For centuries, the art and science of modeling have gone hand in hand with the advancements of technology. Among the most impressive examples of the past modeling were ship models constructed for the British Royal Navy. Referred to as Admiralty models, they were principally constructed during the 18th and 19th centuries to depict proposed warship design. To this day, models are important in the field of engineering, where analytical modeling of a new design needs to be verified. In our project the old practice of building models will be fortified by the most advanced software and 3-D printing technology and used to manufacture a fully working Telbot Master Arm scaled down to 0.4-0.5 of its original size. The Telbot is a robotic arm used in different fields like the nuclear and chemical industfy, often in combination with other products of our company. The main features of the Telbot's sleek construction are: 1) the high load capacity design; 2) unlimited rotation of all axes; 3) no external or internal wiring of the arm; 4) unlimited, fast and precise arm movements; 5) smooth and sealed arm bodies and joints; 6) high repeat accuracy; 7) resistance to radiation, and it can handle precise loads from 5kg to 150kg. Presently, to demonstrate such impressive design features and movement possibilities to its customers, HWM has to build a 3-D virtual reality simulation of the environment where Telbot is proposed to be used and then the arm simulates its movement in this environment. In addition, though HWM does have a showroom for Telbot, due to its weight and size it is not possible to take the full size Telbot on the road to show off its capabilities to customers. The challenge is to build a scaled down full working version of the Telbot robotic arm that can be moved in every direction and angle. The model will be based on the redeveloped T300 Telbot, with 3 joints and 7 free to move pivots. It will be at a 0.4 or 0.5 scale. The outer shell will be 3D printed. The sensors will forward the position and angle to HWM virtual reality software. With these features, any changes made on the model would get displayed in the software one-to-one. The result will be a Telbot Master arm model which can be easily transported; Wallischmiller would be able to present the Telbot not just virtualy, but as a real product with all its functions and versatility and show it all over the world. The extensive construction of the virtual 3-D stimulation can be eliminated and the course of movement to reach specific positions could get simulated faster and easier. It can also be used internally and externally for training. This paper will address the challenges, materials used and manufacturing process of building a fully-working scaled-down version of the Telbot Master Arm.
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