Problem Statement
The robotic arm required a compact, belt-driven actuation system capable of maintaining consistent belt preload over time while minimizing backlash, wear, and alignment issues. Variations in manufacturing tolerances, vendor part discrepancies, and evolving torque requirements further complicated reliable motion transmission and repeatable joint performance.
Design & Implementation
- Designed a spring-loaded belt tensioner using mechanical first principles to maintain consistent belt preload, improve motor-to-belt precision, and extend belt service life.
- Developed CAD models and physical prototypes for a belt-driven 5-DOF actuation system powered by NEMA motors.
- Integrated idler pulleys, shafts, bearings, and couplers to support the tensioning system, ensure proper belt tracking, and enable smooth, controlled actuation.
- Iterated through CAD → 3D print → test cycles, refining tolerances to reduce backlash and improve drivetrain stiffness.
System Integration & Validation
- Completed full mechanical assembly and initial power-up
- Identified and documented design improvements, including tighter tolerance control, vendor specification verification, and motor/gear ratio optimization for torque-limited joints