Algorithm-Driven Development of A Simulation Tool For Industrial Manipulator Stability Analysis
Algorithm-Driven Development of A Simulation Tool For Industrial Manipulator Stability Analysis
Shabnom Mustary1, Mohammod Abul Kashem1, Mohammad Asaduzzaman Chowdhury2, Jia Uddin3
1
Department of Computer and Software Engineering, Dhaka University of Engineering and Technology (DUET), Gazipur, Bangladesh
2
Department of Mechanical Engineering, Dhaka University of Engineering and Technology (DUET), Gazipur, Bangladesh
3
Department of AI and Big Data, Endicott College, Woosong University, Daejeon, Republic of Korea
Corresponding Author:
Jia Uddin
Department of AI and Big Data, Endicott College, Woosong University
Daejeon, South Korea, Republic of Korea
Email: [email protected]
1. INTRODUCTION
This study discusses a simulation tool for assessing industrial manipulator stability, highlighting its
applications in manufacturing. It provides case examples and validation evaluations, highlighting its efficacy
and dependability. The research aims to improve understanding of industrial manipulator stability, leading to
increased productivity, decreased downtime, and safety. The tool also shows potential for future manipulator
design. A considerable amount of research has evolved in response to this pressing requirement, delving into
different methodologies, strategies, and instruments to assess and improve the stability of industrial
manipulators [1], [2]. The review discusses the stability of manipulator systems, including mechanical design,
control techniques, and dynamic stability criteria. It explores factors affecting stability, including structural
dynamics, payload characteristics, and material parameters, and highlights scientific advancements in the field.
In this section, different contemporary research papers has been reviewed to find out the research gap of
respective research objects.
The mechanical stiffness of a manipulator is regarded as a prominent criterion for evaluating robot
performance. The robot is utilized in several industrial sectors, including agriculture, healthcare, and various
forms of small and large-scale production systems [3], [4]. The compliance of reducers and the elasticity of
links contribute to the enhancement of the stiffness of industrial robots [5], [6]. Robot manipulator application
tools are essential for robotics engineers, researchers, and practitioners. Developers may speed up development,
improve robot performance, and enable automation and intelligent manipulation in new sectors and
applications by using these tools [7], [8]. Several simulation tools use different modeling methodologies and
algorithms to analyze industrial manipulator stability. These techniques range from simple kinematic
simulations to dynamic assessments of inertia, friction, and external forces.
In the research paper [9], [10] dynamic modeling is incorporated into advanced simulation tools to
capture the intricate interactions that occur between the manipulator and its surroundings. With the
consideration of variables including inertia, friction, joint compliance, and outside disturbances, dynamic
simulations provide more precise evaluations of stability. To effectively simulate real-world settings, these
tools often use techniques like finite element analysis, multi-body dynamics, and control algorithms [11]–[13].
As a result of the external forces acting on the end-effectors during machining, industrial robots are
prone to static and dynamic deformations, also known as chatter vibrations, because of their comparatively low
stiffness [14]. In the case of robots with variable stiffness require high stiffness for high performance, while low
stiffness is necessary for safety. Their damping capability is their ability to release elastic strain energy during
vibrations. High-damping materials should only be used in specific situations. Cantilever beam theory
characterizes robot deflection, with numerical analysis focusing on the deflection of a cantilever beam [15]–[18].
Robot stability is assessed by taking into consideration the straight or non-straight layouts [19], [20]. The text
discusses a method for computing critical force in serial planar manipulators, focusing on nonlinear phenomena
like quasi-buckling. Depending on the stiffness of the arm and the force delivered, the end-point of a robot
manipulator arm will deflect when a force is applied. The importance of simulation tools for industrial
manipulator guaranteeing the safety [21], [22]. A comprehensive investigation has been taken into account to
determine the necessity of algorithm-driven simulation tools and to understand the involvement of different
parameters of robot manipulators. This investigation is shown in Table 1 using the attributes of various types
of algorithm-driven simulation tools, used parameters of the algorithm, the output of the algorithm,
consideration of the level of stability, and the developed or used database.
This study evaluates and stabilizes manipulator systems to improve industrial automation. It creates
an algorithm-driven simulation tool to investigate manipulator dynamics under different operation situations.
The tool combines mathematical models with stiffness, deflection, and damping. The tool is useful in assessing
the manipulator’s level of stability, providing insights for optimizing performance and ensuring safety. It can
also create robotics research datasets. It is expected that this research work can be applied to real-life problems,
where robot stability is crucial. In this research work, we have reviewed different theoretical and review papers
focusing on material parameters and also taken into account the related research papers addressing on
algorithm-driven simulation tools. A comprehensive investigation has been also considered to identify the
research gap by the predefined objectives of the research. An explicit analysis of material parameters,
development of an algorithm-driven simulation tool using hypothesis rules, and verification of this tool by the
collected data are considered in this research method.
