm2 for M8 ISO series fasteners. The proof strength Sp is taken from
Juvinall and Marshek and is 310 MPa for SAE class 4.8 fasteners.

𝐹𝑖 = 𝑘𝑖 𝐴𝑡 𝑆𝑝

𝐹𝑖 = 0.9 × 36.60 × 310 = 10211.4 𝑁

𝑀𝑡 = 0.20𝐹𝑖 𝑑

𝑀𝑡 = 0.20 × 10211.4 × 0.008 = 16.34 𝑁𝑚

On the motor shafts, a M5 x 12 mm Hexagonal Socket Head Screw is used to hold the links
from falling off the shafts. The tightening torques on those screws will be the same as the Mt
calculated for the M5 nyloc nut and pin arrangements.
Pin Calculations

The aluminium links in the design are connected through a pin arrangement that contains
various different components such as plain bearings and bushings. The purpose of the bushing
is to separate the plates by a specific distance and prevent the plates from deflecting inwards
whilst the end effector is picking up the payload.

Each pin has threaded sections on either end that allows for a fastener to be threaded on either
side to provide the sufficient tightening or clamping force required to hold the links, bearings
and bushes tightly. Each pin connection is modelled as a soft clamped member and the bolt
initial tensioning force, clamping force and external bolt force was calculated.

There are 8 different cases for the pinned joints and each one was analysed separately.

Figure 1: Pin--Bearing-Bushing Arrangement 1

Figure 2: Pin-Bearing-Bushing Arrangement 2

Figure 3: Pin-Bearing Bushing Arrangement 3

Figure 4: Pin-Bearing-Bushing Arrangement 4

Figure 5: Pin-Bearing-Bushing Arrangement 5

Figure 6: Pin-Bearing-Bushing Arrangement 6

 Figure 7: Pin-Bearing-Bushing Arrangement 7

Figure 8: Pin-Bearing-Bushing Arrangement 8

𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛
𝑘𝑛𝑦𝑙𝑜𝑛 =
𝑙𝑏𝑢𝑠ℎ
𝜋 𝜋
𝐴𝐵𝑢𝑠ℎ = × (𝐷𝑜 2 − 𝐷𝑖 2 ) = × (152 − 5.52 ) = 152.96 𝑚𝑚2
4 4
𝐸𝑛𝑦𝑙𝑜𝑛 = 3 𝐺𝑃𝑎

𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎

𝑘𝑛𝑦𝑙𝑜𝑛 (28 𝑚𝑚) = = = 16.388 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 28 𝑚𝑚
𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎
𝑘𝑛𝑦𝑙𝑜𝑛 (32 𝑚𝑚) = = = 14.340 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 32 𝑚𝑚
𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎
𝑘𝑛𝑦𝑙𝑜𝑛 (56 𝑚𝑚) = = = 8.194 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 56 𝑚𝑚
𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎
𝑘𝑛𝑦𝑙𝑜𝑛 (60 𝑚𝑚) = = = 7.648 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 60 𝑚𝑚
𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎
𝑘𝑛𝑦𝑙𝑜𝑛 (84 𝑚𝑚) = = = 5.463 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 84 𝑚𝑚
𝐴𝐵𝑢𝑠ℎ 𝐸𝑛𝑦𝑙𝑜𝑛 152.96 𝑚𝑚2 × 3 𝐺𝑃𝑎
𝑘𝑛𝑦𝑙𝑜𝑛 (88 𝑚𝑚) = = = 5.214 𝑀𝑁/𝑚
𝑙𝑏𝑢𝑠ℎ 88 𝑚𝑚
 𝜋 2 2 2
𝐴𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝐸𝑃𝑇𝐹𝐸 4 × (18 − 5.5 ) 𝑚𝑚 × 0.6 𝐺𝑃𝑎
𝑘𝑃𝑇𝐹𝐸 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 = = = 70.450 𝑀𝑁/𝑚
𝑙𝐵𝑒𝑎𝑟𝑖𝑛𝑔 2 𝑚𝑚

