DESIGN, CONTROL, AND PERFORMANCE EVALUATION OF A LOW-COST INDUSTRIAL ROBOTIC ARM FOR SME AUTOMATION

Abstract

Small and Medium Enterprises (SMEs) increasingly require affordable automation solutions to remain competitive in modern manufacturing. However, the adoption of industrial robotic systems is often constrained by high acquisition costs, complex programming, and limited adaptability. This paper presents the design, control, implementation, and experimental performance evaluation of a low-cost industrial robotic arm developed specifically for SME automation. The proposed system consists of a five-degree-of-freedom (5-DOF) robotic manipulator driven by high-torque servo motors and controlled using an ESP32 microcontroller. An inverse kinematics algorithm combined with proportional-integral-derivative (PID) control is employed to achieve accurate positioning and smooth motion. A vision-assisted object detection module enables adaptive pick-and-place operations under varying workspace conditions. Experimental validation was conducted through material handling, object sorting, and assembly-related tasks. Performance metrics including positioning accuracy, repeatability, cycle time, payload capacity, energy consumption, and system cost were evaluated. The robotic arm achieved an average positioning accuracy of approximately 1.5 mm, repeatability within ±0.8 mm, and a payload capacity of 1 kg while maintaining a total system cost significantly lower than conventional industrial manipulators. The results demonstrate that the proposed robotic system offers an economically viable automation solution suitable for SMEs seeking flexible manufacturing capabilities.