The paper is structured as follows. The second section of the article describes the analysis of material
parameters for stability. Section 3 presents the development of a simulation tool. Section 4 discusses the results
and discussion. Lastly, the conclusions of this work are presented in section 5.
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Table 1. A comprehensive investigation of related work to justify the algorithm-driven simulation tools for
the robot manipulator
Types of algorithm- Considered Database
Used parameters of the Output of the
Ref. driven simulation Level of
algorithm algorithm Stability Developed Used
tools stability
[8] Algorithm-driven Physical properties of Optimized control Yes No No No
simulation tools objects, environmental strategy
such as physics conditions, sensor inputs,
simulations and control strategies
[25] MATLAB, Kinematic and dynamic Optimized virtual Yes No No No
MSC.ADAMS parameters prototype
[26] Smoothly RRT (S- Maximum curvature Ensured efficient and Yes No No No
RRT) algorithm constraint, minimum safe navigation for the
path angle robotic manipulator
[27] Dynamic movement Task configuration Performing Yes No No No
primitives (DMPs) similarity, skill manipulation tasks
as a simulation tool coordinate frames, and
abstractions in the data
[28] PyBullet and V-Rep Metrics of Euclidean Set of metrics that Yes No Yes No
for benchmarking distance error, velocity assess the success of
simulated robotic max, average, and error the simulation
manipulation
[29] Algorithm-driven Euclidean distance error, Threshold values Yes No No No
simulation tool and the young’s modulus
using a continuum matrix (YMM)
manipulator
[30] Algorithm-driven Physical properties, A set of optimized Yes Yes No Yes
simulation tools and environmental robotic control
machine learning conditions, and task- strategies and actions
specific variables
[31] Virtual robot Physical properties, The output consists of Yes No No Yes
experimentation environmental performance metrics
platform (V-REP), conditions, sensor inputs, and data
Gazebo, and and task-specific
MATLAB/Simulink variables such as the
type of crops and field
conditions
[32] Neural network- State variables, actuator Severity of faults Yes No No No
based algorithms signals, fault indicators within the actuator
systems of the robot
manipulators
[33] PID and fuzzy logic Position and velocity Vibration control of a Yes No No No
controllers flexible manipulator
system
[34] Algorithm-driven Mechanical design Accelerate the Yes Yes No No
simulation tools in parameters, control engineering design
robotics policy design cycle by reducing the
parameters, and time associated with
specifications of the the design process
system
(a) (b)
𝑃𝐿3 𝑃
𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = 𝜕𝑚𝑎𝑥 = ;𝐾 = (1)
3𝐸𝐼 𝜕𝑚𝑎𝑥
where, 𝑃 is force, 𝐿 is length of robot link, 𝐸 is young modulus, 𝐼 is moment of inertia, and 𝐾 is spring constant.
This study investigates stiffness in cylindrical manipulators using young’s modulus as a case study.
Stiffness is correlated with the modulus of elasticity and moment of inertia, with the angular frequency being
closely related to natural frequency and the elastic constant. Figure 2(b) shows the involvement of the inner
radius and outer radius of the cylindrical shape of the manipulator, which is incorporated with a moment of
inertia. It has been also analysed that young modules of materials and the moment of inertia correlate with
different material shapes. A consequence evolution of stiffness for different applications has been established
differently. To interconnect the parameter of stiffness with the simulation tool, the following formula for the
material parameter of stiffness [36] is used as (2):
1 𝐾 1 𝐾
𝑆𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠 = 𝑆𝑠𝑡𝑖𝑓𝑓 = 𝐸𝐼 = 2𝜋𝑓𝑐 𝐼 = 2𝜋 ( × √ ) × 𝐼𝑤𝑙 = 𝑚(𝑟12 + 𝑟22 ) × √ (2)
2𝜋 𝑚 2 𝑚
where, 𝐾 is spring constant; 𝑚 is manipulator link mass; 𝑟1 is inner radius; and 𝑟2 is outer radius.