𝑘𝑤𝑎𝑠ℎ𝑒𝑟 𝑖𝑠 𝑣𝑒𝑟𝑦 𝑙𝑎𝑟𝑔𝑒 𝑎𝑛𝑑 → ∞

𝜋 2 2 2
𝐴𝐿𝑖𝑛𝑘 𝐸𝐴𝑙 4 × (30 − 16 )𝑚𝑚 × 69 𝐺𝑃𝑎
𝑘𝐴𝑙 𝐿𝑖𝑛𝑘 = = = 3490.0 𝑁𝑚/𝑚
𝑙𝑙𝑖𝑛𝑘 10 𝑚𝑚

𝐴𝑡 𝐸𝑝𝑖𝑛 14.2 𝑚𝑚2 × 207 𝐺𝑃𝑎

𝑘𝑏 = =
𝑔 𝑔
𝜎
𝐹𝑐𝑙𝑎𝑚𝑝𝑖𝑛𝑔 = 𝑘𝑛𝑦𝑙𝑜𝑛 ∆𝑥 = 𝑘𝑛𝑦𝑙𝑜𝑛 × × 𝑥0
𝐸
These equations were computed for each arrangement and the results are shown below:

Arrangement Fclamping Fext Fbolt

g (mm) kb (MN/m) kc (MN/m) R
Number (N) (N) (N)
1 130 22.61 4.22 0.187 3961.8 0 3961.8
2 130 22.61 3.54 0.157 3961.8 0 3961.8
3 130 22.61 3.74 0.165 3961.8 0 3961.8
4 118 24.91 6.88 0.276 3961.8 0 3961.8
5 32 91.86 18.52 0.202 3961.8 0 3961.8
6 38 77.35 14.65 0.189 3961.8 0 3961.8
7 84 34.99 8.16 0.233 3961.8 0 3961.8
8 130 22.61 4.22 0.187 3961.8 0 3961.8
Static Force Analysis:
Since a dynamic model had not been derived yet for the link mechanism, a static force analysis was
done in order to understand the forces that were acting on the mechanism at all pin joints under the
effects of the external loading of the payload, gravitational forces and the effects of the counterweight.
For such a static analysis, the position of the mechanism determines the magnitude of the static forces.
This means that each position of the mechanism yields a new solution of forces. As a prudent
approach, the mechanism was moved to the furthest stretched position where the assumption it has
picked up the 5 kg payload and is holding the payload stationary above the work area.
The diagram below shows the position of the robot in the workspace being used for the static force
analysis.

Figure 9: Pose of Robot Used for Static Force Analysis

The static force analysis considers that the whole system is in equilibrium and that the sum of forces
and moments nets to zero. The robot mechanism was separated link by link and a free body diagram
drawn for each link.
The free body diagram for the end effector is shown below:

Figure 10: Free Body Diagram for End Effector

The equilibrium sum of forces and moments in the x and y directions are given by:

∑ 𝐹𝑥 = 𝐹𝐺𝑥 − 𝐹𝐻𝑥 = 0 → 𝐹𝐺𝑥 = 𝐹𝐻𝑥

 ∑ 𝐹𝑦 = 𝐹𝐺𝑦 + 𝐹𝐻𝑦 − 𝐹𝑝𝑎𝑦𝑙𝑜𝑎𝑑 − 𝐹𝑒𝑛𝑑 𝑒𝑓𝑓𝑒𝑐𝑡𝑜𝑟 & 𝑔𝑟𝑖𝑝𝑝𝑒𝑟 = 0

∑ 𝑀𝐻 = 0: 𝐹𝑒𝑛𝑑 𝑒𝑓𝑓𝑒𝑐𝑡𝑜𝑟 & 𝑔𝑟𝑖𝑝𝑝𝑒𝑟 × 𝐶𝑂𝐺𝑥 + 𝐹𝑝𝑎𝑦𝑙𝑜𝑎𝑑 × 𝐻𝐼 − 𝐹𝐺𝑦 × 𝐺𝐻𝑥 − 𝐹𝐺𝑥 × 𝐺𝐻𝑦 = 0

