Final report - HHS studentweb12076864/Files/Final report Minor...Final report 25 June 2015 Page 24-6-2015 Automation of pressure vessel winding | The Hague University of Applied Sciences

Final report

25 June 2015 Page

24-6-2015

Automation of pressure vessel winding | The Hague University of Applied Sciences

SMR2 FINAL REPORT Lightweight Structures BV Filament Winder

Final report

25 June 2015 Page i

FINAL REPORT

Lightweight Structures BV Filament Winder

Client Maarten Labordus

[email protected]

Place Delft, Haagse Hogeschool

Date 24-6-2015

Version 1.0

Tutors Frederick de Wit

[email protected]

Thijs Brilleman

[email protected]

Project members Marc Cornet

[email protected]

Justin Gross

[email protected]

Sjors van Leeuwen

[email protected]

Rick den Ouden

[email protected]

Martijn van Paassen

[email protected]

Gerben Taanman

[email protected]

Dirk van Trigt

[email protected]

Jens Vertongen

[email protected]

mailto:[email protected]











Final report

25 June 2015 Page ii

Preface This final report has been written for both the Vessel wrapper project delivered by the Lightweight

Structures and the minor Smart Manufacturing and Robotics presented by the Academy of the TIS Delft.

First off we would like to thank Lightweight Structures for the project assignment and their help during

the project. We would also like to thank mr. T. Brilleman and mr. F. de Wit for their guidance during this

project.

Final report

25 June 2015 Page iii

Summary For Lightweight Structures BV the existing setup to wind tape around a plastic pressure vessel was

improved. The goals were to redesign the EOAT and determine its capabilities; to optimizing the

manipulator control system; make rotation speed of the pressure vessel variable and controllable; and to

build a prototype winding program for the robot.

The pressure vessel manipulator was improved upon in several areas. Bearings were replaced, a new

driveshaft was made and mouting accessories to secure the pressure vessel in the manipulator were

designed and 3d-printed. The motor was replaced by a M56b4, a 0,09 kW motor from Carpanelli. The

motor is mounted on the frame with a reaction compensation connection. Two reductions, a single gear

and a worm reduction, were placed after the motor resulting in a total reduction of 1083 with an

efficiency of 45%. Combined with the E2-201-H1F frequency converter the pressure vessel can now be

rotated with a speed from 0.5 to 1.5 rpm.

To heat the tape a new heating element and aluminum casing was provided by Lightweight Structures BV.

This casing is replaced by a newly created aluminum casing. A new EOAT was developed to mount this

heating element and casing on the robot while also providing isolation around the heating element and

aluminum casing to improve the efficiency. To achieve this a new mounting mechanism was designed. The

outer casing is made out of AlMg3 to prevent oxidation. This casing consists of two parts, a top and a

bottom part, and provides spacing - 2 cm or more - between the heating element and the outer casing.

The space is filled with the insulation material Super Isol. To measure the temperature of the tape exiting

the EOAT an IR-Sensor was mounted on the EOAT. The tape temperature is measured by the MLX90614

from Melexis and read via I2C with an Arduino.

To wind the desired pattern with the tape both the EOAT position and the vessel rotation have to be

controlled. First the path over the vessel was determined. This was done using the CAD-model of the

vessel and the cross section between this vessel and 3 projected planes. One plane for the middle of the

vessel under the desired 25 degree angle and two planes for the rounded ends of the vessel. Points on

these cross-sections, spaced 1,2 cm apart, form the path perpendicular over the vessel. Using the

calculation of the rotation angles the relation of the vessel rotation and the EOAT movement was

determined. A robot program was made to move the EOAT in this desired pattern while also controlling

the vessel speed.

Final report

25 June 2015 Page iv

List of figures Figure 1: Example of wrapped pressure vessel ............................................................................................... 1

Figure 2: Current design .................................................................................................................................. 3

Figure 3: The vessel manipulator .................................................................................................................... 5

Figure 4: Frame analysis .................................................................................................................................. 6

Figure 5: Bottom adapter(left)/ Top adapter (right) ....................................................................................... 7

Figure 6: Final manipulator overview .............................................................................................................. 9

Figure 7: Final manipulator, front view ......................................................................................................... 10

Figure 8: The EOAT design of the previous project group ............................................................................ 12

Figure 9: Redesign aluminium casing ............................................................................................................ 13

Figure 10: First design ................................................................................................................................... 13

Figure 11: First design before test ................................................................................................................. 14

Figure 12: First design after test.................................................................................................................... 14

Figure 13: Final design consisting of casing and cover .................................................................................. 16

Figure 14: Casing and cover assembled with heating element and robot mount ........................................ 16

Figure 15: Assembly casing and cover ........................................................................................................... 16

Figure 16: Line for applying tape to pressure vessel ..................................................................................... 19

Figure 17: Projected assumpted geodesic curve ........................................................................................... 20

Figure 18: Created path across the surface of the pressure vessel CAD model ........................................... 20

Figure 19: Cross Section determine angle related to applying tape ............................................................. 21

Figure 20: Relation rotation PVM and movement EOAT .............................................................................. 21

Figure 21: Movement EOAT and rotation PVM related to time ................................................................... 22

Figure 22: cross-section of the vessel shown multiple variables used in the robot code ............................. 23

Figure 23: Final Inventor design .................................................................................................................... 27

Figure 24: The vessel manipulator ................................................................................................................ 28

Figure 25: Pneumatic scheme of the pneumatic system .............................................................................. 30

Figure 26: Electrical scheme .......................................................................................................................... 32

Figure 27: Frequency display ......................................................................................................................... 33

Figure 28: Render image of the vessel manipulator at the beginning .......................................................... 35

Figure 29: AC motor ...................................................................................................................................... 38

Figure 30: DC motor ...................................................................................................................................... 38

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25 June 2015 Page v

Figure 31: Servo motor .................................................................................................................................. 38

Figure 32: Gear reduction ............................................................................................................................. 39

Figure 33: Worm gear reduction ................................................................................................................... 39

Figure 34: Belt reduction ............................................................................................................................... 39

Figure 35: Chain reduction ............................................................................................................................ 39

Figure 36: Epicyclic gear reduction ................................................................................................................ 40

Figure 37: Encoder ........................................................................................................................................ 41

Figure 38: Frequency converter .................................................................................................................... 42

Figure 39: Schematic rod forces .................................................................................................................... 47

Figure 40: Electric scheme current situation ................................................................................................. 49

Figure 41: Frequency converter screen lay-out ............................................................................................ 50

Figure 42: Electric scheme new situation ...................................................................................................... 51

Figure 43: Driveshaft drawing ....................................................................................................................... 57

Figure 44: Final bearings ............................................................................................................................... 58

Figure 45: Final motor ................................................................................................................................... 58

Figure 46: Final motor with reduction .......................................................................................................... 59

Figure 47:The EOAT design of the previous project group ........................................................................... 65

Figure 48: Aluminium Casing heating element ............................................................................................. 66

Figure 49: First redesign ................................................................................................................................ 66

Figure 50: First design before test ................................................................................................................. 67

Figure 51: First design after test.................................................................................................................... 67

Figure 52: Redesign outer casing assembled with heating element and robot mount ................................ 68

Figure 53: Redesign outer casing in parts ..................................................................................................... 68

Figure 54: Redesign outer casing assembled ................................................................................................ 68

Figure 55: Final EOAT-1,2 .............................................................................................................................. 70

Figure 56: Final EOAT-3 ................................................................................................................................. 71

Figure 57: Test setup ..................................................................................................................................... 75

Figure 58: Scorched glass wool ..................................................................................................................... 77

Figure 59: Glass fibre sticking to the EOAT ................................................................................................... 78

Figure 60: Placing ring to hold the container in place above the sensor ...................................................... 87

Figure 61: A plastic container with ice water above the sensor .................................................................. 87

Figure 62: Holding a realistically sized object above the sensor ................................................................... 89

Final report

25 June 2015 Page vi

Figure 63: Comparing the Melexis sensor with the Testo IR sensor ............................................................. 91

Figure 64: The first test at 11mm distance comparing the MLX90614 vs de Testo ...................................... 91

Figure 65: The second test to confirm our results ........................................................................................ 92

Figure 66: Increasing the distance makes the sensor unusable .................................................................... 92

Figure 67: Comparing the MLX90614 with the Testo at higher temperatures and a shorter distance ........ 93

Final report

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List of tables Table 1: Festo components 31

Table 2: Trade-off motor 38

Table 3: Trade-off reduction 40

Table 4: Trade-off encoder 41

Table 5: Trade-off control 42

Table 6: Morphologic chart 43

Table 7: Magnitudes and units 44

Table 8: Motor poles 45

Table 9: Frequency converter functions 52

Table 10: Relation frequency, motor speed and input voltage 54

Table 11: Test results of the input voltage for each frequency step 55

Table 12: IR-sensor choices 85

Table 13: First measurements 88

Table 14: Measurements where sensor reading stabilize 88

Table 15: Measurements of a smaller object held in boiling water before measuring 89

Final report

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Table of content Preface............................................................................................................................................................. ii

Summary ........................................................................................................................................................ iii

List of figures .................................................................................................................................................. iv

List of tables .................................................................................................................................................. vii

Introduction..................................................................................................................................................... 0

1 Background .............................................................................................................................................. 1

1.1 Client ............................................................................................................................................... 1

1.2 Case description ............................................................................................................................. 1

2 Project definition ..................................................................................................................................... 2

3 Pressure vessel manipulator ................................................................................................................... 3

3.1 Original ........................................................................................................................................... 3

3.1.1 Frame .......................................................................................................................................... 3

3.1.2 Transmission, bearing and shaft ................................................................................................. 4

3.1.3 Clamping ..................................................................................................................................... 4

3.1.4 Motor .......................................................................................................................................... 4

3.1.5 Total assembly ............................................................................................................................ 5

3.2 Optimization points ........................................................................................................................ 6

3.2.1 The frame ................................................................................................................................... 6

3.2.2 Peripherals .................................................................................................................................. 7

3.2.3 Total assembly ............................................................................................................................ 8

3.3 Final design ..................................................................................................................................... 9

3.3.1 Construction ............................................................................................................................. 10

3.3.2 Propulsion ................................................................................................................................. 11

3.3.3 Control ...................................................................................................................................... 11

4 End Of Arm Tool .................................................................................................................................... 12

4.1 Original ......................................................................................................................................... 12

4.2 First redesign ................................................................................................................................ 13

4.3 Optimization ................................................................................................................................. 15

4.4 Final design ................................................................................................................................... 16

4.4.1 Material choice ......................................................................................................................... 17

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25 June 2015 Page ix

4.4.2 Temperature sensor ................................................................................................................. 17

5 Filament properties ............................................................................................................................... 18

6 Winding path ......................................................................................................................................... 19

6.1 Relation EOAT and PVM ............................................................................................................... 19

6.2 Robot code ................................................................................................................................... 23

6.3 Program ........................................................................................................................................ 24

7 Conclusion and recommendations ........................................................................................................ 25

7.1 Pressure vessel manipulator ......................................................................................................... 25

7.2 End Of Arm Tool ........................................................................................................................... 25

7.3 Winding path ................................................................................................................................ 26

Appendix I: Original manipulator specifications ..................................................................................... 27

1. General overview .............................................................................................................................. 27

2. Construction specifications ............................................................................................................... 28

2.1 Motor .............................................................................................................................................. 28

2.2 Transmission, bearing and shaft...................................................................................................... 29

2.3 Frame, materials and conservation ................................................................................................. 29

2.4 Clamping .......................................................................................................................................... 29

3. Pneumatic and electrical specifications ............................................................................................ 30

3.1 Pneumatic scheme .......................................................................................................................... 30

3.2 Electronic scheme rotator ............................................................................................................... 32

3.3 Frequency controller settings .......................................................................................................... 33

Appendix II: Manipulator optimization .................................................................................................... 34

1. Current setup .................................................................................................................................... 35

2. Construction specifications ............................................................................................................... 36

2.1 Motor .............................................................................................................................................. 36

2.2 Transmission, bearing and shaft...................................................................................................... 36

3. Improvements................................................................................................................................... 37

3.1 Motor: ............................................................................................................................................. 38

3.2 Reduction: ....................................................................................................................................... 39

3.3 Encoder: .......................................................................................................................................... 41

3.4 Control: ............................................................................................................................................ 42

3.5 Morphologic chart: .......................................................................................................................... 43

Final report

25 June 2015 Page x

4. Conclusion ............................................................................................................................................. 43

Appendix III: Manipulator peripherals ...................................................................................................... 44

1. Calculations motor ................................................................................................................................ 44

2. Calculations encoder ........................................................................................................................ 48

3. Rotating system setup ........................................................................................................................... 49

3.1 Current setup .................................................................................................................................. 49

3.2 New setup ....................................................................................................................................... 51

Appendix IV: Final manipulator specifications .......................................................................................... 57

1. Driveshaft .......................................................................................................................................... 57

2. Bearings ................................................................................................................................................. 58

3. Motor .................................................................................................................................................... 58

4. Reduction .............................................................................................................................................. 59

5. Encoder ................................................................................................................................................. 60

6. Frequency converter ............................................................................................................................. 60

Appendix V: EOAT Redesign ..................................................................................................................... 61

1 Introduction ...................................................................................................................................... 63

2 Theory ............................................................................................................................................... 64

3 Design and development .................................................................................................................. 65

3.1 Prelude ..................................................................................................................................... 65

3.2 First redesign ............................................................................................................................ 66

3.3 Final design ............................................................................................................................... 68

3.4 Development ............................................................................................................................ 69

4 Result ................................................................................................................................................ 70

Appendix VI: Test report End of Arm Tool and Filament ........................................................................... 72

1. Introduction .......................................................................................................................................... 74

2. Theory ............................................................................................................................................... 74

3. Test ........................................................................................................................................................ 75

3.1 Test goals ......................................................................................................................................... 75

3.2 Test setup ........................................................................................................................................ 75

4. Results ............................................................................................................................................... 77

5. Conclusion ......................................................................................................................................... 79

Appendix VII: Sensor research ................................................................................................................ 80

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2 Introduction ...................................................................................................................................... 82

3 Temperature sensors ........................................................................................................................ 83

3.1 Contact temperature sensors ................................................................................................... 83

3.2 Non-contact temperature sensor ............................................................................................. 84

3.3 Choosing a sensor ..................................................................................................................... 84

4 IR-sensor choice ................................................................................................................................ 85

4.1 Melexis sensor .......................................................................................................................... 86

5 Initial Tests ........................................................................................................................................ 86

5.1 Experiment 1 ............................................................................................................................ 86

5.2 Experiment 2 ............................................................................................................................ 89

5.3 Conclusion ................................................................................................................................ 90

6. Using the sensor .................................................................................................................................... 90

6.1 Testing under expected working conditions ............................................................................ 90

6.2 Increasing the distance ............................................................................................................. 92

6.3 Decreasing the distance ........................................................................................................... 93

6.4 Conclusion ................................................................................................................................ 94

7. Conclusion ............................................................................................................................................. 95

Appendix VIII: Program code ................................................................................................................... 96

Appendix IX: Technical drawings ............................................................................................................... 97

Appendix X: Datasheets .......................................................................................................................... 101

Appendix XI: Gantt Chart planning .......................................................................................................... 122

The Hague University of Applied Sciences Faculty for Technology, Innovation & Society Delft Smart Manufacturing and Robotics 2

25 juni 2015 Pagina 0

Introduction Lightweight Structures BV focusses on innovative lightweight structures. One of the current projects is a

pressure vessel, wrapped around with composite tape in order to make it lighter and safer.

