WeldBot

It is a small-scale welding robot that embodies the automation of a welding robotic arm for the maintenance processes of the mantles of crushers in mining

Project Images

Mathematical Model

Equation of state

Sketch

Sketch

Arm and Rotating Table

Simulation

Simulation

Stress Simulation

Arm Parts

Arm Parts

Truncated Cone

Truncated Cone

Pulley System

Pulley System

Z axis Rods

Z axis Rods

Welding Arm Assembly

Welding Arm Assembly

TEAM

José Alexis del Aguila Ramos

Mechanical Arm bot Welding
Alexis contributed to the mechanical design of the robotic arm, structural analysis of resistances, direct kinematic calculation, and the final construction of the Arm.

See contribution
Alcides Rios Quispe

Electonic Development
Alcides contributed to the design, manufacturing, and programming of electronics to make automation possible.

See contribution
Joaquín de los Rios Rosado

Mechanical Rotating Platform
Joaquín developed the rotating platform actuated by a Nema 17 stepper motor. The manufacturing was executed on the CNC. 

See contribution

Team Planned
Coordination to define the concept
from march 27 to march 31

For this activity, we decided to develop a scale machine for welding the mantles of crushers in mining processes. Here, the initial sketch and the coordination meeting (Google Meet) from Cusco, Arequipa, and Huancayo are shown. Additionally, we created a WhatsApp group to quickly share information.

Schematic Circuit of Control

Raspberri Pico - Shield CNC

Team Planned
Fabrication of parts and selection of electronic components 
from april 01 to april 03

We selected electronic components: Nema 17, Raspberry Pi Pico, SSD1306 Display, A4988, FR4 Board, Dupont Cables, among others.
We also selected mechanical components such as: Threaded rods, Linear and simple bearings, Flexible couplings, Bolts, Timing belts, and Timing pulleys.

Team Planned
Assambly of WeldBot
from april 04 to april 06

In this activity, we integrated the electronic and mechanical parts, taking 20 hours of assembly.

Team Planned
Production Electronic and Programming of WeldBot
from april 04 to april 06

The design was done in EasyEDA, the electronic manufacturing on the small CNC, and finally, the programming in MicroPython.

Schematic Circuit of Control

Raspberri Pico - Shield CNC

Distribution Device Electronics

Raspberry Pi and SSD1306

Team Planned
WeldBot Operational Tests
from april 07 to april 09

The operational test was conducted by first testing the manual control of the X, Y, Z axes, and then the automatic control of the slope based on 3 input variables: Minor Diameter, Major Diameter, and Height.

Raspberry Pico and Oled

Shield CNC

Problems in the Project

Barrier Mitigation Learn
1 Conceptual Phase: The variation in inclination for each layer, as well as the state of the art, which consisted of Cartesian arms that varied according to the layer to be repaired. We can manage this barrier through the end effector, which has a servomotor that allows us to assign a different angle through the programming interface. The learning obtained was about the mining area which we are covering, especially about the variation that exists in the mantles of the crushers.
2 Materialization Phase: We encountered the barrier of the weather, which caused shrinkage issues since we worked with ABS material. We were able to mitigate this barrier through closed ventilation systems and setting a higher bed temperature. The learning obtained was about the sensitivity of this material (ABS) to a sudden change in temperature.
3 Assembly Phase: We had to adapt the materials because when designing, we relied on materials on order. However, they arrived with different dimensions, Another significant factor was the lack of precision tools, as we only had general-purpose tools In order to mitigate this barrier, the digital manufacturing tools that we have in the laboratory were key, manufacturing adaptations for assembly, as well as the tools that generate couplings for suggestion. The learning obtained from this barrier was the best choice for component orders since a failure in material deliveries can play against us over time.

Improve Project

  • IWS (Intelligent Welding System) to add a digital twin and analyze wear patterns of crusher mantles. An IoT system can be integrated to remotely monitor parameters. Artificial Intelligence for quick diagnosis of some wear patterns.
  • Include in the control the maintenance of the mantle nut, as it also wears out and must be refilled by welding.

IWS

Project Documentation

Download Files Design WeldBot

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