Design, Fabrication, and Analysis of A4-Dof Manually Controlled Pick-and-Place Robotic Arm

Authors: Sagar Bhuyan, Biswajit Barik, Priyaranjan Behera, Manas Kumar Sethy, Subhashree Naik

Abstract: This paper presents the design and fabrication of a manually controlled 4-DOF pick-and-place robotic arm mounted on a four-wheeled mobile platform. The robotic arm is actuated using servo motors and gear motors, with movement controlled directly via push buttons, potentiometers, toggle switches, and a servo tester, eliminating the need for microcontrollers or programmable controllers. The structure is fabricated from lightweight materials such as aluminum and foam board to ensure portability and mechanical stability.The robotic arm includes revolute joints at the shoulder, elbow, wrist, and gripper, each capable of independent and simultaneous motion. CAD modeling was performed using Creo software to visualize and validate the design before fabrication. Inverse kinematics analysis was conducted using RoboAnalyzer software to determine joint angles required for specific end-effector positions. Additionally, finite element analysis (FEA) was performed using ANSYS to evaluate stress and deformation across critical arm components. The resulting system provides a cost-effective and functional platform for basic automation tasks, academic demonstrations, and prototyping. Its simplicity and manual control make it especially suitable for learning environments focused on mechanical design, actuation, and robotic system integration.