Making it possible to create different lay-ups of the tape around the pressure vessel, a robot will be used to

apply the tape. A previous group at The Hague University has done research and build a device for rotating

the pressure vessel. During this project the previous setup will be further optimized and upgraded in order to

create a system which can wrap a pressure vessel following a generated path.

This final report concludes the project and is a collection of multiple researches and modifications performed

on the existing setup. For starters it will briefly give the background information of the project as well as the

project definition based on the project plan written at the beginning of the project. The existing setup has

been divided in two parts, the manipulator and the End Of Arm Tool (EOAT). Each of these are shown in a

format of the original followed by optimization and concluding with the final design.

The third part of this report contains the research of the new filament, which differs from the filament the

previous project group used. In final part of this report the winding path program and its code are discussed.

This part explains the mathematics and programming behind the winding path to allow others to operate the

robot used in the setup.



1 Background This chapter will provide information about the company involved in this project and describes the previous

case the project will be based.

1.1 Client Lightweight Structures BV in Delft, Netherlands, is an engineering company that carries out projects to create innovative lightweight structures, mostly but certainly not exclusively with composite materials (fibre reinforced plastics).

Figure 1: Example of wrapped pressure vessel

1.2 Case description

The client wishes to strengthen pressure vessels by wrapping it with a polypropylene and glass fibre

composite material, Figure 1. The new design is cheaper and lighter than the old design whilst withstanding

the same amount of pressure.

The current project is a follow up of an existing project which is not ready for use in a production area. The

previous project was focused on the appliance of the composite coating on the pressure vessels. This was

achieved by heating the tape by using a heating element and applying it onto a rotating vessel using a

manipulator. The previous project only met the wish of winding the tape cylindrical onto the vessel.

Main deliverables previous project group:

Heating element to apply the tape onto the vessel

Turning manipulator to rotate the vessel around its axis

Simulink model of temperature difference of the tape in the heating element.



2 Project definition The project goal has always been to produce a system that could wind filament around a pressure vessel.

Although it took some time before all involved parties came to an agreement on what would be delivered at

the end of project. This chapter discusses the original and final goals which define the project.

Our predecessors have already built a frame and an End Of Arm Tool (EOAT) that could wind simple patterns.

The focus of our project was doing research. This research includes research on the cooling speed of the laid

filament, the heating of the filament whilst using a smaller EOAT provided by Lightweight Structures and

research on how to wind filament with the robots available.

After several meetings, new goals have been set. These new goals were due to an oversight as what had to

be done and what was already completed. The newly defined project still contained research but its focus

switched to optimizing the existing setup to make it capable of winding filament in a more complex pattern.

In order to have a fully functional system, multiple controllable parameters were required and with this in

mind the new goals were:

Redesigning the EOAT and determine its capabilities

Optimizing the manipulator control system

Make it possible to control the rotational speed of the pressure vessel

Built a prototype winding program

The project started with research to deduct what further steps had to be taken, followed by upgrading the

original manipulator and writing the program.



3 Pressure vessel manipulator This chapter describes the original setup left to us by our predecessors followed by what could be optimised.

The final part showcases the upgrade done during this project.

3.1 Original

The current setup of the vessel manipulator is made by previous SMR2 students. The most important

specifications of the vessel manipulator are shown.

3.1.1 Frame

The frame consists of two main parts. The part where the pully and motor are located are responsible for the

rotation of the vessel. The other side of the frame is a shiftable construction which makes this frame

adjustable for different types of vessel. The frame is built by steel tubes, in the sizes 40x40x2, 50x50x3 and

60x60x4.

An air pressure cylinder is used for the clamping of the vessel and secures it into place. A pressure regulator

and a handle provide the right air pressure from the supply to the cylinder.

The frame is made like this because of its (working)height and adjustability. Moving parts such as the V-belt

and the motor are shielded by several plates for safety. Small feet underneath the main frame can adjust

little height differences for stability.

In the pictures below, the current design is shown.

Figure 2: Current design



3.1.2 Transmission, bearing and shaft

The motor side of the rotator contains the two sets of angular contact bearings. Between the two bearings a

pulley is mounted. A shaft connects these parts. The transmission of the mechanical energy goes from the

motor to the pulley via a v-belt and the pulley is attached to the shaft thus is able to make a rotational

movement.

The design uses angular bearings to rotate and hold radial forces of the pully. There is space left between the

shaft and the motor to accommodate to the specific needed speed the manipulator has to rotate. The output

from the motor is adjusted mechanically with a pulley and v-belt.

A 25 mm driveshaft is used. On the end of the drive shaft a fitting for the vessel is added. The pulley which will be used on the drive shaft, will have a diameter of 630 mm. This is needed to reduce the outgoing speed sharply. On the motor side a pulley of just 50 mm will be used.

3.1.3 Clamping

A pneumatic cylinder is used for clamping. It is a double-acting cylinder, because single-acting cylinders

cannot generate enough force to clamp these vessels. With a lever, the cylinder can be operated. On the end

of the piston-rod, there is made a mechanical system which will suspend the horizontal force and the

rotation of the vessel.

3.1.4 Motor

For the drive of the rotator a Siemen’s motor(D91066) is used in combination with an easy-drive frequency

controller (E2-202) to control the speed of the motor.



3.1.5 Total assembly

The current setup is working and controllable as stated, but not everything works well enough. This setup can

be used for more types of vessels. The current setup is not working good and accurate enough for the

applying of the tape on a particular type of vessel that is going to be used on this next task. Some

optimizations have to be made. The current assembly is as shown in Error! Reference source not found..

More specifications on the current setup are in appendix I.

Figure 3: The vessel manipulator



3.2 Optimization points

The frame made by another project group offers a good base for the manipulator. However, the frame does

not meet the necessary requirements in order for the project to succeed. Same changes have to be made in

order for the manipulator to work with the new pressure vessel setup.

3.2.1 The frame

The frame is not steady enough. When the pressure is set at the pneumatic cylinder, the whole frame bends.

In order to adopt the force, two bars are already added to the frame by previous project group. This is simple

but not a very good solution. In Figure 4: Frame analysis, force is applied to the frame. This gives an overview

how the frame bends.

Figure 4: Frame analysis

It is possible that, because the frame bends, the tape cannot be added well. It is necessary to test this before

additional steps are added to strengthen the frame. The two bars may be enough to cope with the bending of

the frame.

To strengthen the frame, extra steel pipes can be added. This however, takes a lot of time and effort.



3.2.2 Peripherals

Aside from the frame, multiple peripherals of the manipulator can be optimized. These are; the motor,

encoder, rod, bearings and adapter.

Motor

The motor of the manipulator is not the right motor. The tape needs to be added at a low speed. The current

motor cannot deliver this low speed. The new motor has to be calculated.

Encoder

The robot needs to know exactly how much the pressure vessel rotates. Therefore, an encoder can be added

to the rod. This encoder can be part of the motor or can be added separate.

Rod

The current rod is too short in order to fit the new setup. By making a new rod, the new motor can be added

without making changes to the frame.

Bearings

The current bearings are not right bearings. The bearings were not fixed and not well aligned. Therefore

other bearing are necessary. A pillow block bearing is needed, because this type of bearing can be added

right to the frame. Also, the rod can be fixed in this bearing.

Adapter

To secure the pressure vessel, two different adapters have been made. A top adapter to secure the top side

(gap side) of the vessel. A bottom adapter to secure the bottom of the pressure vessel. Those two adapters

are 3d printed.

Figure 5: Bottom adapter(left)/ Top adapter (right)



3.2.3 Total assembly

The changes to the current frame are important optimizations. The new frame should be a lot more accurate.

The movement of the pressure vessel has to be as accurate as possible. As a result, the robot stick the tape

precisely on the pressure vessel.



3.3 Final design

In order to improve the pressure vessel manipulator there were some improvements needed on the setup.

This chapter is divided into two parts. The first improvement part is the construction and the second is the

propulsion improvements of the manipulator. In Figure 6 andFigure 7 the new setup is displayed. For the full

list of specifications see appendix IV.

Figure 6: Final manipulator overview



3.3.1 Construction

This part will handle the constructional changes of the pressure vessel manipulator such as the frame, the

bearings and the driveshaft.

Frame

The motor is mounted on the frame by using a reaction compensation connection between the motor and

the side of the frame. This mounting has the purpose to keep the motor in the same position while rotation

the driveshaft. The technical drawings are in the appendix IX.

Bearings In order to support the shaft which will transfer the rotation of the engine onto the barrel, two tapped based

pillow blocks ‘UCPA 205’ bearings will be used. The technical datasheet is in the appendix X.

To align the bearings well with the current setup, small optimizations were made. Spacers and sheets are

added to the frame to fasten the bearings. Technical drawings of the production of these parts are in

appendix IX.

Driveshaft The driveshaft which will transfer the rotation of the motor onto the vessel is custom made for this

application. The diameter of the driveshaft which will go inside the reduction of the motor is 25mm. The

technical drawings are in appendix IX.

Figure 7: Final manipulator, front view



3.3.2 Propulsion

This second part will handle the propulsion improvements of the pressure vessel manipulator. These

improvements will cover the motor, the reduction, the encoder and the control of the motor.

Motor

The motor used for the rotation of the barrel is a 0,09 kW, M-series (M56b4) from Carpanelli, three phase

motor provided by ‘MAK aandrijvingen’. The motor has a rotation speed of 1360 rpm. The technical

datasheet is in appendix X.

The motor selection is chosen on the basis of several calculations. These calculations are in appendix III-1.

The research of the right motor is based on the calculations. The research can be found in appendix II.

Reduction

Because the application needs to rotate at really low speeds around 1 rpm, a great reduction is necessary to

slow the engine down to the required speeds. To achieve this reduction, a combination of two reductions is

used. The first one is the gear reduction ‘HW 030’ from ‘Motovario’. This gear reduction reduces the rotation

speed by 10,83. The second reduction, which is mounted directly onto the first one, is the worm reduction

‘NMRV-P 063’ from ‘Motovario’. This worm reduction reduces the rotation by 100. This reduction will be

attached to the driveshaft with a diameter of 25mm. Because the two reductions are combined, the final

reduction is 1083 (10,83 * 100 = 1083). The efficiency of this combined reduction is around 45% (gears: ± 90%

worm: ±50%). The technical datasheet is in appendix X.

Encoder

In order to control the system properly, there is a need to know at which speed or at which position the

barrel is. Therefor an encoder on the driveshaft is used. The encoder used is an incremental shaft encoder

type RI 32 from ‘Hengstler’. This encoder has a maximum pulse count of 1500 pulses. According to the

calculations in the annex this is sufficient enough for this application. The technical datasheet is in appendix

X. The encoder selection is chosen on the basis of several calculations. These calculations are in appendix III-

2.

3.3.3 Control

To control the motor, the frequency converter ‘E2-201-H1F’ from ’T-Verter’ will be used. The reach of the

frequency converter is from 1Hz till 200Hz. The frequency converter can be set manually or by means of a

variable input voltage on an input on the frequency controller. For this application we will use a variable

input voltage from the robot controller to alter the speed of the motor through the frequency converter. The

maximum rotation speed of the motor is 60Hz. Because the maximum rotation speed of the motor is 60Hz

the maximum frequency of the frequency controller has to be set to 60Hz. The technical datasheet is in

appendix X.

The frequency convertor is tested and developed. The test report is in appendix III-3.



4 End Of Arm Tool An End of Arm Tool was designed and built by the previous project group. The client himself downscaled the

EOAT and gave the project group the parts to build the smaller EOAT. This chapter briefly described all the

EOATs so far followed by an optimization list of which some a used to design the final EOAT.

4.1 Original

The previous project group developed a EOAT consisting 30 cm aluminum tubing, plaster wall plating

wrapped in aluminum foil, aluminum plating on which the heating elements were mounted. Between the

aluminum tubing and the plaster wall plating was glass wool to insulate that little bit extra. The previous

setup is shown in Figure 8.

This EOAT is developed for a filament with different dimensions and a higher throughput speed because of its

length and the use of multiple heating elements.

At the start of this current project there was almost nothing left off the EOAT from the previous group.

And since the client had developed a filament with new specifications and dimensions, a new EOAT had

to be created.

Figure 8: The EOAT design of the previous project group



4.2 First redesign

At the start of the project we were given a new heating element and aluminum casing for this element.

The aluminum casing was in a bad condition and a new one had to be sawed, milled and drilled (See

Figure 9).

The first design of the EOAT is made of 1mm thick steel. It was cut and bend in the beta factory, 3D

result is shown in Figure 10. As insulating materials we used the same materials the previous project

group, which were plaster board, glass wool and aluminum foil.

Figure 9: Redesign aluminium casing

Figure 10: First design



The first design of the EOAT as shown in Figure 11, started smoking after 45 minutes of testing (see

Figure 12Error! Reference source not found.). The contact heat was too long too high for the used

materials and the insulation started to smoulder .After doing some research it turned out that most

insulating materials used to insulate houses were only capable of resisting that much heat for 60

minutes. The next day the outer casing was starting to oxidize, so a proper redesign was necessary.

