Design, Analysis and Development of a 6-DOF Robotic Manipulator for Manufacturing Automation

Verma, Vivek; Sahu, Chandra Shekhar

doi:10.26706/ijaefea.13.2.20260403

Abstract

Industrial automation increasingly demands flexible and cost-effective robotic systems capable of performing complex manufacturing operations. This research presents the design, modelling, kinematic analysis, and simulation of a robotic manipulator developed for industrial automation applications. A complete three-dimensional CAD model of the manipulator was created and analyzed to achieve the desired workspace, payload capacity, and motion characteristics. Forward and inverse kinematic models were formulated using the Denavit–Hartenberg (D-H) convention to establish the relationship between joint parameters and end-effector position and orientation. The developed robotic system was simulated using RoboDK and validated through virtual motion studies to evaluate trajectory generation, reachability, and operational performance. Structural assessment of critical components was performed using Finite Element Analysis (FEA) to ensure adequate stiffness and load-carrying capability under working conditions. The simulation results demonstrated smooth joint coordination, accurate end-effector positioning, and reliable path execution within the designated workspace. The structural analysis confirmed that the designed manipulator operates within permissible stress and deformation limits, ensuring safe and stable operation. The proposed methodology integrates CAD modelling, kinematic analysis, simulation, and structural validation into a unified framework for robotic manipulator development. The outcomes of this work demonstrate the feasibility of developing an efficient and economical robotic system suitable for material handling, welding, inspection, and other industrial automation tasks. The study provides a foundation for future integration of advanced control algorithms, vision systems, and real-time industrial applications.

Keywords

Robotic Manipulator Industrial Robot Forward Kinematics Inverse Kinematics RoboDK CAD Modelling Finite Element Analysis Industrial Automation

References

J. Denavit and R. S. Hartenberg, “A kinematic notation for lower-pair mechanisms based on matrices,” Journal of Applied Mechanics, vol. 22, no. 2, pp. 215–221, 1955.
J. J. Craig, Introduction to Robotics: Mechanics and Control, 4th ed. Upper Saddle River, NJ, USA: Pearson, 2018.
B. Siciliano, L. Sciavicco, L. Villani, and G. Oriolo, Robotics: Modelling, Planning and Control. London, U.K.: Springer, 2010.
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L. W. Tsai, Robot Analysis: The Mechanics of Serial and Parallel Manipulators. New York, NY, USA: John Wiley & Sons, 1999.
J. Angeles, Fundamentals of Robotic Mechanical Systems: Theory, Methods, and Algorithms, 4th ed. Cham, Switzerland: Springer, 2014.
V. Shah and D. Dhananjay, “CAD modelling and kinematic analysis of a six-axis robotic manipulator using simulation techniques,” International Journal of Engineering Research and Technology, vol. 6, no. 5, pp. 1–6, 2017.
A. Kumar, R. Singh, and P. Sharma, “Finite element analysis of robotic manipulator arm for structural optimization,” Materials Today: Proceedings, vol. 27, pp. 2160–2165, 2020.

[1] J. Denavit and R. S. Hartenberg, “A kinematic notation for lower-pair mechanisms based on matrices,” Journal of Applied Mechanics, vol. 22, no. 2, pp. 215–221, 1955.

[2] J. J. Craig, Introduction to Robotics: Mechanics and Control, 4th ed. Upper Saddle River, NJ, USA: Pearson, 2018.

[3] B. Siciliano, L. Sciavicco, L. Villani, and G. Oriolo, Robotics: Modelling, Planning and Control. London, U.K.: Springer, 2010.

[4] M. W. Spong, S. Hutchinson, and M. Vidyasagar, Robot Modeling and Control. Hoboken, NJ, USA: John Wiley & Sons, 2006.

[5] P. Corke, Robotics, Vision and Control: Fundamental Algorithms in MATLAB, 2nd ed. Cham, Switzerland: Springer, 2017.

[6] S. B. Niku, Introduction to Robotics: Analysis, Control, Applications, 3rd ed. Hoboken, NJ, USA: John Wiley & Sons, 2020.

[7] L. W. Tsai, Robot Analysis: The Mechanics of Serial and Parallel Manipulators. New York, NY, USA: John Wiley & Sons, 1999.

[8] J. Angeles, Fundamentals of Robotic Mechanical Systems: Theory, Methods, and Algorithms, 4th ed. Cham, Switzerland: Springer, 2014.

[9] V. Shah and D. Dhananjay, “CAD modelling and kinematic analysis of a six-axis robotic manipulator using simulation techniques,” International Journal of Engineering Research and Technology, vol. 6, no. 5, pp. 1–6, 2017.

[10] A. Kumar, R. Singh, and P. Sharma, “Finite element analysis of robotic manipulator arm for structural optimization,” Materials Today: Proceedings, vol. 27, pp. 2160–2165, 2020.