Similarly, the same process of drawing the free body diagram for each individual link and evaluating
the sum of forces in the x and y direction was done:

Figure 12: Free Body Diagram for Link Connecting End Effector to Triangle Link

∑ 𝐹𝑥 = 𝐹𝐷𝑥 − 𝐹𝐺𝑥 = 0 → 𝐹𝐷𝑥 = 𝐹𝐺𝑥

∑ 𝐹𝑦 = 𝐹𝐷𝑦 − 𝐹𝐺𝑦 − 𝐹𝑔(𝑒𝑛𝑑 𝑒𝑓𝑓𝑒𝑐𝑡𝑜𝑟−𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒) = 0 → 𝐹𝐷𝑦 = 𝐹𝐺𝑦 + 𝐹𝑔(𝑒𝑛𝑑 𝑒𝑓𝑓𝑒𝑐𝑡𝑜𝑟−𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒)

Figure 11: Free body Diagram for Bottom Arm Links

∑ 𝐹𝑥 = 𝐹𝐶𝑥 + 𝐹𝐻𝑥 − 𝐹𝐵𝑥 = 0 → 𝐹𝐵𝑥 = 𝐹𝐶𝑥 + 𝐹𝐻𝑥

 ∑ 𝐹𝑦 = 𝐹𝐶𝑦 − 𝐹𝐻𝑦 − 𝐹𝑔(𝐵𝐴) − 𝐹𝐵𝑦 = 0 → 𝐹𝐵𝑦 = 𝐹𝐶𝑦 − 𝐹𝐻𝑦 − 𝐹𝑔(𝐵𝐴)

∑ 𝑀𝐵 = 0: 𝐹𝐻𝑥 × 𝐻𝐵𝑦 + 𝐹𝐻𝑦 × 𝐻𝐵𝑥 + 𝐹𝑔(𝐵𝐴) × 𝐶𝑂𝐺𝑥 + 𝐹𝐶𝑦 × 𝐶𝐵𝑥 = 0

Figure 13: Free Body Diagram for Triangle Link

∑ 𝐹𝑥 = 𝐹𝐸𝑥 − 𝐹𝐶𝑥 − 𝐹𝐷𝑥 = 0 → 𝐹𝐸𝑥 = 𝐹𝐶𝑥 + 𝐹𝐷𝑥

∑ 𝐹𝑦 = 𝐹𝐸𝑦 − 𝐹𝐷𝑦 − 𝐹𝑔(𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒) − 𝐹𝐶𝑦 = 0 → 𝐹𝐸𝑦 = 𝐹𝐶𝑦 + 𝐹𝐷𝑦 + 𝐹𝑔(𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒)

Figure 14: Free Body Diagram for Connecting Link from Triangle to Base

∑ 𝐹𝑥 = 𝐹𝐹𝑥 − 𝐹𝐸𝑥 = 0 → 𝐹𝐸𝑥 = 𝐹𝐹𝑥

∑ 𝐹𝑦 = 𝐹𝐹𝑦 − 𝐹𝐸𝑦 − 𝐹𝑔(𝑏𝑎𝑠𝑒− 𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒) = 0 → 𝐹𝐹𝑦 = 𝐹𝐸𝑦 + 𝐹𝑔(𝑏𝑎𝑠𝑒− 𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒)

 Figure 15: Free Body Diagram for Main Arm Links

∑ 𝐹𝑥 = 𝐹𝑂𝑥 − 𝐹𝐶𝑥 = 0 → 𝐹𝑂𝑥 = 𝐹𝐶𝑥

∑ 𝐹𝑦 = 𝐹𝐹𝑦 − 𝐹𝐸𝑦 − 𝐹𝑔(𝑏𝑎𝑠𝑒− 𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒) = 0 → 𝐹𝐹𝑦 = 𝐹𝐸𝑦 + 𝐹𝑔(𝑏𝑎𝑠𝑒− 𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒)