Figure 11: First design before test

Figure 12: First design after test



4.3 Optimization

As the previous chapter shows. The first redesign of the EOAT can still be optimized further. Due to the fact

that not all the parts were assembled or functioning properly, five adjustments had to be made in order to

optimize the EOAT:

A mounting mechanism had to be designed

The EOAT had to be insulated

A external IR sensor had to be installed to measure the tapes temperature

The internal thermocouple had to be calibrated

A pressure roller had to be designed

The results of these five adjustments will be shown in the next paragraph.



4.4 Final design

In the final design the following requirements had to be implemented:

1. Outer casing made of a material that would not oxidize;

2. Casing consists of a top part and bottom part;

3. The top part must be mounted to the robot arm so only the bottom part needs to be unbolted

when servicing the EOAT;

4. At least 2 cm of spacing between the outer casing and the aluminum block all around;

5. Finding an insulating material that is capable of resisting the temperature at all times.

These requirements came forth out of testing the first redesign of the EOAT.

In Figure 13 is shown how the casing and lit are two different parts. Error! Reference source not found.

shows how the casing and lit are assembled. Figure 8 is the complete assembly, excluding the insulating

material.

Figure 13: Final design consisting of casing and cover

Figure 15: Assembly casing and cover Figure 14: Casing and cover assembled with heating element and robot mount



4.4.1 Material choice

The material choice for the outer casing was not as difficult. The choice was AlMg3, this was available and

good for welding and bending.

To inquire more information about insulating materials several hardware stores were visited and asked if

they could provide a material that could withstand the heat generated by the heating element. And the

lengthy duration of the heating process.

All of them confirmed that the previously used material and every other material used for the insulation of

houses would not meet the requirements. Even those that did meet the heating requirement could not

handle the heat for longer than sixty minutes without degrading and losing their insulating properties.

In the end a hearth salesman gave the advice to use a material for hearths which resulted into a gift of a

board of Super Isol. The hearth salesman uses it to stick it between the wooden walls and the stone tiles in a

fireplace. Stone tiles do not insulate at all which means the board of Super Isol prevents the wood from

getting hot or burning.

For the full report see appendix V

4.4.2 Temperature sensor

To measure the temperature of the tape leaving the heating element a temperature sensor is needed. From

all the possible sensors that are available an IR-sensor is seen as the best solution. Two of those sensors were

considered. After the initial sensor of our choice, the TI TMP007, was dead on arrival so another sensor was

used. This Melexis MLX90614 IR-sensor was initially tested using ice-water and nearly boiling water. When

the sensor was believed to work correctly it was put up against our reference sensor, de Testo 835-T2.

The MLX90614 was tested by heating tape with a soldering iron and comparing the results with the

reported temperature of the Testo sensor. At 5mm, 11mm and 28mm distance between tape and the

Melexis sensor the results were compared. Only the 5mm and 11mm distances gave good results. At those

distances and at lower temperatures (< 60 °C) the differences were only a few degrees. At higher

temperatures (> 65 °C) the Melexis sensor reported up to a 17 °C higher temperature when the result was

102,6 °C versus 85 °C as measured by the Testo.

The tests have proven that this Melexis sensor can be used for the purpose of measuring the tape

temperature at a distance of 5mm and 11mm. However, when using the sensor in the final product the

Melexis results will have to be calibrated to compensate for the over reported temperature at higher

temperatures.

For the full research see appendix VII.



5 Filament properties The use of PP-glass fibre tape is a relatively new in the market. Due to the lack of information and references

research had to be done in order to gather the correct information to fulfil the assignment. Our predecessors

have already done some research on the subject, but at the start of the project to mayor changes were made

to the EOAT and filament.

First the size of the EOAT and heating element were decreased from a 150mm long block with a heating

capacity of about 1000W to an aluminium block of about 50 mm with a heating capacity of 250W.

Secondly the PP-glass fibre tape was decreased in size from 20mm in width to 5mm. In order to use both in

the project research had to be done on the following:

- Heating capacity of the EOAT

- Insulation of the aluminium block

- PP-glass fibre tape material specifications

- Operating temperature

The answers and the research report itself can be found in Appendix VI.



6 Winding path The winding path of the filament onto the pressure vessel is rather complex and therefore this chapter first

explain the mathematics behind the program followed by the program itself.

6.1 Relation EOAT and PVM

The composite tape needs to be applied following a geodesic curve, the shortest path from one point to

another, preventing the tape to slip of the pressure vessel. Applying the tape following a geodesic curve

means the End-Of-Arm-Tool (EOAT) and Pressure Vessel Manipulator (PVM) need to operate related to each

other. In order to determine this relation some assumptions have to be made:

Composite tape will be applied on top of the pressure vessel as shown in Figure 16. This creates a

plane to determine the needed rotation of the PVM in relation to the EOAT.

Figure 16: Line for applying tape to pressure vessel



The actual geodesic curve with an angle of 25 degree to the rotation axis is assumed by three

projected planes. The cross section of these projected planes are shown in Figure 17. This

assumption makes it possible to create a three dimensional path across the surface of the pressure

vessel. Though the actual geodesic path is not exactly 360 degrees, the result of the assumed pattern

can be multiplied to conform to the needed geodesic path.

Figure 17: Projected assumpted geodesic curve

The above mentioned assumptions make it possible to determine the needed rotation angle of the PVM and

to derive a path from the CAD-model. First, points with a distance of 1,2cm are generated to create the

necessary path as shown in Figure 18.

Figure 18: Created path across the surface of the pressure vessel CAD model

The created path is then exported manually into a spreadsheet, shown in Spreadsheet path coordinates. The

coordinates are used to calculate the rotation angle at the cross section of every coordinate, as shown in

Figure 19.



Figure 19: Cross Section determine angle related to applying tape

With the calculation of the rotation angles the relation between the movement of the EOAT and the rotation

of the PVM is determined. This relation is presented in Figure 20.

Figure 20: Relation rotation PVM and movement EOAT



The condition for applying composite tape at constant speed makes clear the variable time has to be

introduced. Because the distance between the coordinates of the path is equal, each step requires an equal

amount of time for constant speed of applying tape. Figure 21 shows the movement of the EOAT and

rotation of the PVM related to time. There needs to be noted: Units different than SI-units are used to

present both diagrams in the same figure.

Figure 21: Movement EOAT and rotation PVM related to time

Figure 21 makes clear the PVM adapts speed to compensate the movement of the EOAT. The middle of the

diagram shows how the EOAT almost stops moving while the PVM is rotating, meaning the pole of the

winding is reached (bottom or top of the pressure vessel). This movement makes it possible to follow a

geodesic path around the pressure vessel.



6.2 Robot code

To get the heated tape correctly wound around the pressure vessel the head needs to follow a certain

trajectory. This accomplished by attaching the head to a robot arm.

The robot will supply translation over two axes and rotation around two axes. Rotation of the vessel around

its own center axis makes sure the other translation and rotation are managed.

Approach

This approach gives the easiest way to process the wrap trajectory of the tape around the vessel. It means

the robot however will only move through one given plane. In the case of the test subject this is the XZ-plane.

Two ways were determined how to control the robots movements; TCP location wise or formula wise.

Location

A string of locations could be exported from a step-file using Inventor. These can then be entered into the

robot program and simply let the robot attend all poses subsequently. However this is the easiest approach

to a complex problem it offers very little room for adjustments and the change to another vessel would mean

a lot of work.

Formula

Option two offers more flexibility but needs more skill to figure out what need to be done. Luckily the design

of the vessel is relatively easy to follow. The contours exist of two parts of an arc circle and a straight line.

This is relatively easy to program and can (when variables are used) be easily adjusted to ensure maximum

compatibility. 1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

ASSY-10X17-DWE

Sjorsbob 17-06-15

Designed by Checked by Approved by Date

1 / 1 Edition Sheet

Date

R128,00

r =

168,00l =

21,8

5°

Angle

_st

art

=

teta

dx

Wrap_start

Figure 22: cross-section of the vessel shown multiple variables used in the robot code



6.3 Program

The program exists of a several different sub programs. These are: Before start, calculate pose values, assign

pose values, execute move, Read encoder, calculate PID response and execute PID response.

Below is shown a PFD that show the contents of the main program that controls the robot.

Before start

Set all values to standard value

Move to position Wrap_start + 200m in Z-direction

Main program

Set x : To cos(tetaY)*r+dx

Set y = 0

Set z = sin(tetaY)*r

Set rx = 0

Set ry = 0,5*pi-tetaY

Set rz = tetaZ

Jmove to Wrap_start + (x, y, z, rx, ry, rz)

If Wrap_back == False

If tetaY < 0,5*pi, x>-l, tetaY < pi-Angle_start_Y, else If

Reverse of everything left Recalculate tetaY

Recalculate tetaZ

teta = 0,5pi

tetaZ = Angle_Z

dx=x–l/Stap_recht

Telrecht ++

Recalculate tetaY

Recalculate tetaZ

Wrap_back = True

Return Main



7 Conclusion and recommendations It is possible to strengthen pressure vessel by wrapping it with a polypropylene and glass fiber composite

material. This can be done if the following components are working well:

7.1 Pressure vessel manipulator

The pressure vessel manipulator is responsible for turning and clamping the pressure vessel. Due to a

frequency controller, the robot can communicate with the pressure vessel manipulator in terms of rotation

speed. This is necessary for the tape winding path. The pressure vessel manipulator is still adjustable for

future productions of other types of vessel. It may be necessary to design new adapters in order to fit the

different pressure vessels.

Make sure that frame is fixed while winding. This can be done by the fixing screws at the bottom of the

frame. It is also recommended to check if the vessel is properly placed before starting to wind. Don’t let the

pressure vessel fall after winding and releasing the vessel by lowering the air pressure. This may break the

adapter, different parts of the machine or even the vessel. It is also recommended to screw the white shell

into the pressure vessel before fixing it in the manipulator. Hold the pressure vessel steady at the right height

when applying air pressure on the cylinder for clamping.

7.2 End Of Arm Tool

By redesigning the EOAT tool and determine its capabilities, it was clear that the newly designed EAOT was

much better suited than the previous prototype. This new EOAT is heating the tape and measuring its

temperature. The EAOT is well insulated and ensures a good flow of the outgoing tape.

The tape width is 5 mm and the EAOT is made for this size of tape. It is recommend that only this type of tape

is used. When using other types of tape, it is necessary to test this tape and/or design a new EAOT.

When heating the tape, smoke is coming of the EOAT. This smoke may contain toxic chemicals so a good

extraction is recommended. It is possible to suck away this smoke right at the exit of the outgoing tape, by

holding or attaching a vacuum cleaner next to it.

The EAOT is well insulated but some heat is still coming of the EAOT, especially the outgoing tape. Don’t get

to close to the EOAT for safety reasons (burning and toxic air). Don’t touch the EOAT or other parts of the

robot while functioning. This can deviate the robot from its path or hurt people around.

It is also recommend to bring the EOAT as close to the pressure vessel as possible. This is important because

the heated tape will cool down between the EOAT and the vessel. If the tape is to cold it may not stick well

enough to stay. If the tape becomes too hot it may break, so rising the temperature of the EAOT is not a good

solution.



7.3 Winding path

The winding path is important for the strength of the pressure vessel after winding. To make sure the

pressure vessel is correctly winded, the robot and the manipulator must work together seamlessly. The path

covered by the robot is important for the final path of the tape.

The path the robot follows is approximately the correct path. The path is an assumption of the correct path

by an angle of 25 degrees. This path is been devised for this particular vessel. A mathematical model or other

assumption has to be made if other pressure vessels are going to be used.



Appendix I: Original manipulator specifications The current setup of the vessel rotator is made by SMR2 students before. To understand their decisions, it

was necessary to look up their reports. Most of the information of the specifications of the rotator is based

on their information and tests. It is necessary to test those results ourselves to be sure of those results. The

most important specifications of the vessel rotator are shown.

1. General overview

In the pictures below, the final design is shown.

Figure 23: Final Inventor design

A pneumatic cylinder is used for clamping. To hold the drive shaft two bearings are used. On the left it is a

simple ball bearing to suspend the down force which will be generated by the pulley, which will be place

between the two bearings. The bearing on the right is an angular contact bearing, which will suspend down

force, but also the horizontal force which is given by the cylinder to clamp the vessel. On the end of the drive

shaft a fitting for the vessel is added. The pulley which will be used on the drive shaft, will have a diameter of

630 mm. This is needed to reduce the outgoing speed sharply. On the motor side a pulley of just 50 mm will

be used.

On the other side of the drive shaft, the pneumatic cylinder is added. It is a double-acting cylinder, because

single-acting cylinders cannot generate enough force to clamp these vessels. With a lever, the cylinder can be

operated. On the end of the piston-rod, there is made a mechanical system which will suspend the horizontal

force and the rotation of the vessel.



Figure 24: The vessel manipulator

2. Construction specifications

In order for the rotator to work, several parts where needed. A list of specifications of those parts are shown

below.

2.1 Motor

For the drive of the rotator a Siemen’s motor (D91066) is used in combination with an easy-drive frequency

converter (E2-202) to control the speed of the motor. The reach of the frequency converter is from 1Hz till

200Hz. The frequency converter can be set manually or by means of a variable input voltage on an input on

the frequency converter. The maximum rotation speed of the motor is 60Hz. Because the maximum rotation

speed of the motor is 60Hz the maximum frequency of the frequency converter has to be set to 60Hz.



2.2 Transmission, bearing and shaft




movement.

The design uses angular bearings to rotate and hold radial forces. When a force comes through the shaft the

angular bearing prevents the shaft from slipping through bearing. There is space left between the shaft and

the motor to accommodate to the specifics needs in speed the rotator has to rotate. The output from the

motor is adjusted mechanically with a pulley and a v-belt.

2.3 Frame, materials and conservation

The frame is built by steel tubes, in the sizes 40x40x2, 50x50x3 and 60x60x4.

To prevent this steel frame for any rust a surface treatment is added. Because of that this machine is a

demonstration machine, the treatment has no other reason but rust prevention. Therefore, there is chosen

for paint.

