Session: 08-03-01: Design and Control of Robots, Mechanisms and Structures I

Paper Number: 165558

Dynamic Simulation and Design Optimization of an Advanced Robotic Arm for High-Performance Concrete Drum Cleaning 

Introduction:

The concrete distribution industry continually faces the challenge of efficiently cleaning truck-mounted concrete drums. Although current washing systems successfully automate the exterior cleaning of trucks, the interior of the concrete drum is either cleaned manually or, in some cases, neglected entirely. This manual process not only reduces overall operational efficiency but also exposes workers to hazardous dust and residues, raising significant health and safety concerns. Therefore, there is a need for an innovative mechanism that delivers thorough, rapid, and automated cleaning of the drum interior. Traditional methods, such as mounting water jets to spray pressurized water, have been widely implemented but often prove inadequate in reaching all critical areas within the drum.

Contribution:

In contrast, our mechanism introduces a novel solution by employing an advanced robotic arm designed specifically for this task. Using dynamic simulation and design optimization, we seek to refine key factors such as the robotic arm's configuration, travel distance, and speed to improve cleaning performance. Our investigation considers two primary configurations: (1) a curved arm engineered to fit past the angle between the concrete drum and the fill hopper; (2) a telescopic arm that remains compact during entry before extending to clean the interior effectively.

Methodology:

At a concrete manufacturing facility in Northwest Indiana, the existing cleaning process requires approximately one minute for exterior washing, followed by an additional three to five minutes for manual interior cleaning, resulting in a total processing time of five to six minutes. In addition to safety concerns, overall wash time is another critical factor that must be optimized through design improvements. Our objective is to reduce this total cleaning cycle to less than two minutes by fully automating the interior cleaning process. To accomplish this, we have integrated comprehensive dynamic simulation techniques with rigorous design optimization and mathematical analysis. The dynamic simulations enable us to evaluate the robotic arm’s performance under various operating conditions, while the optimization framework systematically identifies the best balance between cleaning efficiency, time and mechanical constraints.

Preliminary Results and Conclusions:

This integrated approach promises not only significant improvements in cleaning efficiency but also enhanced worker safety by reducing direct human exposure to hazardous conditions. Moreover, the anticipated reduction in cycle time is expected to lower maintenance costs and boost overall productivity, aligning with current trends toward smart automation. Our research project demonstrates that advanced simulation and optimization enable the development of a high-performance robotic arm for automated concrete drum cleaning, offering a safer, faster, and more cost-effective alternative that sets a new industry benchmark. Currently deployed at a local facility in Indiana, this scalable mechanism holds the promise of widespread adoption, paving the path for future advancements in industrial automation.

Presenting Author: Roman Ford Purdue University Northwest

Presenting Author Biography: Roman Ford is a student at Purdue University Northwest in Hammond, Indiana. His major is Mechanical Engineering Technology with a minor in Industrial Robotics, with a focus on design and automation. He has been on the Dean’s List every semester and has been honored for high academic achievement. Roman has experience with SOLIDWORKS, AutoCAD, Autodesk Inventor, and GMAW and SMAW welding. His current project of interest is in conjunction with a local concrete distribution facility to design a robotic arm to clean the inside drum of concrete trucks. Upon graduation in May 2026, Roman looks forward to entering the field as a design engineer in product development. In his free time, he enjoys hiking, bike riding, and raising dairy goats.

Authors:

Roman Ford Purdue University Northwest
Maged Mikhail Purdue University Northwest
AmirHossein MajidiRad Purdue University Northwest