Building a robot might seem like a daunting task, but with the right approach, it can be surprisingly manageable. As industries increasingly adopt robotics to cut costs, maintain quality, and free up human time for more creative tasks, companies now have two main options: buy pre-made robots or build their own. While purchasing ready-made robots offers convenience, creating your own can be a cost-effective alternative if you have limited engineering resources.
In this article, I’ll walk you through the steps we followed to build a seven-axis robotic arm, share some insights we gained along the way, and highlight ways to streamline the process with fewer components. Let’s dive in!
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### **1. Brainstorm: What Do You Need to Achieve Your Goal?**
The brainstorming phase is crucial for defining the scope of your robotic project. During this stage, you’ll need to determine the type of robot you’re building, its required tasks, and performance benchmarks. For instance, when designing a robotic arm, key decisions include the number of axes of motion and the types of components that best suit your needs. Will you opt for PNP or NPN output sensors? Incremental or absolute encoders? Parallel or right-angle gearheads?
Each component comes with its own set of advantages and challenges. For example, servo motors and stepper motors both get the job done, but factors like speed, noise, and heat generation might sway your decision. Companies like Oriental Motor have been refining closed-loop stepper motor technology to address these concerns, making it a viable alternative for applications that don’t require extremely high speeds. Researching how similar robots are constructed can also provide valuable insights. Don’t forget to factor in labor costs to ensure your budget stays in check.
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### **2. Design: Ensuring Everything Fits and Sizing Motors Properly**
Once the brainstorming phase is complete, it’s time to move into the design stage. Here, you’ll focus on laying out all the necessary components in your robot and verifying their specifications and dimensions to ensure compatibility. Creating 3D CAD models is a great way to visualize the design and identify any potential conflicts early on. Working with manufacturers who offer a wide range of components, including CAD files, can significantly reduce your workload.
Another critical aspect is ensuring that the selected motors are up to the task. Many manufacturers provide motor-sizing tools to help you find the perfect match for your application. At Oriental Motor, their engineers are always ready to assist with sizing analysis, ensuring you maximize the potential of their products.
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### **3. Bill of Materials: Making Sure Nothing Is Missing**
After finalizing your component list, it’s time to create a detailed Bill of Materials (BOM). Recording part numbers, quantities, prices, and lead times meticulously can prevent costly delays caused by ordering errors. Additionally, keep a record of this information to avoid duplicating efforts down the line.
Double-check every detail—part numbers, specifications, dimensions, and lead times—to avoid mistakes. Don’t overlook seemingly minor items like mounting brackets or pre-made cables from manufacturers—they can save you significant time. Consider ordering slightly more than you need to account for potential accidents during assembly.
**Pro Tip:** Look for built-in features that can replace additional components. For example, Oriental Motor’s AZ Series closed-loop stepper motors come equipped with a multi-rotation mechanical absolute encoder, eliminating the need for separate sensors, cables, or batteries.
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### **4. Build: Assembling One Axis at a Time**
With all the components and materials in hand, it’s time to start building. Starting with the bottom axis is generally the easiest approach, especially for multi-axis arms. The bottom axis typically handles the heaviest loads and manages moment forces, so securing it to a stable base first simplifies the modular assembly process.
Some designers prefer to build and test individual axes separately before completing the final assembly. Either way, testing as you go ensures that each component performs as expected and reduces the risk of major setbacks later on.
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### **5. Wiring: Organizing Cables for Optimal Performance**
Cable management is just as important as the physical assembly itself. Poorly organized cables can cause twisting, disconnections, or even connector breakage, limiting the robot’s range of motion. Simple practices like using cable ties or installing cable tracks for linear actuators can make a big difference. Flexible cables, designed for repeated bending, are particularly useful in applications where the cable moves with the mechanism.
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### **6. Programming: Expect It to Take Longer Than You Think**
Programming the robot’s software can be time-consuming, especially if you’re unfamiliar with the platform. Manufacturers often use proprietary software for their motors, and learning curves can vary depending on the complexity of the system. Allow ample time for programming, and consider using universal software or products from the same manufacturer to simplify the process. Simplifying the motion data storage within the drivers can also reduce the complexity of PLC/HMI programming.
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### **7. Testing: Anticipating Every Scenario**
Testing is the most exciting part of the process! Once everything is built, assembled, wired, and programmed, thorough testing is essential to simulate real-world scenarios. Put yourself in your customer’s shoes and anticipate potential issues. For instance, what happens if two buttons are pressed simultaneously?
Our seven-axis robotic arm, designed for pick-and-place operations, was a rewarding project. Check out the video below to see it in action:
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We’re currently developing a new version with “mini†drivers, so stay tuned for updates at upcoming trade shows!
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### **Conclusion**
Building a robot doesn’t have to be overwhelming. By following a structured approach, leveraging the right components, and paying attention to details like cable management and testing, you can create a functional and efficient machine. Oriental Motor’s AZ Series stepper motors, with their built-in absolute encoders and advanced features, streamlined much of our process.
If you’re interested in learning more about how Oriental Motor’s solutions can help, feel free to reach out for a technical seminar or product demo. Robotics might be complex, but with the right tools and mindset, it’s entirely achievable.
Thanks for reading, and enjoy the videos!
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