Recent research links damping coefficient to stiffness and amplitude reduction factor. Damping
stabilizes manipulator motion, releasing energy and minimizing oscillations. Inadequate damping can cause
instability, while excessive damping hinders response and energy consumption. The amplitude reduction factor
is directly linked to a material’s capacity to dissipate vibrational energy, with steel having a higher capacity
than copper and copper having a higher capacity than aluminum. Figure 2(c) shows the amplitude reduction
factor for different materials (steel, copper, and aluminum). The simulation tool enables engineers to assess the
damping characteristics of the manipulator system and fine-tune damping coefficients for stable and efficient
performance in different operating situations. To interconnect the parameter of damping with the simulation
tool, the following [9] for material parameter of damping is used as (3):
𝜉 𝛿 𝑥 2𝜋𝛿𝑚
𝐷𝑎𝑚𝑝𝑖𝑛𝑔 𝐶𝑜𝑜𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 𝐶𝑎𝑣𝑔 = ; 𝜉 = ; 𝐶𝑐 = √4𝑚𝑆𝑠𝑡𝑖𝑓𝑓 ; 𝑙𝑛 ( 1 ) = (3)
𝑛 𝐶𝑐 𝑥2 √1−𝛿 2
where, 𝐶𝑎𝑣𝑔 is average damping coefficient, 𝜉 is damping ratio; 𝑛 is number of damping ratio, 𝛿 is logarithmic
𝑥
decrement. ln ( 1 )is amplitude reduction factor and 𝐶𝑐 is critical damping coefficient.
𝑥2
Figure 2. Focusing on (a) the deflection characteristics of a cantilever beam, (b) the geometric configuration of an open-
end cylindrical tube, and (c) the amplitude reduction factor for different materials
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Int J Reconfigurable & Embedded Syst ISSN: 2089-4864 73
The case study of manipulators reveals that the stability of robot manipulators is linked to material
parameters like stiffness, damping, and deflection. Stiffness increases stability, while deflection and damping
decrease it. The stability hypothesis can be validated using a simulation tool and different numerical values of
measurable issues.
Algorithm 2 can be applied to find the different level of stability as output, which is calculated from
the numerical values of deflection, stiffness, and damping as input. The pseudo code of this algorithm is shown
in Algorithm 2.
Algorithm 3 can be applied to determine the status of stability using material parameters, where input
value considered from different factors of the robot manipulator (mass, length, diameter, force, and young
modulus of respective materials). The material parameter of deflection, stiffness, and damping are derivate
from (1) to (3). The pseudo-code of this algorithm is shown in Algorithm 3.
Algorithm-driven development of a simulation tool for industrial manipulator stability … (Shabnom Mustary)
74 ISSN: 2089-4864
10: stiffness.insert([stiffnessTemp])
11: minCriticalDampingCoefficient = Math.Sqrt(4 * mass * stiffness)
12: dampingTemp = dampingCoefficient / minCriticalDampingCoefficient
13: damping.insert([dampingTemp])
14: end while
15: deflection.sort(), stiffness.sort(), and damping.sort() sort by ascending order
16: minDeflection = deflection[0], minStiffness = stiffness[0], minDamping = damp-ing[0]
17: mediumDeflection = (deflection[0] + deflection[n-1]) / 2.0
18: mediumStiffness = (stiffness[0] + stiffness[n-1]) / 2.0
19: mediumDamping = (damping[0] + damping[n-1]) / 2.0
20: maxDeflection = deflection[n-1], maxStiffness = stiffness[n-1], maxDamping =
damping[n-1]
Step2: Calculation stability value
1: finalStiffness = [minStiffness, mediumStiffness, maxStiffness]
2: finalDeflection = [minDeflection, mediumDeflection, maxDeflection]
3: finalDamping = [minDamping, mediumDamping, maxDamping]
4: countLow = 0, countMedium = 0, countHigh = 0
5: for i, j, k less than 3 do
6: status = CheckStability(finalStiffness[i],finalDeflection[j],finalDamping[k])
7: if status equal to 0 then
8: countLow = countLow + 1
9: else if status equal to 1 then
10: countMedium = countMedium + 1
11: else if status equal to 2 then
12: countHigh = countHigh + 1
13: end if
14: i=i+1, j=j+1, k=k+1
15: end for
Step3: Return Math. Max (countLow, countMedium, countHigh)3
These simulation algorithms or methods can be used by computer programs to imitate the behaviour
of real-world systems or processes. This algorithm can generate data that reflects the possible outcomes of
different actions or events, based on certain assumptions and rules. An experimental activities has been
completed for the proposed algorithm where, the front-end of this algorithm is written in C#, and the back end
is written in SQL. In the process of developing an architecture for the database, the attributes of the database
are taken into consideration by the given specifications, as well as their related classification and target value
requirements.
The simulator can be used to ascertain the stability classifications of robot manipulators for
commercially accessible robots. The simulator consists of two panels: one designated for the Admin and the
other for the User. The respective numerical values of ABB and FANUC have been computed using the
proposed and updated formula, and the real value is inserted into the simulation interface shows in Figure 3.