2.4 Clamping

There are two types of clamps that are used in the design. A fitting and a pneumatic cylinder. The fitting is

fastened on the shaft. The pneumatic cylinder is mounted on the construction with a steel block. The fitting

holds the force from the pneumatic cylinder. The vessel connects to the fitting and the pneumatic cylinder

presses against the vessel. The fitting centres the vessel through the opening of the vessel. The pneumatic

cylinder has a support at the end of the piston with a bearing for rotating. Between each clamping and the

vessel there is a rubber pad that uses the friction forces to not let the vessel slip.



3. Pneumatic and electrical specifications

In order to understand the pneumatics and electrical components used in the current setup the schemes of

the different product groups are necessary.

3.1 Pneumatic scheme

In this part all the information about the pneumatic system of the machine can be found. The system is used

to clamp the barrel in place.

Figure 25: Pneumatic scheme of the pneumatic system

The air supply comes in at the quick connector (7), standard air hoses can be connected on this. A pressure of

8 to 12 bar is set on this system. Because there are different lengths, diameters and weights of the vessel the

clamping pressure needs to be regulated. Therefor a pressure regulator is installed (5), its scope is 0,5 to 12

bar. A pressure gauge (6) is fitted on top of it to see the amount of bar it is set on.



To control the pneumatic piston (1) a 4/3 valve (3) is used. The valve is hand-operated by a handle. A 4/3

valve has 4 connections to put components on and 3 positions. 3 positions are ideal for this system, the

piston can be opened, closed and locked. From the 4/3 valve two connections go to the piston (1). On the

outgoing connection of the piston (1) a speed controller (2) is placed so the stroke of the piston is going

smoothly and can be controlled better. One connection on the 4/3 valve is an exhaust to release the

pressure. To prevent loud noises of escaping air, a muffler (4) is placed in the connection.

The system is connected with ¼ pluggable couplings where 6mm flexible tube can be put in.

In the table below the part numbers are found, the components used are from Festo.

Table 1: Festo components

Part ID Part Number Part Name Amount

1 1376307 Piston: DSBC-50-100-PPSA-N3

1

2 193146 Speed controller: GRLA-¼-QS-6-D

2

3 538195 4/3 valve: VHER-BH-M04C-G14-UD

1

4 165004 Muffler: UC-1/4

1

5 - 6 527690 Pressure regulator: MS4-LR-¼-D7-VS-DM2

1

7 531636 Quick coupling: KD4-¼-I

1

186097 Pluggable couplings: QS-G1/4-6

6



3.2 Electronic scheme rotator

This part contains the information of the electronic components and how they are connected.

Figure 26: Electrical scheme

To connect the frequency controller to the robot-controller 4 pins from the robot controller are needed. Two

pins are needed to determine the rotation way of the motor. If voltage is put on pin 3 of the frequency

controller the motor will turn left, if voltage is put on pin 4 the motor will turn right. If there is voltage on

both pin 3 and 4 the motor will not turn. 24V is needed from the robot controller for the emergency stop,

which is connected to pin 6 of the frequency controller. The emergency stop is a normally closed connection,

so if the emergency stop is pushed the frequency controller get a signal on pin 6 and the motor stops

running. Pin 10 of the frequency controller is connected to the ground of the robot controller.



3.3 Frequency controller settings

The frequency controller has multiple parameters who needs to be set to the right value. The setting can be

set on the display of the frequency controller.

Figure 27: Frequency display

The parameters are set by pushing the DSP/FUN button and move to the right parameter with the up and

down buttons. If you navigate to the right parameter then press the DATA/END button and set the

parameter to the right value by the up and down buttons. If the parameter is set on the right value, press the

DATA/END button again and the parameter is set.

The parameters on the frequency controller that needs to be set to work together with the robot controller

are the parameters F06, F07, F10, F11, and F19.

- The parameter F06 has to be set on 50Hz to determine the maximum frequency.

- The parameter F07 has to be set on 0Hz to determine the minimum frequency.

- The parameter F10 has to be set on 1 to do the controls through the external clamps.

- The parameter F11 has to be set on 0 to set the speed by the pushbuttons on the frequency

controller.

- The parameter F19 has to be set on 3 to activate the emergency stop on clamp 6.



Appendix II: Manipulator optimization

RESEARCH MOTOR, ENCODER AND FREQUENCY CONVERTER

The goal of this research is to explore the possibilities of changes which could be made according to the

rotation of the vessel. For the rotation of the vessel there are different parts needed. The research will start

with the motor. This is a critical part for the application because it gives the necessary rotation to the vessel.

All motors have a rotation speed which is too high for this application. Therefore a reduction of the motor

speed is needed. For the control system there are two more parts needed. An encoder which can determine

where the vessel is or at what speed the vessel rotates. In order to be able to control the rotation of the

motor there is a controlling device necessary to alter the rotation speed of the motor when required.



1. Current setup

Figure 28: Render image of the vessel manipulator at the beginning

The image above (Figure 1) is a model of the current setup used for the vessel rotator.

To hold the drive shaft two bearings are used. On the left it is a simple ball bearing to suspend the down

force which will be generated by the pulley, which will be placed between the two bearings. The bearing on

the right is an angular contact bearing, which will suspend down force, but also the horizontal force which is

given by the cylinder to clamp the vessel. The pulley which will be used on the drive shaft, will have a

diameter of 630 mm. This is needed to reduce the outgoing speed sharply. On the motor side a pulley of just

50 mm will be used.



2. Construction specifications

2.1 Motor

For the drive of the rotator a Siemen’s motor (D91066) is used in combination with an easy-drive frequency

controller (E2-202) to control the speed of the motor. The reach of the frequency controller is from 1Hz till

200Hz. The frequency controller can be set manually or by means of a variable input voltage on an input on

the frequency controller. The maximum rotation speed of the motor is 60Hz. Because the maximum rotation

speed of the motor is 60Hz the maximum frequency of the frequency controller has to be set to 60Hz.

2.2 Transmission, bearing and shaft




movement.

The design uses angular bearings to rotate and hold radial forces. When a force comes through the shaft the

angular bearing prevents the shaft from slipping through bearing. There is space left between the shaft and

the motor to accommodate to the specifics needs in speed the rotator has to rotate. The output from the

motor is adjusted mechanically with a pulley and a v-belt.



3. Improvements

There are some improvements possible and necessary in order to make the vessel rotate at the desired

speeds around 1 rpm and be able to control it in a proper way. In the next paragraphs there will be an

enumeration for each part which will be improved. For each part there will be given multiple options which

their pro’s and con’s for each option. For each part needed to be improved there will be a trade-off matrix to

choose the best option considering the requirements for each part.

After the choice of the individual parts the final concept will be displayed by using a morphologic chart where

it is clear which parts will be combined into the final concept.



3.1 Motor:

The motor is the power of the manipulator. There are a lot of different motors

available. Here are the most important ones listed.

- AC motor:

o Most common for this application

o Easy to use

o Easy to control with frequency converter

o Not too expensive

- DC motor:

o Cannot be used with frequency converter

o Cheap

o Power not equally divided over 360°

- Servo:

o Expensive

o Can be controlled over small steps

- Trade-off matrix:

Concepts AC Motor DC Motor Servo

Fixed Requirements

factor (f) score (s) f*s score (s) f*s score (s) f*s

Cost 3 3 9 2 6 1 3

Controlable 2 2 4 0 0 3 6

Reliability 1 2 2 2 2 3 3

Total 15 8 12

Table 2: Trade-off motor

In the trade-off matrix is clear that the AC motor scores the highest and will be the best option for this

application.

Figure 29: AC motor

Figure 30: DC motor

Figure 31: Servo motor



3.2 Reduction:

The reduction is necessary in order to rotate at the required speeds.

Now there will be some options listed in order to make a choice.

- Gears:

o High efficiency

o Possible to mount on motor

o Parallel to motor shaft

- Worm gear:

o Lower efficiency


o Prependicular to motor shaft

- Belt:

o Lower efficiency

o Vulnerable to slip

o Not mountable on motor

o Big construction


- Chain:

o High efficiency


o Noisy


Figure 35: Chain reduction

Figure 32: Gear reduction

Figure 33: Worm gear reduction

Figure 34: Belt reduction



- Epicyclical gearing:

o Very high efficiency


o Concentric to motor shaft

o Expensive

- Trade-off matrix:

Concepts Gears Worm Gear Belt Chain Epicyclical gearing

Requirements factor (f) score (s) f*s score (s) f*s score (s) f*s score (s) f*s score (s) f*s

high reduction 9 4 36 5 45 5 45 5 45 4 36

Slip 8 5 40 5 40 2 16 3 24 5 40

Safety 7 5 35 5 35 3 21 3 21 5 35

Efficiency 6 4 24 2 12 3 18 3 18 5 30

Cost 5 4 20 4 20 5 25 5 25 1 5

Reliability 4 4 16 4 16 3 12 3 12 4 16

Space 3 4 12 4 12 2 6 2 6 5 15

Noise 2 4 8 4 8 5 10 3 6 4 8

Maintenance 1 5 5 5 5 3 3 2 2 5 5

Total 196 193 156 159 190

Table 3: Trade-off reduction

In the trade-off matrix is clear that the gears and the worm gear scores the highest and will be the best

option for this application. In order to achieve the high reduction a combination of these two parts is possible

and may be necessary.

Figure 36: Epicyclic gear reduction



3.3 Encoder:

The encoder will be used as a sensor in the control system. It is necessary to measure the rotation of the

barrel.

- Incremental:

Gives a specified number of pulses each

turn

Determines speed of the drive

- Absolute:

Gives the angular position

o Singleturn:

One turn divided in different steps

New measurement every turn

o Multiturn:

One turn divided in different steps

Counts also the amount of rotations

- Trade-off matrix:

Concepts Incremental Absolute Singleturn Absolute Multiturn

Requirements factor (f) score (s) f*s score (s) f*s score (s) f*s

Useability 2 3 6 2 4 2 4

Accuracy 1 3 3 1 1 2 2

Total 9 5 6

Table 4: Trade-off encoder

In the trade-off matrix is clear that the incremental encoder scores the highest and will be the best option for

this application.

Figure 37: Encoder



3.4 Control:

In a control system there needs to be a unit which can control

the engine and can communicate with other subsystems.

Below are some options listed which are possible for the motor

control.

- Frequency converter:

o Can change the speed of the motor

o Variable voltage input for speed setting

o Easy to use with AC motor

o Easy to program and control

o Usable in a control system

- Softstarter:

o Can control the start-up of the engine

o Not able to control the rotation speed of the

motor in a control system

- Trade-off matrix:

Concepts Frequency converter Softstarter

Requirements factor (f) score (s) f*s score (s) f*s

Cost 2 2 4 0 0

Controlling 1 2 2 1 1

Total 6 1

Table 5: Trade-off control

In the trade-off matrix is clear that the frequency converter scores the highest and will be the best option for

this application.

Figure 38: Frequency converter



3.5 Morphologic chart:

In this morphologic chart all the functions are displayed on the left and all the technical options are shown on

the right of each function. The options which are inside the red square are the ones which scored the highest

in the trade-off matrices and which will be used in the final concept. For each function one option is chosen

but for the reduction there will be made a combination with the gears and the worm gear in order to achieve

the very high reduction which is necessary.

Table 6: Morphologic chart

4. Conclusion

The best and most suitable solution for the improvements would be the AC motor which can be controlled by

the frequency converter. For the reduction a combination of the gears and worm gear will be used. Together

with the incremental encoder these parts will be combined into the final concept.



Appendix III: Manipulator peripherals

1. Calculations motor

For the propulsion of the barrel there is a need for a motor. In the next calculations some parameters will be

calculated concerning the rotation of the pressure vessel. At first several reductions will be calculated based

on the requirements of the application. The reductions are dependent on the different rotation speeds

possible of motors. In the second part the torque and the motor power will be calculated based on the

properties of the pressure vessel and the tape feed of the application. These calculations will be used to

make a proper decision for the reduction and the motor. Because there are some uncertainties about the

final pressure vessel, this calculations will be based on the barrel that will be used in the final demonstration.

Facts - Diameter barrel: 𝐷 = 254 𝑚𝑚

- Radius outside barrel: 𝑅 = 127 𝑚𝑚 = 0,127 𝑚

- Radius inside barrel: 𝑟 = 123 𝑚𝑚 = 0,123 𝑚

- Tape feed speed: vt = 1 𝑚/𝑚𝑖𝑛

- Distance of one revolution: 𝑥 = 120 𝑐𝑚

- Time for one revolution: 𝑡 =Distance of one revolution

𝑇𝑎𝑝𝑒 𝑓𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑=

120 𝑐𝑚

100 𝑐𝑚/𝑚𝑖𝑛= 1,2 𝑚𝑖𝑛 = 72 𝑠𝑒𝑐

- Average motor revolutions: 𝑛 = 𝑇𝑎𝑝𝑒 𝑓𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑

𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛=

100 𝑐𝑚/𝑚𝑖𝑛

120 𝑐𝑚= 0,83 𝑟𝑝𝑚

- Angular velocity: 𝜔 = 2𝜋

72= 0,087 𝑟𝑎𝑑/𝑠

- Density barrel: 𝜌 = 946 𝑘𝑔/𝑚³ (Polypropylene)

- Volume barrel: 𝑉 = 0,00183 𝑚³

- Mass barrel: 𝑚 = 1,73 𝑘𝑔

Assumptions

● 𝐹𝑡 = 50𝑁

● Acceleration time: 𝑎 = 0,1 𝑚/𝑠2

Table 7: Magnitudes and units

Name Magnitude Unit

Tape force Ft N

Motor torque Mm Nm

Reduction ratio i

Angular velocity ω rad/s

Efficiency η

Inside radius r1 m

Outside radius r2 m



Density ρ Kg/m³

Power P W

Inertia I Kgm²

Angular acceleration α rad/s²

Reduction

An asynchronous motor has a fixed synchronized rotation speed related to the poles inside the motor. An 8

pole motor has the lowest speed so this is the motor which fits the most for this application. However, a

motor with 8 poles is rare to find and will not be recommended. In the setup we will use a frequency

converter in order to be able to control the speed of the motor by changing the frequency.

The motor is preferred not to be used under 15Hz because it can get too hot and be damaged. The most

preferable frequencies of a motor are 40-60Hz. Therefore the standard set point of the motor must be inside

this frequency window. The reduction needed for the motor will be calculated with the condition of keeping

the set point inside the window.

Until this point it is not certain which motor will be used for the application so the reduction calculation will

be conducted for all the different speeds available.

