6-DOF Teleoperated Robotic Arm Mechanical Architecture & Kinematics

Objectives

What the project needed to achieve

• Package 6 articulated joint axes within an aggressive total arm weight envelope
• Achieve a 920 mm spherical working reach volume with low backlash
• Design cycloidal joint housings with integrated cross-roller bearing seats
• Conduct FEA deflection analysis on upper arm and forearm links under 5 kg payload
• Deliver production drawing packages using ASME Y14.5 GD&T practices for CNC machining

Challenge

Engineering constraint

The client required an articulated 6-DOF manipulator capable of operating in compact workstations while maintaining structural rigidity at maximum reach under a 5 kg rated payload. Off-the-shelf industrial collaborative arms were too bulky and costly for the required integration envelope. Key engineering challenges included packaging high-reduction cycloidal joint mechanisms into low-profile housing envelopes, managing torsional deflection along the forearm, and routing internal motor power and encoder wiring through hollow joint axes without mechanical pinching.

Approach

How YantriX approached the work

1. 01

   Modeled forward and inverse kinematics to verify link lengths, joint velocity limits, and workspace reachability.

2. 02

   Engineered modular joint stacks integrating cycloidal drive discs, eccentric shafts, dynamic seals, and absolute magnetic encoders.

3. 03

   Conducted finite element analysis (FEA) on structural arm links in SolidWorks Simulation, iterating wall thicknesses to resist peak torque without excessive mass.

4. 04

   Established internal wiring harness channels with protected service loops through hollow joint shafts to eliminate external snag hazards.

5. 05

   Prepared 2D engineering drawing packages with geometric tolerancing for critical bearing fits, concentricity, and seal gland compression.