The interface of input values for FANUC shows in Figures 3(a) and 3(b) shows the interface of input values
for ABB.These figures demonstrate how to input various numerical values for the respective factors of material
parameters. After entering the information, the backend database will be created. The simulator can modify
and remove existing data, which can then be utilized for additional study of different data sets. The overall
output and different dimensions of numerical values are discussed in the next section.
(a) (b)
Figure 3. Inserted real value for (a) FANUC and (b) ABB
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Int J Reconfigurable & Embedded Syst ISSN: 2089-4864 75
examination of how the stiffness of materials affects the stability of a manipulator yielded enlightening
discoveries. Manipulators made from materials with increased stiffness showed decreased deflection and
enhanced resistance to structural deformation, which can be further investigated using (1) and (2). Moreover,
the damping characteristics have been identified as a crucial component that influences the dynamic behaviour.
The logarithmic decrement, which can be obtained from the amplitude reduction factor of industrial
manipulators as described in (3), plays a key role in this analysis. The correlation between the stiffness of
materials and the stability of a manipulator highlights the need of choosing suitable materials during the design
stage to improve overall performance and dependability.
The simulation tool utilized a novel algorithm as its backend and various interfaces were designed to
input the necessary variables. This technique facilitated precise forecasting and assessment of manipulator
stability across a wide range of operating situations. The simulation program enabled a thorough evaluation of
manipulator stability using different performance indicators. The findings indicated that the stability levels
were affected by variables such as the bulk of the payload, velocity, and the intricacy of the trajectory. The
stability of manipulators was found to be influenced by diverse operating conditions, emphasizing the need to
take dynamic aspects into account when designing manipulators and developing control systems. This is crucial
to maintain the safe and dependable functioning of manipulators in industrial settings. Figure 4 shows the
screenshot of the output result for the FANUC manipulator’s stability level as in Figure 4(a) low, Figure 4(b)
medium, and Figure 4(c) high.
(a) (b)
(c)
Figure 4. Screenshot of interface for the output result as (a) low, (b) medium, and (c) high
The manipulator’s mass of arm, length of arm, and inner diameter-outer diameter are monitored and
assessed as effective factors for determining the varying levels of stability. The simulation tool also provides
various processed data that is saved in the cloud. Figure 5 shows the screenshot of the interface of saved data,
in Figure 5(a) user data and Figure 5(b) sample database.
The results of our study emphasise the crucial significance of the characteristics of materials, the
design of algorithms, and the operational factors in affecting the stability of industrial manipulators. Engineers
can utilize the developed simulation tool to obtain significant insights into the behaviour of manipulators and
make well-informed design choices to enhance stability and performance. By using sophisticated algorithms
and simulation approaches, the tool’s ability to make accurate predictions is improved. This allows for more
streamlined iterations in manipulator design and decreases the necessity for expensive experimental testing.
Algorithm-driven development of a simulation tool for industrial manipulator stability … (Shabnom Mustary)
76 ISSN: 2089-4864
(a) (b)
Figure 5. Screenshot of the interface of (a) user data and (b) of database
5. CONCLUSION
Our research conclusively shows that the created algorithm-driven simulation tool is highly effective
in assessing the stability of industrial manipulators. The tool offers useful insights for optimizing manipulator
performance and guaranteeing safe and reliable operation in industrial settings by taking into consideration
variables like as material features, algorithm design, and operating conditions. Additionally, the developed tool
can be used to build a specific dataset in the relevant area for additional research as needed. This work enhances
the progress of robotics technology and simplifies the development of more resilient and effective industrial
automation systems. However, it is crucial to acknowledge the constraints of simulation-based methodologies,
which encompass simplifications in modelling assumptions and uncertainty in real-world operating settings.
Future research should prioritize the improvement of simulation approaches, the verification of results through
experimental testing, and the expansion of the simulation tool’s usefulness to a broader range of manipulator
configurations and situations.
ACKNOWLEDGEMENT
The corresponding authors are thankful to the Ministry of Posts, Telecommunication and Information
Technology, The People’s Republic of Bangladesh, under the Information and Communication Technology
(ICT) Division (G.O.56.00.0000.028.33.007.20-105). This research is funded by Woosong University
Academic Research 2024
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BIOGRAPHIES OF AUTHORS
Algorithm-driven development of a simulation tool for industrial manipulator stability … (Shabnom Mustary)
78 ISSN: 2089-4864
Int J Reconfigurable & Embedded Syst, Vol. 14, No. 1, March 2025: 69-78