Table 8: Motor poles

poles pole-pairs

n sync (rpm)

2 1 3000

4 2 1500

6 3 1000

8 4 750

Assumptions: The motor needs to go faster when the tape is applied on the poles and needs to go slower

when the tape is applied on the middle of the barrel to keep the tape feed speed constant. As an assumption

of the average rotation speed we will use 1 rpm for the calculations of the reduction. The variations in speed

will be realized with the use of the frequency converter in the control system.

- Reduction at 750 rpm (motor with 8 poles):

f = 50 Hz: 𝑛 = 750 𝑟𝑝𝑚

f = 60 Hz: 𝑛 = 750 𝑟𝑝𝑚 ∗60 𝐻𝑧

50 𝐻𝑧= 750 𝑟𝑝𝑚 ∗ 1,2 = 900 𝑟𝑝𝑚

f = 40 Hz: 𝑛 = 750 𝑟𝑝𝑚 ∗40 𝐻𝑧

50 𝐻𝑧= 750 𝑟𝑝𝑚 ∗ 0,8 = 600 𝑟𝑝𝑚

Reduction: 𝑖 = 1

600= 0,00167




f = 50 Hz: 𝑛 = 1000 𝑟𝑝𝑚

f = 60 Hz: 𝑛 = 1000 𝑟𝑝𝑚 ∗60 𝐻𝑧

50 𝐻𝑧= 1000 𝑟𝑝𝑚 ∗ 1,2 = 1200 𝑟𝑝𝑚

f = 40 Hz: 𝑛 = 1000 𝑟𝑝𝑚 ∗40 𝐻𝑧

50 𝐻𝑧= 1000 𝑟𝑝𝑚 ∗ 0,8 = 800 𝑟𝑝𝑚

Reduction: 𝑖 = 1

800= 0,00125


f = 50 Hz: 𝑛 = 1500 𝑟𝑝𝑚

f = 60 Hz: 𝑛 = 1500 𝑟𝑝𝑚 ∗60 𝐻𝑧

50 𝐻𝑧= 1500 𝑟𝑝𝑚 ∗ 1,2 = 1800 𝑟𝑝𝑚

f = 40 Hz: 𝑛 = 1500 𝑟𝑝𝑚 ∗40 𝐻𝑧

50 𝐻𝑧= 1500 𝑟𝑝𝑚 ∗ 0,8 = 1200 𝑟𝑝𝑚

Reduction: 𝑖 = 1

1200= 0,00083


f = 50 Hz: 𝑛 = 3000 𝑟𝑝𝑚

f = 60 Hz: 𝑛 = 3000 𝑟𝑝𝑚 ∗60 𝐻𝑧

50 𝐻𝑧= 3000 𝑟𝑝𝑚 ∗ 1,2 = 3600 𝑟𝑝𝑚

f = 40 Hz: 𝑛 = 3000 𝑟𝑝𝑚 ∗40 𝐻𝑧

50 𝐻𝑧= 3000 𝑟𝑝𝑚 ∗ 0,8 = 2400 𝑟𝑝𝑚

Reduction: 𝑖 = 1

2400= 0,0004167



Power

Torque: 𝑇 = 𝑙𝑜𝑎𝑑 + 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 ∗ 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛

Load: TL = 𝐹 ∗ 𝑟 = 50𝑁 ∗ 0,127𝑚 = 6,35 𝑁𝑚

Inertia: 𝐼 = 1

2 ∗ 𝑚 ∗ (𝑟2² + 𝑟1²) = 0,027 𝑘𝑔𝑚²

Angular acceleration: 𝛼 = 𝜔

𝑡 =

2𝜋∗4

60

0,1 =

0,42

0,1 = 4,2 𝑟𝑎𝑑/𝑠²

Torque: 𝑀𝑚 = 𝐼𝑣𝑎𝑡 ∗ 𝛼 + 𝐹𝑡 ∗ 𝑟 = 0,027 𝑘𝑔𝑚² ∗ 4,2 𝑟𝑎𝑑/𝑠² + 50𝑁 ∗ 0,127𝑚 = 6,46 𝑁𝑚

Power: 𝑃 = 𝑀 ∗ 𝜔 = 6,46 ∗ 2 𝜋 ∗ 4

60= 2,7 𝑊𝑎𝑡𝑡

Conclusion

The motor which will be chosen needs to be discussed with the supplier of the motor in order to know the

exact specifications of the motor.

Based on this calculations the most suitable solution will be to choose an available motor with an angular

velocity as low as possible. In that case the reduction will be the lowest too. The calculated motor power

needed to power this setup is 2,7 Watt. This is a very low required power so the motor can be low on power.

Almost every industrial motor is strong enough to power this application.

Figure 39: Schematic rod forces



2. Calculations encoder

In this setup we will use an encoder to detect in which position the barrel is in the time. With this information

the control system can adapt on the speed of the robot and the rotation of the barrel.

This calculation is based on the assumption of an encoder which gives 360 pulses in one rotation. The

calculations can be easily adapted if the specifications of the encoder would change. Because the rotation of

the pressure vessel and the tape feed is not constant throughout one rotation, this calculation will be based

on the maximum values. The maximum rotation speed and a tape feed of 90° on the pressure vessel will be

used in this calculation.

360 𝑝𝑢𝑙𝑠𝑒𝑠/𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛

1° = 1

360𝐶 (𝐶 = 𝑜𝑢𝑡𝑙𝑖𝑛𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑎𝑟𝑟𝑒𝑙)

𝐷 = 10 𝑖𝑛𝑐ℎ 𝐷 = 10 ∗ 2,54 𝐷 = 25,4 𝑐𝑚 𝐷 = 254 𝑚𝑚 (𝐷 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑏𝑎𝑟𝑟𝑒𝑙)

𝐶 = 𝜋 ∗ 𝐷 = 804 𝑚𝑚

𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑠𝑡𝑒𝑝: 𝐶

𝐷𝑒𝑔𝑟𝑒𝑒𝑠=

804 𝑚𝑚

360 ° = 2,2 𝑚𝑚

𝑇𝑎𝑝𝑒 𝑓𝑒𝑒𝑑: 1𝑚

𝑚𝑖𝑛

1000 𝑚𝑚

60 𝑠 16,6 𝑚𝑚/𝑠

𝑆𝑡𝑒𝑝𝑠 𝑠𝑒𝑐𝑜𝑛𝑑⁄ :

𝑚𝑚𝑠𝐶

𝐷𝑒𝑔𝑟𝑒𝑒𝑠

= 16,6 𝑚𝑚/𝑠

2,2 𝑚𝑚= 7,57 𝑠𝑡𝑒𝑝𝑠/𝑠𝑒𝑐𝑜𝑛𝑑

Conclusion

If the encoder will have 360 pulses in one rotation the accuracy of the encoder will be sufficient for the

application. If the encoder would give more pulses the accuracy will be increased and this will be for the

better for the application. If the encoder would give less than 360 pulses there will need to be a recalculation

in order to see if the encoder is accurate enough for the application.



3. Rotating system setup

In this chapter the setup of the rotating system will be described. It will handle all the electrical parts in the

setup and the connections between them. This will be divided into two pieces. At first the current setup at

the beginning of the project is described. This will contain of the electric parts, their relations and their

settings. In the second part, the new setup will be described by the electric parts, their relations and

communication, their settings and at the testing of the frequency converter.

3.1 Current setup

In the current setup, every electric part made by previous groups will be discussed. This setup will be the

start of this project.

3.1.1 Electric scheme rotator This chapter is the information of the electronic components is given and how they are connected.

Figure 40: Electric scheme current situation

To connect the frequency converter to the robot-controller 4 pins from the robot controller are needed. Two

pins are needed to determine the rotation way of the motor. If voltage is put on pin 3 of the frequency

converter, the motor will turn left. If voltage is put on pin 4 of the frequency converter, the motor will turn

right. If there is voltage on both pin 3 and 4 the motor will not turn. We need 24V from the robot controller

for the emergency stop which is connected to pin 6 of the frequency converter. The emergency stop is a

normally closed connection, so if the emergency stop is pushed the frequency converter get a signal on pin 6

and the motor stops turning. Pin 10 of the frequency converter is connected to the Ground of the robot



controller. If there is a voltage applied on the input pin Vin the frequency converter will change the output

speed according to the voltage on the pin.

3.1.2 Frequency controller settings

The frequency controller has multiple parameters who needs to be set to the right value. The setting can be

set on the display of the frequency controller.

Figure 41: Frequency converter screen lay-out

The parameters are set by pushing the DSP/FUN button and move to the right parameter with the up and

down buttons. If you navigate to the right parameter then press the DATA/END button and set the

parameter to the right value by using the up and down buttons. If the parameter is set on the right value,

press the DATA/END button again and the parameter is set.

The parameters on the frequency controller that needs to be set to work together with the robot controller

are the parameters F06, F07, F10, F11 and F19.

- The parameter F06 has to be set on 60Hz to determine the maximum frequency.

- The parameter F07 has to be set on 20Hz to determine the minimum frequency.

- The parameter F10 has to be set on 1 to do the controls through the external clamps.

- The parameter F11 has to be set on 0 to set the speed by the pushbuttons on the frequency

controller.

- The parameter F19 has to be set on 3 to activate the emergency stop on clamp 6.

This are the settings that needs to be changed for the barrel rotator. For the settings of the other parameters

check the user guide of the frequency controller delivered by the producer.



3.2 New setup

3.2.1 Electric scheme

The electric scheme (Figure 3) below shows the connections between the robot controller, the frequency

converter, the motor and the encoder.

Figure 42: Electric scheme new situation



3.2.2 Frequency controller settings

To program the frequency controller in the right way for the application there are some functions which are

needed to be set. For this application we want the maximum frequency of the converter at 60Hz and the

minimum at 20Hz-30Hz (depending on the required minimum rotation speed). Next it needs to be able to

control the on/off mode of the frequency converter by a signal from the robot controller. There is also a need

for an emergency stop. The robot controller has a function for an emergency stop and will stop the frequency

controller too if the emergency button is pressed from the robot. At last the frequency itself needs to be

controlled from the robot controller. To make this happen there are some functions to be set good.

To be able to control the start/stop of the frequency converter, the following functions are needed to be

altered:

F03 needs to be set on 1


To be able to operate the emergency button from the robot for the frequency converter too, the following

functions are needed to be altered:


To be able to control the frequency by using the robot controller, the following functions are needed to be

altered:


In the table below (Table 1) there are all the functions described with the factory setting and with the

adapted settings for this application.

Table 9: Frequency converter functions

Description Function Setting Factory Setting Explanation

Acceleration time 1 0,1 5.0

Deceleration time 2 0,1 5.0

Operation mode

3 1 0 0 = Forward/Stop , Reverse/Stop 1 = Run/Stop , Forward/Reverse (TM3)

Motor direction 4 0 0

0 = Forward 1 = Reverse

V/F Pattern 5 1 1

Frequency upper limit 6 60 Hz 50/60 Hz

Frequency lower limit 7 15 Hz 0.0 Hz

SP1 Frequency 8 10 Hz 10 Hz Frequency bij SP1 input

JOG frequency 9 6 Hz 6 Hz



Start/Stop Control 10 1 0

0 = Keypad 1 = Terminal TM2

Frequency Control

11 1 0

0 = Keypad 1 = Terminal (0-10 V) 2 = Terminal (4-20 mA)

Carrier frequency control 12 5 5

Torque compensation 13 0,00% 0,00%

Stop Method 14 0 0

0 = controlled deceleration stop 1 = Free run to stop

DC braking time 15 0,5 0,5s

DC braking injection freq 16 1,5 Hz 1,5 Hz

DC braking level 17 8,00% 8,00%

Protection base on motor rated current 18 100,00% 100%

Multifunction input SP1

19 3 2 1 = Jog 2 = SP1

3 = Emergency Stop 4 = External Base Block

5 = Reset 6 = SP2*4

Multifunction input RESET

20 5 5

Multifunction output terminal

21 2 3

1 = Operating 2 = Frequency reached 3 = Fault

Reverse Lock-Out 22 0 0

Momentary power loss 23 0 0

Auto restart 24 0 0

Factory setting 25 010

SP2 frequency 26 20 20

SP3 frequency 27 30 30

Direct start 28 1 1

Software version 29 / /

Fault log 30 / /

3.2.3 Communication

Table 2 on the next page shows the relation between the frequency output of the frequency converter, the

motor speed according to this frequency and the required input voltage on the Vin pin of the frequency

converter from the robot controller.

Table 3 shows the test results from two tests regarding the input voltages necessary and the according

voltage gaps between each frequency step. These tests made clear that the voltage gap between each

frequency step are not equal. This could give problems with the programming, but the deviations are not too

big.



Table 10: Relation frequency, motor speed and input voltage

Frequency [Hz] Motor speed [rpm] Input Voltage 1 [V]

20 0,52 3,32

21 0,54 3,48

22 0,57 3,65

23 0,59 3,83

24 0,62 3,97

25 0,65 4,15

26 0,67 4,3

27 0,70 4,46

28 0,72 4,64

29 0,75 4,8

30 0,78 4,95

31 0,80 5,1

32 0,83 5,25

33 0,85 5,45

34 0,88 5,6

35 0,90 5,75

36 0,93 5,9

37 0,96 6,05

38 0,98 6,25

39 1,01 6,4

40 1,03 6,55

41 1,06 6,7

42 1,09 6,85

43 1,11 7,03

44 1,14 7,2

45 1,16 7,35

46 1,19 7,5

47 1,21 7,7

48 1,24 7,85

49 1,27 8

50 1,29 8,15



51 1,32 8,35

52 1,34 8,5

53 1,37 8,65

54 1,40 8,8

55 1,42 8,95

56 1,45 9,12

57 1,47 9,3

58 1,50 9,45

59 1,52 9,6

60 1,55 9,77

Table 11: Test results of the input voltage for each frequency step

Input Voltage 1 [V] Voltage differences 1 [V] Input Voltage 2 [V] Voltage differences 2 [V]

3,32 3,33

3,48 0,16 3,49 0,16

3,65 0,17 3,65 0,16

3,83 0,18 3,8 0,15

3,97 0,14 3,97 0,17

4,15 0,18 4,15 0,18

4,3 0,15 4,3 0,15

4,46 0,16 4,45 0,15

4,64 0,18 4,62 0,17

4,8 0,16 4,8 0,18

4,95 0,15 4,94 0,14

5,1 0,15 5,1 0,16

5,25 0,15 5,26 0,16

5,45 0,2 5,42 0,16

5,6 0,15 5,6 0,18

5,75 0,15 5,74 0,14

5,9 0,15 5,91 0,17

6,05 0,15 6,08 0,17

6,25 0,2 6,23 0,15



6,4 0,15 6,4 0,17

6,55 0,15 6,56 0,16

6,7 0,15 6,72 0,16

6,85 0,15 6,87 0,15

7,03 0,18 7,03 0,16

7,2 0,17 7,2 0,17

7,35 0,15 7,35 0,15

7,5 0,15 7,53 0,18

7,7 0,2 7,68 0,15

7,85 0,15 7,85 0,17

8 0,15 8 0,15

8,15 0,15 8,16 0,16

8,35 0,2 8,33 0,17

8,5 0,15 8,48 0,15

8,65 0,15 8,64 0,16

8,8 0,15 8,8 0,16

8,95 0,15 8,96 0,16

9,12 0,17 9,13 0,17

9,3 0,18 9,29 0,16

9,45 0,15 9,45 0,16

9,6 0,15 9,6 0,15

9,77 0,17 9,79 0,19



Figure 43: Driveshaft drawing

Appendix IV: Final manipulator specifications

1. Driveshaft

The driveshaft which will transfer the rotation of the motor onto the vessel is custom made for this

application. The drawing below shows the dimensions of the driveshaft. The diameter of the driveshaft which

will go inside the reduction of the motor is 25mm.



