CASE STUDY // SYS-ROBOTIC-ARMOperational Prototype
5-DOF Precision Mechatronic Robotic Arm
Inverse-kinematics controlled robotic manipulator for precise spatial positioning and pick-and-place tasks.
#MECHATRONICS#ROBOTICS#EMBEDDED
DEVELOPMENT YEAR2024
MY ROLECAD Mechanical Design, Kinematics Solver & Actuator Driver Firmware
TEAM STRUCTUREMechatronics Project
VALIDATION STATUSOperational Prototype
THE ENGINEERING PROBLEM
Low-cost educational robotic arms often suffer from mechanical backlash, structural deflection, and jerky open-loop stepping.
THE ARCHITECTURAL SOLUTION
Engineered a 5-DOF structural robotic arm utilizing high-torque servo actuators, custom 3D-printed load-bearing joints, and smooth trajectory interpolation.
SYSTEM OVERVIEW & ARCHITECTURE
Combines Autodesk Fusion 360 parametric joint modeling with a Python/C++ inverse kinematics solver to convert cartesian XYZ coordinates into joint angle motor outputs.
SYSTEM ARCHITECTURE BLOCK DIAGRAM FLOW:
User / Path Planner (Python IK Solver) → Serial JSON Stream → ESP32 Servo Controller → Multi-Channel PWM Drivers → Servos.
KEY TECHNICAL HIGHLIGHTS:
- ✓Parametric Fusion 360 structural design optimized for weight distribution and motor torque limits.
- ✓Real-time inverse kinematics solver using numerical Jacobian transformation.
HARDWARE & ELECTRONICS
- High-Torque Metal Gear Servos
- PETG Custom 3D Printed Chassis
- ESP32 Microcontroller
- PCA9685 PWM Driver
SOFTWARE & FIRMWARE
- Python
- C++
- Autodesk Fusion 360
- Arduino Framework
ALGORITHMS & CONTROL LOOPS
- Analytic & Numerical Inverse Kinematics (IK)
- S-Curve Servo Speed Interpolation
COMMUNICATION PROTOCOLS
- I2C
- UART Serial Command Protocol
ENGINEERING CHALLENGES OVERCOME
- Eliminating mechanical backlash at joint bearings without adding bulk weight.
MY DIRECT CONTRIBUTIONS
- Modeled complete mechanical arm in Fusion 360, calculated torque load requirements, and programmed joint motion profiles.
VALIDATED SYSTEM RESULTS
- ▸Demonstrated repeatable pick-and-place operation with millimeter spatial accuracy.
KEY ENGINEERING LESSONS LEARNED
- ▸Incorporate mechanical counter-weights near base joints to reduce motor torque stress on long linkage arms.