Workspace and structural analysis of a counterbalanced manipulator for pick-and-place applications

Abstract

This thesis focuses on the modification and analysis of an existing counterbalanced manipulator design. The main aim of this study was to evaluate whether the original manipulator design could be adapted into a more suitable solution for industrial pick-and-place applications in line with Industry 3.0 principles. A literature review and comparison with commercial manipulators were carried out to identify practical design expectations and loading requirements. The original design was revised by removing components that were not suitable for the intended operating concept. The hook and the main manipulator structure were analyzed separately to provide a clearer structural evaluation. Finite Element Analysis was conducted under a selected 2500 N working load at different arm position configurations to evaluate deformation, stress distribution, and safety factor. The FEA results showed that the modified manipulator remained within acceptable stress and deformation limits under the selected loading conditions. The analysis also indicated that the most critical stress regions were concentrated around the connection and transition areas. In addition, a workspace analysis was carried out to determine the manipulator's reachable workspace. Compared with selected commercial examples, the modified design provided a smaller workspace. The findings demonstrate that the modified manipulator has practical potential, although some aspects still require improvement. Although factors such as prototype manufacturing and experimental testing were not addressed, the study provides a strong foundation for future improvements to manipulators for industrial pick-and-place applications.