2. Bearings To support the shaft which will transfer the rotation of the engine onto the barrel, two tapped based pillow

blocks ‘UCPA 205’ bearings will be used. The picture below shows the bearings and the driveshaft used in this

application.

3. Motor

The motor used for the rotation of the barrel is a 0,09 kW, M-series (M56b4) from Carpanelli, three phase

motor provided by ‘MAK aandrijvingen’. The motor has a rotation speed of 1360 rpm. The picture below

shows the specifications of the motor.

Figure 44: Final bearings

Figure 45: Final motor



4. Reduction

Because the application needs to rotate at really low speeds around 1 rpm, a great reduction is necessary to

slow the engine down to the required speeds. To achieve this reduction, a combination of two reductions is

used. The first one is the gear reduction ‘HW 030’ from ‘Motovario’. This gear reduction reduces the rotation

speed by 10,83. The second reduction, which is mounted directly onto the first one, is the worm reduction

‘NMRV-P 063’ from ‘Motovario’. This worm reduction reduces the rotation by 100. This reduction will be

attached to the driveshaft with a diameter of 25mm. Because the two reductions are combined, the final

reduction is 1083 (10,83 * 100 = 1083). The efficiency of this combined reduction is around 45% (gears: ± 90%

worm: ±50%).

The picture below shows the motor attached to the two reductions.

Figure 46: Final motor with reduction



5. Encoder

In order to control the system properly, there is a need to know at which speed or at which position the

barrel is. Therefor an encoder on the driveshaft is used. The encoder used is an incremental shaft encoder

type RI 32 from ‘Hengstler’. This encoder has a pulse count of 360 pulses. According to the calculations in the

annex this is sufficient for this application.

6. Frequency converter

To control the motor, the frequency converter ‘E2-201-H1F’ from ’T-Verter’ will be used. The reach of the

frequency converter is from 1Hz till 200Hz. The frequency converter can be set manually or by means of a

variable input voltage on a input on the frequency controller. For this application we will use a variable input

voltage from the robot controller to alter the speed of the motor through the frequency converter. The

maximum rotation speed of the motor is 60Hz. Because the maximum rotation speed of the motor is 60Hz

the maximum frequency of the frequency controller has to be set to 60Hz.



Appendix V: EOAT Redesign

FACULTY FOR TECHNOLOGY, INNOVATI ON & SOC IETY

REPORT REDESIGN END OF ARM TOOL

Name: Dirk van Trigt

Course: SMR2 - Project

Period: April 2015 – July 2015

Tutor: Ir. T. Brilleman



Content 1 Introduction ................................................................................................................................................ 63

2 Theory ......................................................................................................................................................... 64

3 Design and development ............................................................................................................................ 65

3.1 Prelude ............................................................................................................................................... 65

3.2 First redesign ...................................................................................................................................... 66

3.3 Final design......................................................................................................................................... 68

3.4 Development ...................................................................................................................................... 69

4 Result .......................................................................................................................................................... 70

5 Appendices .................................................................................................... Error! Bookmark not defined.



1 Introduction

The main goal of this project is to wrap polypropylene glass fibre reinforced filament around a pressure

vessel. One of the most important tools to establish this is the End Of Arm Tool (EOAT). In this report explains

how the EOAT is designed and developed.



2 Theory

The End Of Arm Tool consists of a milled block of aluminium that encloses a heating element. This heating

element generates heat and conducts this heat through the aluminium block to the filament that is pulled

through a narrow opening in the aluminium block. While the filament is pulled through the polypropylene

reaches a viscose state which is necessary to make the filament stick to the pressure vessel or the previous

layer of filament.

The aluminium block could directly be mounted to the robot arm, but for the following reasons this is not the

most efficient way of using the heating element:

- Heat loss, therefore loss of energy that should be used to heat up the filament;

- Heats up the robot, which causes a shutdown when it reaches a certain temperature;

- Difficult to mount on the robot

- No ability to service the heating element after use because it will be too hot to handle.



3 Design and development

3.1 Prelude The previous project group developed a EOAT consisting 30 cm aluminum tubing, plaster wall plating

wrapped in aluminum foil, aluminum plating on which the heating elements were mounted. Between the

aluminum tubing and the plaster wall plating was glass wool to insulate that little bit extra (see Figure 47).

They developed this for a filament with different dimensions, so a new EOAT had to be created.

Figure 47:The EOAT design of the previous project group



3.2 First redesign

The aluminum casing for the heating element was already manufactured by the client. The aluminum casing

was poor workmanship and a new one had to be sawed, milled and

drilled (See Figure 48)

Main reasons for redoing aluminum casing were:

- multiple holes in the lid left unused;

- the slot for the filament was milled to deep and wide (This would cause heat loss because there

would be no contact between the lid and filament).

The first design of the EOAT is made of 1mm thick steel. It was cut and

bend in the beta factory, result is shown in Figure 49. There were several

problems with the first design of the EOAT. Bendig didn´t go as planned,

the top did not close off, the opening to feed the filament through or

out was not big enough, there was not enough room for the insulating

materials and mounting to the robot arm was not thought of before

bending the material.

Figure 48: Aluminium Casing heating element

Figure 49: First redesign



The first design of the EOAT as shown in Figure 11, started smoking after 45 minutes of testing (see Figure

12Error! Reference source not found.). The contact heat was too long too high for the used materials and

the insulation started to smoulder .After doing some research it turned out that most insulating materials

used to insulate houses were only capable of resisting that much heat for 60 minutes. The next day the outer

casing was starting to oxidize, so a proper redesign was necessary.

Figure 50: First design before test

Figure 51: First design after test



3.3 Final design

In the redesign the following requirements needed to be implemented:

6. Outer casing made of a material that would not oxidize;

7. Casing consists of a top part and bottom part;

8. The top part must be mounted to the robot arm so only the bottom part needs to be unbolted when

servicing the EOAT;

9. At least 2 cm of spacing between the outer casing and the aluminum block all around;

10. Finding an insulating material that is capable of resisting the temperature at all times.

The outer casing shown in figures 5,6, and 7 is the end result of the redesign.

Figure 53: Redesign outer casing in parts

Figure 54: Redesign outer casing assembled Figure 52: Redesign outer casing assembled with heating element and robot mount



The material choice for the outer casing was not as difficult. Steel and stainless steel both oxidize when they

are submitted to high temperatures. Except for AISI310 which is a stainless steel made for these temperature

changes. This material was unavailable in time span for the development of the EOAT. The next best choice

was either titanium or a type of aluminum. Since titanium is too expensive and also unavailable in the time

span, the choice for aluminum was the best option. The choice was AlMg3, this was available and good for

welding and braking.

To inquire more information about insulating materials several hardware stores were visited and asked the

question if they had a material that could withstand the heat generated by the heating element. All of them

confirmed the previous found out facts that all insulating materials for the construction of houses would not

withstand the heat for longer than 60 minutes before losing their insulating capabilities and degrading. Their

advice was to visit a hearth salesman or builder.

At the hearth salesman good advice was acquired which resulted into a gift of a board of Super Isol. The

hearth salesman used it to stick it between the wooden walls and the stone tiles in a fireplace. Stone tiles do

not insulate at all which means the board of Super Isol prevents the wood from getting hot or burning. The

specifications of this material are in the appendices.

3.4 Development

The aluminum casing was cut by a laser at a company in Haarlem. The cut sheet metal was bend by a press

brake and the sides were welded with the GTA process. All the 2D drawings for the new design are attached

in the appendices.

The Super Isol board was sawed and filed in shape with tools to shape wood. The preformed Super Isol

boards were glued into the aluminum casing with Bison Kit especially made for fire places. The specifications

of this glue are in the appendices.



4 Result

The end result is shown in the pictures below.

Figure 55: Final EOAT-1,2



Figure 56: Final EOAT-3



Appendix VI: Test report End of Arm Tool and Filament

FACULTY FOR TECHNOLO GY, INNOVATION & SOC IETY

TEST REPORT END OF ARM TOOL AND FILAMENT

Name: Dirk van Trigt

Rick den Ouden






Content 1 Introduction ............................................................................................................................................... 74

2 Theory ............................................................................................................................................................. 74

2 Test ............................................................................................................................................................. 75

2.1 Test goals ........................................................................................................................................... 75

2.2 Test setup .......................................................................................................................................... 75

3 Results ........................................................................................................................................................ 77

4 Conclusion ...................................................................................................... Error! Bookmark not defined.



1. Introduction The main goal of this project is to wrap polypropylene glass fiber reinforced filament around a pressure

vessel. The End Of Arm Tool (EOAT), the tool at the end of the robot that is used to perform tasks, is an

important part in the system and therefor will be developed and tested thoroughly.

2. Theory The End Of Arm Tool consists of a milled block of aluminum that encloses a heating element. This heating

element generates heat and conducts this heat through the aluminum block to the tape that is pulled

through a narrow opening in the aluminum block. While the tape is pulled through, the polypropylene

reaches a viscose state which is necessary to make the filament stick to the pressure vessel or the

previous layer of filament. This complicated process is yet unknown and research is therefore needed.



3. Test

3.1 Test goals

First the end of arm tool needs to be tested to get the following information:

1. Heating capacity of the heating element;

2. Isolation of the heating element to ensure that not too much heat is lost;

Second the filament has to be tested for:

3. Verification of specifications, predominately:

a. The maximum heating temperature before degrading;

b. The temperature range of viscose state;

c. the self-lubricating temperature;

4. Determine the right temperature of the filament so it:

a. Sticks to the plastic pressure vessel

b. Sticks to the previous layer of filament

Third the filament in combination with the end of arm tool:

5. Determine the right throughput speed of the filament through the end of arm tool;

6. Determine the necessary force to pull the filament through the end of arm tool;

3.2 Test setup

The end of arm tool will be connected to a thermistor and an Arduino, as shown in Figure 57, which is able

to give feedback about the temperature which the heating element has reached. With a thermal camera,

the heat loss at of the EOAT will be registered and compared to determine if there is not too much heat

loss in the process.

Figure 57: Test setup

The maximum heating temperature of the filament will be verified by heating the filament until the

temperature (given in the material datasheet) is reached and measured with a thermal camera or infra-red

heat sensor.

The temperature range of viscose state will be verified by heating the filament till the temperature (given in

the material datasheet) is reached and measured with a thermal camera or infra-red heat sensor. After

comparing the maximum heating temperature and the temperature which is needed for a viscose state, a

temperature range will be determined in which the filament needs to be when it’s being wrapped.



Somewhere in this viscose state temperature range the filament becomes self-lubricating. The only way to

find out this temperature is to feed multiple strings of filament through the end of arm tool at different

temperatures and checking the residue left in the end of arm tool.

The determination of the right temperature at which the filament will stick the PP-pressure vessel or

another piece of tape can be achieved by heating the filament somewhere in the viscose state temperature

range, measure this temperature and apply it to one of these conducts.

When the right temperature is measured to let the filament stick to the plastic pressure vessel or the

previous layer of filament we can determine how long the filament needs to be heated before it reaches

this temperature. According to this time a throughput speed can be determined.

The necessary torque to pull the tape through the heating element at determined speed can be measured

with a spring scale or hanging a weight onto the filament.



4. Results

First test:

During the first test the insulation of the casing couldn’t withstand the heat. Therefor the glass wool

touching the aluminum block was switched with plaster board, see Figure 58.

Figure 58: Scorched glass wool

With the insulation the test could be continued. Using a thermal camera, we concluded that the

thermocouple wasn’t accurate. Although the thermocouple wasn’t accurate we could determine that the

estimated temperature before degradation is 250 °C. This result was measured with a contact free

thermometer. By using this tool we gained different measurement results when measuring in different

spots on the aluminum casing. Most constant results were gained measuring in the opening of the

aluminum casing where the heating slides in.

Second test

The thermocouple has been replaced with a thermistor normally used in a 3D printer. With the thermistor

wired through Arduino it works and can measure the high temperatures more accurate and keep the

heating element at a more constant temperature.



Third test:

Setting the temperature in the Arduino to 200 °C, 250 °C and 300 °C and pulling the tape through the

EOAT with a rate of 1 pressure vessel revolution per minute the results deviated greatly.

At 200 °C the tape doesn’t reach its self-lubricating temperature and leaves glass fiber behind in the

EOAT, see Figure 59.

Figure 59: Glass fibre sticking to the EOAT

With the Arduino set to 300 °C the tape reaches its self-lubricating temperature (250°C) and melts the

outer layer of the pressure vessel and stick to it.



5. Conclusion 1. Heating capacity of the heating element;

The heating capacity of the heating element is good. Conclusion is the set temperature of 250 degrees on the thermocouple which caused degrading. The thermocouple was not accurate. Reason for this was probably that the thermocouple was not calibrated right. 250 degrees Celsius was not the maximum heating capacity of the element so we can conclude that it is enough for this application.

