Manufacture of a 4-Degree-of-Freedom Robot to Support an IRB 120 Robot

In this work, we present the construction and control of a four-degrees-of-freedom (DOF) manipulator aimed at addressing one of the key challenges faced by the Academy-Industry Cooperation Center (CCAI): the need for mechatronic equipment to support and facilitate the development of advanced robotic cells. We begin by designing the robot’s structure and components using SolidWorks software for computer-aided design (CAD) modeling. This ensures that all the links and parts fit together properly without collisions. The robot links are then manufactured using 3D printing. Additionally, we performed kinematic modeling, dynamic analysis, and PI-V control, along with control using a trigonometric function (hyperbolic tangent). To evaluate the robot’s movement, we simulate these processes using Matlab R2019a/Simulink software, focusing on key parameters such as position, velocity, and acceleration, which inform the design of PI-V control for each link. We also present the electrical and electronic designs, followed by system implementation. The kinematics of the robot play a crucial role in the dynamics and controller design. We validate the kinematics using Peter Corke’s libraries based on the Denavit–Hartenberg parameters. The results show that the controller based on the trigonometric function improves the response time, particularly enhancing the performance of axes 2 and 3.