Figure 16: Free Body Diagram of Slotted Counterweight Link

∑ 𝐹𝑥 = 𝐹𝐴𝑥 − 𝐹𝑆𝑙𝑜𝑡𝑥 = 0 → 𝐹𝐴𝑥 = 𝐹𝑆𝑙𝑜𝑡𝑥

∑ 𝐹𝑦 = 𝐹𝐴𝑦 + 𝐹𝑠𝑙𝑜𝑡𝑦 − 𝐹𝑔(𝑠𝑙𝑜𝑡𝑡𝑒𝑑−𝑙𝑖𝑛𝑘) − 𝐹𝑔(𝑐𝑜𝑢𝑛𝑡𝑒𝑟𝑤𝑒𝑖𝑔ℎ𝑡) = 0 → 𝐹𝑠𝑙𝑜𝑡𝑦

= 𝐹𝑔(𝑠𝑙𝑜𝑡𝑡𝑒𝑑−𝑙𝑖𝑛𝑘) + 𝐹𝑔(𝑐𝑜𝑢𝑛𝑡𝑒𝑟𝑤𝑒𝑖𝑔ℎ𝑡) − 𝐹𝐴𝑦
 Figure 17: Free Body Diagram for CW link

∑ 𝐹𝑥 = 𝐹𝐴𝑥 − 𝐹𝑂𝑥 = 0 → 𝐹𝐴𝑥 = 𝐹𝑂𝑥

∑ 𝐹𝑦 = 𝐹𝐴𝑦 − 𝐹𝑂𝑦 − 𝐹𝑔(𝐶𝑊 𝐿𝑖𝑛𝑘) = 0 → 𝐹𝑂𝑦 = 𝐹𝐴𝑦 − 𝐹𝑔(𝐶𝑊 𝐿𝑖𝑛𝑘)

Figure 18: Free Body Diagram for Connecting Link from CW link to
Bottom Main Arm

∑ 𝐹𝑥 = 𝐹𝐵𝑥 − 𝐹𝐴𝑥 = 0 → 𝐹𝐴𝑥 = 𝐹𝐵𝑥

∑ 𝐹𝑦 = 𝐹𝐵𝑦 − 𝐹𝐴𝑦 − 𝐹𝑔(𝐶𝑊−𝐵𝐴) = 0 → 𝐹𝐵𝑦 = 𝐹𝐴𝑦 + 𝐹𝑔(𝐶𝑊−𝐵𝐴)

 Figure 19: Free Body Diagram of Connecting link from
Slotted Link to Motor Bracket

∑ 𝐹𝑥 = 𝐹𝐵𝑥 − 𝐹𝐴𝑥 = 0 → 𝐹𝐴𝑥 = 𝐹𝐵𝑥

∑ 𝐹𝑦 = 𝐹𝐵𝑦 − 𝐹𝐴𝑦 − 𝐹𝑔(𝐶𝑊−𝐵𝐴) = 0 → 𝐹𝐵𝑦 = 𝐹𝐴𝑦 + 𝐹𝑔(𝐶𝑊−𝐵𝐴)

For this pose shown in the figure above, the angles of the relevant links were found using a sketch
driven by the movement of the mechanism in Autodesk Inventor. The following results were obtained
and is shown in the table below:

Amount
Force Description
(N)
FGy 4,64
FGx 18,03
FG 18,61
Fend effector and gripper 12,91
Fpayload 49,05
FHx 18,03
FHy 57,32
FDx 18,02
FDy 7,02
FgTriEndEffector 2,39
FgBA 12,99
FCy 136,16
FCx 93,31
FC 165,06
FBy 65,85
FBx 111,33
 FEy 144,65
FEx 111,33
FgTriangle 1,45
FFy 147,00
FFx 111,33
FgConTri 2,36
FO2x 93,30
FO2y 144,84
FgMA 8,67
FgSlottedLink 1,88
Fgcounterweight 46,74
Fsloty 14,83
Fslotx 111,33
FAy 63,45
FAx 111,33
FgCWBA 2,40
FO1x 111,33
FO1y 60,68
Fg (CW) 2,77