Topology Optimization of KUKA KR16 Industrial Robot Using Equivalent Static Load Method

The application of industrial manipulators or robots is increasing annually due to its productivity, superiority, and accuracy. The manipulator-links (arms) play an important role in supporting the structure of robots and bares the various loadings such as; inertial, bending, torsional, etc. A topology optimization method is the best way to distribute the useful material in the design space; thereby, needless densities can be removed. This approach reduces the mass and makes the industrial manipulator components as energy efficient. At the same time, it also maximized the stiffness of the robotic components and helped to improve the dynamic performance and stability. In this work, a topology optimization technique is implemented on upper arm and forearm of the KUKA KR16 industrial manipulator by considering volume fraction within a range of 0.3 to 0.9. The complete robot model is designed using SOLIDWORKS 2018 software and imported into Altair Inspire software for multibody dynamic analysis and topology optimization. To make the study realistic, the complete model is operated in dynamic environments within the working range and obtained boundary conditions such as; joint forces and torques. These boundary conditions are used as load cases for topology optimization study. The objective function is chosen as maximization of stiffness or minimization of compliance. To get the better manufacturability of the final topology shape controls of the geometry applied such as; symmetry, split draw and extrusion surface, etc. The obtained topology is analyzed using post-simulation methods and obtained performance values of displacement and Von-Mises stress. Within stated range, the volume reduction of 30-50% gives better performance values compared to the before optimization.