2. Isolation of the heating element to ensure that not too much heat is lost;

We measured on different occasions around 300 degrees Celsius on the opening of the aluminum casing. After an hour of testing the materials we used to isolate the heat in de EOAT started to smoulder, dry out and losing their capacity to isolate the heat. After 60 minutes of testing the steel casing that surrounds the isolation material and the aluminum block became too hot to touch, which wasn’t the case at the start of the test.

3. Verification of specifications, predominately:

a. The maximum heating temperature before degrading;

The given temperature from the thermocouple was 250 degrees Celsius.

b. The temperature range of viscose state;

The given temperature from the thermocouple ranges between 200 and 249 degrees Celsius.

c. the self-lubricating temperature;

The given temperature by the Arduino through the thermistor was 300 degrees Celsius.

4. Determine the right temperature of the filament so it:

a. Sticks to the plastic pressure vessel


b. Sticks to the previous layer of filament


5. Determine the right throughput speed of the filament through the end of arm tool;

1 meter per minute.

6. Determine the necessary force to pull the filament through the end of arm tool;

About 10 Newton.



Appendix VII: Sensor research

FACULTY FOR TECHNOLO GY, INNOVATION & SOC IETY

TEMPERATURE SENSOR REPORT

Name: Marc Cornet






Content 1 Abstract .......................................................................................................... Error! Bookmark not defined.

2 Introduction ............................................................................................................................................... 82

3 Temperature sensors ................................................................................................................................. 83

3.1 Contact temperature sensors ............................................................................................................ 83

3.1.1 Thermistors ............................................................................................................................... 83

3.1.2 Resistence thermometer ........................................................................................................... 83

3.1.3 Thermocouple ........................................................................................................................... 83

3.2 Non-contact temperature sensor ...................................................................................................... 84

3.3 Choosing a sensor .............................................................................................................................. 84

4 Choosing the IR-sensor .............................................................................................................................. 85

4.1 Melexis sensor ................................................................................................................................... 86

5 Initial Tests ................................................................................................................................................. 86

5.1 Experiment 1 ..................................................................................................................................... 86

5.2 Experiment 2 ..................................................................................................................................... 89

5.3 Conclusion ......................................................................................................................................... 90

6 Using the sensor......................................................................................................................................... 90

6.1 Testing under expected working conditions ..................................................................................... 90

6.2 Increasing the distance ...................................................................................................................... 92

6.3 Decreasing the distance. ................................................................................................................... 93

6.4 Conclusion ......................................................................................................................................... 94

7 Conclusion .................................................................................................................................................. 95



2 Introduction

In this project polypropylene glass fibre enforced tape is fed through a heating element. After heating it needs to be applied and wrapped around a plastic pressure vessel. If this process is completed with the correct temperature the wrap of polypropylene glass fibre enforced tape around the pressure vessel will make the plastic pressure vessel as strong as a steel one. To know if the tape is heated to the right temperature and applied with the right temperature to the pressure vessel there is need for a temperature sensor. Measuring if the tape leaves the heating element at the correct temperature is also invaluable for automatic temperature correction. This correction can be achieved for example by adjusting the power input of the heating element or the speed of the tape through the heating element. In order to measure the temperature of the tape after it leaves the heating element a sensor needs to be chosen. In the following chapter a brief rundown of the available temperature sensors is given. It is decided that for our needs an IR-sensor will be a good choice. The details about this choice can be found in chapter 4. After the initial choice was made the sensor however took more time to arrive than hoped and turned out to be quite dead on arrival. This resulted in using an IR-sensor from Melexis. A few initial tests, detailed in chapter 5, gave a good idea about how the sensor worked with the default settings and software. The performance of the sensor was also compared to our reference sensor, the Testo 835-T2. The results of these tests are written in chapter 6. The conclusion of this report is the last chapter.



3 Temperature sensors

A temperature sensor is a part that converts temperature to a procesable electrical output. These sensors

can be divided in two separate groups: Contact and Non-contact.

3.1 Contact temperature sensors

Contact temperature sensors are using physical contact to determine temperature by conduction. These

kinds of sensors are able to measure temperature from solids, liquids or gases in a wide range of

temperature depending on the selected sensor. Example of a contact temperature sensor is a lollipop

thermometer.

3.1.1 Thermistors

Thermistors are thermally sensitive resistors whose prime function is to exhibit a large, predictable and

precise change in electrical resistance when subjected to a corresponding change in body temperature.

Negative Temperature Coefficient (NTC) thermistors exhibit a decrease in electrical resistance when

subjected to an increase in body temperature and positive Temperature Coefficient (PTC) thermistors

exhibit an increase in electrical resistance when subjected to an increase in body temperature.

3.1.2 Resistence thermometer

Resistance thermometers, also called resistance temperature detectors (RTDs), are sensors used to

measure temperature by correlating the resistance of the RTD element with temperature. Most RTD

elements consist of a length of fine coiled wire wrapped around a ceramic or glass core. The element is

usually quite fragile, so it is often placed inside a sheathed probe to protect it. The RTD element is made

from a pure material, typically platinum, nickel or copper. The material has a predictable change in

resistance as the temperature changes and it is this predictable change that is used to determine

temperature. They are slowly replacing the use of thermocouples in many industrial applications below

600 °C, due to higher accuracy and repeatability.

3.1.3 Thermocouple

A Thermocouple is a temperature-measuring device consisting of two dissimilar conductors that contact

each other at one or more spots. Here a temperature difference is experienced by the different

conductors (or semiconductors). It produces a voltage when the temperature of one of the spots differs

from the reference temperature at other parts of the circuit. Thermocouples are a widely used type of

temperature sensor for measurement and control, and can also convert a temperature gradient into

electricity. Commercial thermocouples are inexpensive, interchangeable, are supplied with standard

connectors, and can measure a wide range of temperatures. In contrast to most other methods of

temperature measurement, thermocouples are self-powered and require no external form of excitation.

The main limitation of thermocouples is accuracy; system errors of less than one degree Celsius (°C) can

be difficult to achieve.



3.2 Non-contact temperature sensor

An infrared (IR) temperature sensor, a noncontact temperature sensor, measures infrared radiation of a

surface. If the object gets hotter, the frequency of the radiated infrared will increase. This frequency will

be converted to an electrical output.

3.3 Choosing a sensor

To make sure the sensor is always giving an accurate measuring a contact free sensor is necessary.

Otherwise molten polypropylene could clot onto the sensor and prevent an accurate measuring in the

future. To prevent a temperature drop from going unnoticed a quick response from the sensor is

required. For these reasons there is a need for a IR-temperature sensor with:

Accuracy of measured temperature with tolerances of 5 degree Celsius

Respond time of around a 1 second.

No contact with the composite tape

Additionally a sensor that is able to operate on 5 volts is preferred in order to connect it to an Arduino.



4 IR-sensor choice

To measure the temperature a contact-less sensor would be needed. There are two options that were considered. One option would be to buy an industrial IR sensor, but a quick look at the Farnell website showed that these would cost several hundreds of euros.

So given the support school gives for using the Arduino it seems reasonable to explore those options. The first option considered was a sensor from Texas Instruments. Texas Instruments is known to provide their IC’s for free in the form of samples. However the sensor was not usable in sample form due to the package it comes in: a ball grid package which would offer some hurdles to successfully use this sensor as soldering this would be a real challenge.

Another mentioned sensor on several Arduino sites was from Melexis, the MLX90614. When trying to find a vendor for this sensor it turned out that Adafruit (a popular American supplier of Arduino accessories, complete with software libraries to use it, with European shops carrying some of their catalog in their online shops) offered both these two sensors, so the search stopped here. The TMP007 would even come with an easy to use breakout board with all the supporting electronics, a few resistors and capacitors, already soldered on it as well.

Table 12: IR-sensor choices

Melexis MLX90614 TI TMP007

Package: Tin can with radial leads Ball grid, but Adafruit offers breakout board with male headers

Sampling / averaging Number of samples per reading; % rise / drop between samples adjustable, single sample quicker than TMP007

Sample speed of 4 per second.

1/2/4/8/16 samples per reading with arduino

Connectivity I2C; But not compatible with arduino’s wire.h library, but adafruit support

I2C

Accuracy ±1°C from -40 °C to 120 °C ±2°C typ, from -15°C to 80°C

Voltage 3Ven5V 5V

Outside temperature influence on sensor stability

Severity unknown; More expensive

versions with compensation

techniques

Severity unknown

Price Adafruit: $15.95, but with more

expensive versions available via

other vendors

Adafruit: $12.50

Because the extra functionality of the Melexis sensor was hard to value just from reading about it in the datasheet the easier I2C communication with the TMP007 seemed a very big plus, this is why the TMP007 was ordered.



4.1 Melexis sensor

The sensor arrived but never worked. Because it took more time than expected for the sensor to arrive

another vendor was found. This vendor carried the Melexis sensor, but with a breakout board. In

hindsight this would have been the preferred choice since the shipping made up for the price difference

and the break-out board also made up the difference in easy connectivity.

5 Initial Tests

To get a rough idea of how well the sensor works two experiments are conducted. The first experiment

will try to give insight in the measured temperature when the object temperature is known with two

different distances. The second experiment will try to determine what the sensor will report when using a

realistic distance from the sensor with a smaller sized object that does not cover the whole viewing area

of the sensor. The sensor transmits both its own temperature and the temperature from the object it

measures over I2C. The default Adafruit program with 4 samples per reading, resulting in 1 measurement

each second, was used.

5.1 Experiment 1

To determine the difference between a known temperature and the measured temperature ice-water

and boiling water is used. Especially the ice water is great for its temperature stability over time. Using

two rings and a thin plastic container, the ice-water and the boiling water is placed on two different

distances from the sensor. This can be seen in the picture below. Ring 1 gives a distance of about 1.5 cm

to the sensor. Ring two adds another centimetre distance between the plastic container with the water.



Figure 60: Placing ring to hold the container in place above the sensor

Figure 61: A plastic container with ice water above the sensor



The first 7 measurements of the results can be found below, the first column of each measurement

contains the sensors own temperature and the second column contains the temperature the sensor

reports the object to be:

Table 13: First measurements

Ice water, ring 1 Ice water, ring 2 Hot water, ring 1 Hot water, ring 2

# °C sen. °C obj. °C sen. °C obj. °C sen. °C obj. °C sen. °C obj.

1 24.15 22.35 21.67 23.75 23.09 28.51 24.55 22.81

2 24.15 17.09 21.67 15.15 23.13 72.25 24.53 23.15

3 24.15 6.17 21.71 8.55 23.13 81.19 24.55 34.97

4 24.13 5.33 21.71 8.51 23.13 81.67 24.55 65.67

5 24.13 5.19 21.71 8.27 23.13 81.97 24.55 72.39

6 24.13 4.89 21.71 7.83 23.19 82.29 24.55 72.41

7 24.11 4.59 21.73 7.61 23.19 82.49 24.55 72.59

It takes a while for the sensor to stabilize, this is shown in the tables below where the first column is the

measurement number and the second and third column are the sensor own temperature and the object

temperature:

Table 14: Measurements where sensor reading stabilize

Ice water, ring 1 Ice water, ring 2 Hot water, ring 1 Hot water, ring 2

# °C Sens °C obj. # °C Sens °C obj. # °C Sens °C obj. # °C Sens °C obj.

29 23.57 2.77 47 21.11 4.97 35 24.15 83.67 68 25.37 75.15

30 23.57 2.69 48 21.11 4.89 36 24.21 83.71 69 25.37 75.19

31 23.53 2.59 49 21.07 4.81 37 24.25 83.73 70 25.39 75.23

32 23.53 2.55 50 21.07 4.79 38 24.27 83.75 71 25.41 75.25

33 23.53 2.43 51 21.05 4.79 39 24.31 83.77 72 25.41 75.25

34 23.47 2.35 52 21.01 4.89 40 24.35 83.79 73 25.43 75.31

The table shows that further the distance from the sensor offers less accurate the measurements and

longer time for a stable readout. The sensor noise however seems to fall within a few tenths of a degree

Celsius.



5.2 Experiment 2

From the previous test it has been shown that the distance of the sensor has a big influence on the

temperature measured. In the previous test the object also covered the whole cone the sensor measures.

To test a more practical viewing area a piece of electrical tape is placed in boiling water and hold above

the IR-sensor using the smallest ring to simulate a realistic distance. The results are shown in the next

table.

Figure 62: Holding a realistically sized object above the sensor

Table 15: Measurements of a smaller object held in boiling water before measuring

Hot tape

# °C Sens °C obj.

1 23.59 37.19

2 23.59 37.03

3 23.59 36.97

4 23.61 36.63

5 23.61 35.51

6 23.61 35.15

Given that the tape was as hot as the container that measured almost 84 degrees Celsius, the influence of

the viewing area is clearly visible.



5.3 Conclusion

Given the influence of the distance to the object measured it is advised to place the sensor closer to the

tape rather than further. From the second experiment the object size also showed to influence the

measured temperature due to the viewing angle of the sensor. In order to be able to still use the

measured data the background behind the tape may have to be kept at the same temperature. The best

solution is probably to place the sensor quite close to the heating tool, while blocking the view of the

sensor behind the tape. This closer placement should allow for this extra extruding material to block the

view of the sensor from the background without interfering with the winding process. While the sensor

readout might not be correct in an absolute sense, it is expected to be usable when the readouts are

calibrated with the real world results.

6. Using the sensor

From the initial experiments detailed in the previous chapter a basic idea about the sensor performance

was formed. It was suggested that the sensor needed a rather small distance to measure correctly. In this

chapter the sensor performance will be examined more closely. This will be done by comparing the

measurements of our Melexis MLX90614 IR-sensor with the Testo 835-T2.

6.1 Testing under expected working conditions

From the previous chapter we already knew that the sensor distance from the tape should be kept rather

small. In the lab we placed a piece of wood next to the sensor, when holding the tape at this distance

there would be 11 mm between tape and sensor.

The tape was heated using a soldering iron. Determining if the tape was hot enough was done by visual

inspection This is when the plastic begins to melt and the tape becomes slightly wider, but before the

plastic drips away from the glass fibre.

The hot tape was held in front of the Melexis sensor and in front of that setup the IR handgun was held.

With a mobile phone both the reference sensor and the Melexis sensor output were captured in a movie.

A picture of the test setup can be found below, and the results of the tests are found in the graphs below.

