Section 1:Introduction:
In the dynamic field of robotics and automation, the demand for components that offer precision and durability is paramount. At Zigoal, we faced a challenging yet exhilarating project to develop advanced springs for robotic arms used in assembly lines. This case study details our engineering journey, focusing on the specifications and solutions provided.
Section 2: Background:
2.1: Client Profile:
Automaton Robotics, a leading player in industrial automation, specializing in robotic arms for assembly lines.
2.2: Challenge:
Automaton Robotics sought to enhance the efficiency and precision of their robotic arms. The existing torsion spring in the articulation joints were not meeting the performance requirements, leading to reduced accuracy and increased wear.
2.3: Objective:
To design torsion spring that could offer precise torque, withstand continuous use, and improve the overall functionality of the robotic arms.
Section 3: Engineering Process:
3.1: Material Selection:
We chose AISI 302 stainless steel for its excellent corrosion resistance and high tensile strength, ensuring durability and consistent performance in the variable industrial environment.
3.2: Model Specifications:
The custom torsion spring were developed under the model ZG-RA300. Key specifications included:
- Wire Diameter:2mm for optimal balance between flexibility and strength.
- Outer Diameter: 15mm, designed to fit within the compact joint spaces of the robotic arms.
- Free Length:45mm, providing the necessary range of motion.
3.3: Performance Requirements:
- Torque:The custom torsion spring was required to deliver a precise torque of 5 Nm with a tolerance of ±0.5 Nm.
- Durability:Designed to withstand over 500,000 cycles without significant degradation in performance.
3.4: Spring Design Details:
- Pitch:Engineered with a tight pitch to minimize space and maximize energy storage.
- Ends:custom torsion spring with straight torsion arms tailored for robotic joint applications.
- Tolerance:Maintained at ±2% to ensure consistent performance across all units.
- Load and Pressure:Each custom torsion spring was calibrated to sustain a continuous load without deformation.
3.5: Surface Treatment Requirements:
- Passivation Treatment:Applied to enhance corrosion resistance and longevity.
- Dry Lubrication Coating:Added to reduce friction in the moving parts, crucial for the smooth operation of robotic arms.
Section 4: Manufacturing and Testing:
4.1: Precision Manufacturing:
Employing CNC coiling technology, we achieved high precision in manufacturing, meeting the exact specifications of the robotic arms.
4.2: Rigorous Testing:
- Torque Testing:Confirmed the precise torque delivery of the custom torsion spring.
- Fatigue Testing:Simulated the operational conditions to test for endurance and performance consistency.
Section 5: Results and Impact:
5.1: Enhanced Robotic Arm Efficiency:增
The integration of ZG-RA300 springs led to a notable improvement in the precision and longevity of the robotic arms. The accuracy of assembly tasks was enhanced, increasing overall line efficiency.
5.2: Quantitative Outcomes:
Automaton Robotics observed a 20% increase in assembly line speed and a 30% reduction in maintenance due to the improved durability of the custom torsion spring.
5.3: Client Feedback:
The client reported significant improvements in operational efficiency and a reduction in downtime, highly valuing the advancements brought by the new custom torsion spring design.
Section 6: Conclusion:
6.1: Contributions to Robotics and Automation:
This project exemplifies our ability to innovate and provide solutions that meet the evolving demands of the robotics industry. Our dedication to precision engineering and quality manufacturing has led to a significant breakthrough in the functionality of industrial robotic arms.
6.2: Future Directions:
Based on this success, we are exploring further enhancements in material science and surface treatments to advance the capabilities of custom springs in more demanding robotic applications.
In this case study, I aimed to present a detailed narrative of the engineering challenges and solutions in developing torsion spring for robotic applications, emphasizing the technical specifications, design process, and the tangible outcomes of our work at Zigoal.
