In industrial applications, particularly in assembly and material handling processes that require human-machine collaboration, balanced manipulators play a critical role. The primary objective of these systems is to compensate for the gravitational force of a load, imparting a sensation of “weightlessness” to the operator, thereby enhancing both positioning and ergonomics simultaneously. In industrial production, operator support systems are typically either pneumatic balanced manipulators or fully automated robots. These systems possess disadvantages such as the requirement for compressed air, energy inefficiency, and maintenance costs. This study aims to present a method of dimensioning to select the necessary electrical actuator for the balanced manipulators. The proposed methodology follows a sequential optimization approach: first, structural synthesis derives the link lengths and kinematic architecture directly from the required workspace volume; second, kinematic analysis validates the reachable boundaries against the task requirements; and third, dynamic analysis utilizes a static equilibrium model to determine the optimal counterweight mass, thereby minimizing the load on the actuator. Finally, a motion simulation identifies the peak force requirements. The results validate the method by successfully dimensioning a system capable of handling a 1000 N payload using an 8 kN electrical linear actuator.

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Dimensioning Human Operated Balanced Manipulators for Material (Un)Loading Operations

  • İlkim Zahide Bozdemir,
  • Ünal Dana,
  • Erkin Gezgin,
  • Levent Çetin

摘要

In industrial applications, particularly in assembly and material handling processes that require human-machine collaboration, balanced manipulators play a critical role. The primary objective of these systems is to compensate for the gravitational force of a load, imparting a sensation of “weightlessness” to the operator, thereby enhancing both positioning and ergonomics simultaneously. In industrial production, operator support systems are typically either pneumatic balanced manipulators or fully automated robots. These systems possess disadvantages such as the requirement for compressed air, energy inefficiency, and maintenance costs. This study aims to present a method of dimensioning to select the necessary electrical actuator for the balanced manipulators. The proposed methodology follows a sequential optimization approach: first, structural synthesis derives the link lengths and kinematic architecture directly from the required workspace volume; second, kinematic analysis validates the reachable boundaries against the task requirements; and third, dynamic analysis utilizes a static equilibrium model to determine the optimal counterweight mass, thereby minimizing the load on the actuator. Finally, a motion simulation identifies the peak force requirements. The results validate the method by successfully dimensioning a system capable of handling a 1000 N payload using an 8 kN electrical linear actuator.