The time on the horizontal axis is the time taken from the video.



Figure 63: Comparing the Melexis sensor with the Testo IR sensor

While the sensors don’t always match very closely, often the difference is only a few degrees. The sudden

drops and raises in temperature are likely caused by accidentally moving the tape or the handheld sensor

while measuring. The results are displayed in the graphs below.

Figure 64: The first test at 11mm distance comparing the MLX90614 vs de Testo

35

40

45

50

55

60

6 7 8 9 10 11 12 13 14

Tem

per

atu

re

Time

Testo vs Melexis - 11mm distance - 1

Testo (*C) Melexis (*C)



Figure 65: The second test to confirm our results

6.2 Increasing the distance

Another short test was done to prove the suspicion that a longer distance would make the sensor very

inaccurate, as expected from the first experiment in chapter 4. This proved to be true. Using a larger

distance resulted in a measured temperature of about 32 degrees, while the other sensor still measured

the correct temperature.

Figure 66: Increasing the distance makes the sensor unusable

30

35

40

45

50

55

60

65

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Tem

per

atu

re (

°C)

Time (s)

Testo vs Melexis - 11mm distance - 2




6.3 Decreasing the distance

Using another piece of wood we also tested what happened if the tape is held 5mm away from the

sensor. This time the tape was (over) heated a bit more as well on purpose, to see what the influence

would be. The result showed that the higher the temperature the bigger the difference between the

Testo and the Melexis MLX90614 IR-sensor. At the same temperatures as in the previous tests the

results were almost identical. The result can be found in the graph below.

Figure 67: Comparing the MLX90614 with the Testo at higher temperatures and a shorter distance

35

45

55

65

75

85

95

105

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Tem

per

atu

re (

°C)

Time (s)

Testo vs Melexis - 5mm distance




6.4 Conclusion

The MLX90614 IR-sensor was tested under a variety of conditions with the tape that is to be used for

the winding process. The first test with a distance of about 11mm between the tape and the sensor

resulted in a very usable reading from the Melexis sensor. It showed only a few degrees difference

between the Melexis and Testo sensor that is used as a reference. When the distance was decreased the

difference was still only a few degrees at the lower temperatures as tested when the distance was 11mm.

However at higher temperatures (> 65 °C) the MLX90614 reported a much higher temperature than the

Testo. This difference however will not hinder the usability of the results.

When the distance is increased, the measurement become unusable, this was to be expected given the

earlier tests in chapter 4. In that chapter it is also briefly explained how the cone shaped viewing area of

the sensor will only see the hot tape as a part of the whole object.

Since both the tape and the Testo sensor where held in place manually during these tests, creating inaccuracies in the reported distance and the measured temperature, it was deemed unnecessary to explore the optimum distance any further at this point. However when placing this sensor in the final product this has to be taken into account.

The takeaway is that both the 5mm and 11mm distance gave usable results, any differences between the Testo and the Melexis can be compensated with calibration in the final product.



7. Conclusion

In order to determine the temperature of the tape leaving the heating element a list of sensor types was made. From all the different temperature sensors available an IR-sensor was chosen due to the Non-contact nature of this type of sensor. This will prevent the tape from influencing the sensor performance over time if tape residue will stick to the sensor.

Because industrial sensors were to expensive it was decided to try to use a cheaper sensor in combination with an Arduino. The choice was between the TI TMP007 and the Melexis MLX90614. Both very comparable for our needs, but the TI sensor from the initial vendor came in a easier to use form. This sensor however did not work properly and the other choice, the MLX90614, was ordered after another vendor was found that also sold this sensor on a so called break-out board.

This sensor was tested as written in chapter 5 and 6 and turned out to be usable in this project. When compared to our reference sensor, the Testo 835-T2, the differences at lower temperatures (< 60 °C) and smaller distances (5 mm, 11 mm) were only a few degrees celcius. At larger distances the sensor is unusable and at higher temperatures (> 65 °C) the MLX90614 will report a temperature that is too high.

With calibration the MLX90614 is a good sensor for this project, meeting the requirements and being much cheaper than the professional alternatives.



Appendix VIII: Program code Below is shown a PFD that show the contents of the main program that controls the robot.

Before start

Set all values to standard value

Move to position Wrap_start + 200m in Z-direction

Main program

Set x : To cos(tetaY)*r+dx

Set y = 0

Set z = sin(tetaY)*r

Set rx = 0

Set ry = 0,5*pi-tetaY

Set rz = tetaZ

Jmove to Wrap_start + (x, y, z, rx, ry, rz)

If Wrap_back == False

If tetaY < 0,5*pi, x>-l, tetaY < pi-Angle_start_Y, else If

Reverse of everything left Recalculate tetaY

Recalculate tetaZ

teta = 0,5pi

tetaZ = Angle_Z

dx=x–l/Stap_recht

Telrecht ++

Recalculate tetaY

Recalculate tetaZ

Wrap_back = True

Return Main



Appendix IX: Technical drawings









Appendix X: Datasheets Spreadsheet path coordinates

Z (rotatieas vat)

Y (hoogte)

X (horizontale verplaatsing)

Theta [rad]

Graden [o]

Pulsen [-]

Pulsen afgerond [-]

Z (rotatieas vat)

delta Z

som delta Z

-24,45 0 5,918 0,000 0,00 0,00 0 0 0 0

-24,384 -1,276 5,907 0,213 12,19 33,86 34 0,66 0,66 0,66

-24,187 -2,538 5,872 0,408 23,38 64,93 65 2,63 1,97 2,63

-23,861 -3,772 5,815 0,575 32,97 91,58 92 5,89 3,26 5,89

-23,411 -4,964 5,735 0,713 40,88 113,55 114 10,39 4,5 10,39

-22,839 -6,102 5,634 0,825 47,28 131,34 131 16,11 5,72 16,11

-22,153 -7,174 5,513 0,916 52,46 145,72 146 22,97 6,86 22,97

-21,362 -8,167 5,374 0,989 56,65 157,37 157 30,88 7,91 30,88

-20,473 -9,07 5,217 1,049 60,09 166,92 167 39,77 8,89 39,77

-19,495 -9,874 5,045 1,098 62,94 174,82 175 49,55 9,78 49,55

-18,44 -10,57 4,859 1,140 65,31 181,42 181 60,1 10,55 60,1

-17,319 -11,15 4,661 1,175 67,31 186,98 187 71,31 11,21 71,31

-16,144 -11,608 4,454 1,204 69,01 191,69 192 83,06 11,75 83,06

-14,929 -11,938 4,24 1,230 70,45 195,68 196 95,21 12,15 95,21

-13,689 -12,138 4,02 1,251 71,68 199,10 199 107,61 12,4 107,61

-13,1 -12,186 3,917 1,260 72,18 200,50 201 113,5 5,89 113,5

-12,375 -12,289 3,579 1,287 73,76 204,90 205 120,75 7,25 120,75

-11,65 -12,383 3,241 1,315 75,33 209,26 209 128 7,25 128

-10,925 -12,467 3,093 1,328 76,07 211,30 211 135,25 7,25 135,25

-10,2 -12,54 2,565 1,369 78,44 217,89 218 142,5 7,25 142,5

-9,475 -12,605 2,227 1,396 79,98 222,17 222 149,75 7,25 149,75

-8,75 -12,66 1,888 1,423 81,52 226,44 226 157 7,25 157

-8,025 -12,706 1,55 1,449 83,04 230,68 231 164,25 7,25 164,25

-7,3 -12,742 1,212 1,476 84,57 234,91 235 171,5 7,25 171,5

-6,575 -12,77 0,874 1,502 86,08 239,12 239 178,75 7,25 178,75



-5,85 -12,789 0,536 1,529 87,60 243,33 243 186 7,25 186

-5,124 -12,798 0,198 1,555 89,11 247,54 248 193,26 7,26 193,26

-4,399 -12,799 -0,14 1,582 90,63 251,74 252 200,51 7,25 200,51

-3,674 -12,791 -0,478 1,608 92,14 255,94 256 207,76 7,25 207,76

-2,949 -12,774 -0,816 1,635 93,66 260,15 260 215,01 7,25 215,01

-2,224 -12,748 -1,154 1,661 95,17 264,37 264 222,26 7,25 222,26

-1,499 -12,713 -1,493 1,688 96,70 268,61 269 229,51 7,25 229,51

-0,774 -12,668 -1,831 1,714 98,22 272,85 273 236,76 7,25 236,76

-0,049 -12,615 -2,169 1,741 99,76 277,10 277 244,01 7,25 244,01

0,676 -12,552 -2,507 1,768 101,30 281,38 281 251,26 7,25 251,26

1,401 -12,48 -2,845 1,795 102,84 285,67 286 258,51 7,25 258,51

2,216 -12,398 -3,183 1,822 104,40 290,00 290 266,66 8,15 266,66

2,851 -12,306 -3,521 1,849 105,97 294,35 294 273,01 6,35 273,01

3,576 -12,204 -3,859 1,877 107,55 298,74 299 280,26 7,25 280,26

4,896 -12,057 -4,128 1,901 108,90 302,50 302 293,46 13,2 293,46

6,072 -11,808 -4,335 1,923 110,16 306,00 306 305,22 11,76 305,22

7,219 -11,44 -4,537 1,948 111,63 310,09 310 316,69 11,47 316,69

8,323 -10,958 -4,732 1,978 113,36 314,88 315 327,73 11,04 327,73

9,375 -10,366 -4,918 2,014 115,38 320,50 321 338,25 10,52 338,25

10,363 -9,671 -5,092 2,055 117,77 327,13 327 348,13 9,88 348,13

11,278 -8,878 -5,253 2,105 120,61 335,03 335 357,28 9,15 357,28

12,11 -7,997 -5,4 2,165 124,03 344,53 345 365,6 8,32 365,6

12,851 -7,036 -5,531 2,237 128,17 356,03 356 373,01 7,41 373,01

13,494 -6,005 -5,644 2,325 133,22 370,07 370 379,44 6,43 379,44

14,033 -4,913 -5,739 2,434 139,43 387,32 387 384,83 5,39 384,83

14,461 -3,773 -5,814 2,566 147,02 408,38 408 389,11 4,28 389,11

14,775 -2,594 -5,87 2,725 156,16 433,77 434 392,25 3,14 392,25

14,971 -1,39 -5,904 2,910 166,75 463,20 463 394,21 1,96 394,21

15,048 -0,172 -5,918 3,113 178,34 495,38 495 394,98 0,77 394,98



14,971 3,354 192,19 533,86 534 394,21 0,77 395,75

14,775 3,550 203,38 564,93 565 392,25 1,96 397,71

14,461 3,717 212,97 591,58 592 389,11 3,14 400,85

14,033 3,855 220,88 613,55 614 384,83 4,28 405,13

13,494 3,967 227,28 631,34 631 379,44 5,39 410,52

12,851 4,057 232,46 645,72 646 373,01 6,43 416,95

12,11 4,130 236,65 657,37 657 365,6 7,41 424,36

11,278 4,190 240,09 666,92 667 357,28 8,32 432,68

10,363 4,240 242,94 674,82 675 348,13 9,15 441,83

9,375 4,282 245,31 681,42 681 338,25 9,88 451,71

8,323 4,316 247,31 686,98 687 327,73 10,52 462,23

7,219 4,346 249,01 691,69 692 316,69 11,04 473,27

6,072 4,371 250,45 695,68 696 305,22 11,47 484,74

4,896 4,393 251,68 699,10 699 293,46 11,76 496,5

3,576 4,429 253,76 704,90 705 280,26 13,2 509,7

2,851 4,456 255,33 709,26 709 273,01 7,25 516,95

2,216 4,469 256,07 711,30 711 266,66 6,35 523,3

1,401 4,511 258,44 717,89 718 258,51 8,15 531,45

0,676 4,538 259,98 722,17 722 251,26 7,25 538,7

-0,049 4,564 261,52 726,44 726 244,01 7,25 545,95

-0,774 4,591 263,04 730,68 731 236,76 7,25 553,2

-1,499 4,618 264,57 734,91 735 229,51 7,25 560,45

-2,224 4,644 266,08 739,12 739 222,26 7,25 567,7

-2,949 4,671 267,60 743,33 743 215,01 7,25 574,95

-3,674 4,697 269,11 747,54 748 207,76 7,25 582,2

-4,399 4,723 270,63 751,74 752 200,51 7,25 589,45

-5,124 4,750 272,14 755,94 756 193,26 7,25 596,7

-5,85 4,776 273,66 760,15 760 186 7,26 603,96

-6,575 4,803 275,17 764,37 764 178,75 7,25 611,21



-7,3 4,829 276,70 768,61 769 171,5 7,25 618,46

-8,025 4,856 278,22 772,85 773 164,25 7,25 625,71

-8,75 4,883 279,76 777,10 777 157 7,25 632,96

-9,475 4,910 281,30 781,38 781 149,75 7,25 640,21

-10,2 4,937 282,84 785,67 786 142,5 7,25 647,46

-10,925 4,964 284,40 790,00 790 135,25 7,25 654,71

-11,65 4,991 285,97 794,35 794 128 7,25 661,96

-12,375 5,019 287,55 798,74 799 120,75 7,25 669,21

-13,689 5,042 288,90 802,50 802 107,61 13,14 682,35

-14,929 5,064 290,16 806,00 806 95,21 12,4 694,75

-16,144 5,090 291,63 810,09 810 83,06 12,15 706,9

-17,319 5,120 293,36 814,88 815 71,31 11,75 718,65

-18,44 5,155 295,38 820,50 821 60,1 11,21 729,86

-19,495 5,197 297,77 827,13 827 49,55 10,55 740,41

-20,473 5,247 300,61 835,03 835 39,77 9,78 750,19

-21,362 5,306 304,03 844,53 845 30,88 8,89 759,08

-22,153 5,379 308,17 856,03 856 22,97 7,91 766,99

-22,839 5,467 313,22 870,07 870 16,11 6,86 773,85

-23,411 5,575 319,43 887,32 887 10,39 5,72 779,57

-23,861 5,708 327,02 908,38 908 5,89 4,5 784,07

-24,187 5,867 336,16 933,77 934 2,63 3,26 787,33

-24,384 6,052 346,75 963,20 963 0,66 1,97 789,3

-24,45 6,254 358,34 995,38 995 0 0,66 789,96





































Appendix XI: Gantt Chart planning

Documents

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