SSRG International Journal of Mechanical Engineering Volume 12 Issue 9, 37-45, September 2025

ISSN: 2348-8360/ [Link] © 2025 Seventh Sense Research Group®

Original Article

Analyses of a Modified SCARA Manipulator (RRRRP)

for Pick and Place Application
PVS Subhashini1, Bharadwaj Aditya Singh1
1
Department of Mechanical Engineering, Vasavi College of Engineering, Hyderabad, India.
1Corresponding Author : [Link]@[Link]

Received: 05 July 2025 Revised: 06 August 2025 Accepted: 07 September 2025 Published: 30 September 2025

Abstract - Selective Compliance Assembly Robot Arm (SCARA) manipulator implementations are effective in the workplace
(industrial) world, basically due to their exceptional accuracy and quickness in horizontal task assembly. The only constraint to
their functionality is their modulus of vertical motion, which limits their applications with items in warehouse space and in very
flexible manufacturing systems, with orientation being highly imperative, where vertical motion is an absolute movement aspect,
it can be included. The study employed CAD modelling to engage design contextualization, draft a prototype, structural and
kinematic contextualization, and motion contextualization, followed by material selection. This work also included kinematic
modelling using the Denavit-Hartenberg method to conceptualize the capture of the workspace, trajectory planning, and finite
element analysis of the theoretical concept for stress analysis under loading. A comparison to a traditional SCARA system model
showed greater fit with diminished workspace and tolerating mass loads with a greater load capability factor, and it had
reasonably significant trajectory planning accuracy. The stress calculations, once sent through the serial chain, confirmed that
the system also remained confined to static equilibrium with insignificant displacements of stated loads and totally insignificant
deflections that reside in elastic limits. Overall, the ability to realize additional functionality with the proposed product is
beneficial both in the workplace by having a greater ability to provide a broader functionality workspace with items that require
movement in both planes.

Keywords - Modified SCARA, CAD modelling, Motion study, Mathematical modelling, 5 DOF, Pick and place operations.

1. Introduction
SCARA manipulators are well known for their
application in assembly operations because they have high
speed of operation, accuracy, and reliability. SCARA
manipulators are especially suited for assembly, packaging of
components, and the manufacture of electronic devices. The
structural design of a SCARA manipulator includes a
significant strength - allowing for flexibility in the X–Y plane,
while displaying rigidity in the Z-axis. Because of this,
SCARA manipulators are very well suited to high-precision
operations in horizontal planes. There is thus a need for
manipulators to work in the horizontal and vertical planes to
achieve flexibility in orientations.

This clearly signals a gap in both research and practical

application. Therefore, the aim is to develop the traditional
SCARA architecture by modifying the action in such a manner
that the motion capabilities are extended and thus greatly
exploit the benefits of speed, accuracy, and lower costs are still Fig. 1 Configuration of traditional SCARA
available. Any augmentations would greatly increase and
expand the functioning of SCARA manipulators, making This study presents an improved SCARA manipulator
them user-friendly and easier to manoeuvre for multiple with five degrees of freedom, with four revolute joints and one
industrial applications. prismatic joint. Unlike traditional SCARA architectures, the

This is an open access article under the CC BY-NC-ND license ([Link]

 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

improved design facilitates smooth functional use in both Most recently, Bouzid et al. [8] and Panchanand Jha et al.
horizontal and vertical planes - thus extending its flexibility [9] applied neural net learning to address their kinematics
and use for a broader range of industrial automation problems with the goals of reduced computation time and less
applications. reliance upon 'off the shelf' models.

This study provided a comparative assessment of the new The recent methods include Mittal RK et al. [10], who
5-degree-of-freedom SCARA manipulator versus traditional presented reinforcement learning for path planning, Tay, See
frameworks. The results show that the reinterpretation Han et al. [11], who proposed adaptive algorithms for payload
represents a dramatic change as opposed to an incremental variation, and Ning, W et al. [12], who have applied topology
change. This more sophisticated manipulator showed optimization with the goal of reducing weight.
increased flexibility, improved structural integrity and more
engagement for transitional or operational manipulation Liu et al. [13] have enabled a standard set of studies on
applications, which makes for an efficient solution for a wide workspace dynamics, while Qiu et al. [14] studied complex
range of manufacturing and automation applications. inverse kinematics, and Chen et al. [15] studied dynamic error
compensation, which were able to further enhance SCARA
SCARA Robots were born from the industrial demand for system performance. Finally, Khan et al. [16] and
precision and efficiency in small production lots. Early on, Mohammed, Yousif et al. [4] implemented vision systems and
Yamazaki [1] described the challenges he first faced when fuzzy logic to increase systems' adaptability to uncertain work
assembling wristwatches, which Dr. Hiroshi Makino's team environments.
addressed with a new degree of selective compliance in the X-
Y plane to create a robot that achieved cost, labour and From the literature, SCARA robots were developed to
delivery time savings that established SCARA robots as face industrial automation challenges, especially in precision
credible devices for dedicated assembly projects. assembly. It is clear that in order to maximize the benefits of
SCARA and overcome the workspace limitation, a modified
Low-cost, without loss in performance, has always been SCARA with 5DOF is proposed.
a priority. Shariatee et al. [2] presented the FUM SCARA
robot, made only from commercial, off-the-shelf components 2. Methodology
and was able to achieve ±0.01mm repeatability and high The SCARA manipulator was redesigned in multiple
speeds. Conducting finite element analysis and utilising phases, beginning with the 3D models in SolidWorks. Each
adaptive control architectures utilization increased its link and joint was modeled as a separate part and later
industrial application and research applicability. assembled into the final manipulator. The focus was on
integrating four revolute joints with a single prismatic joint to
Recent literature focuses on SCARA's responsiveness to attain rigidity while providing the needed vertical flexibility.
a dynamic production landscape. Suri et al. [3] studied the
Delta SCARA robot and underscored adapting and integrating After the CAD model was completed, a structural analysis
other surrounding devices within modular production lines. was carried out to confirm the response to load. The analysis
This study found SCARA robots offered better workflow showed areas of stress concentration and confirmed that the
efficiency compared to Cartesian systems and represented a manipulator will accept loads expected while causing minimal
new level of versatility in solving contemporary automation deflection.
issues.
The next step involves a kinematic study using a Denavit–
Control systems have made gains as well, although the Hartenberg (DH) convention to determine the forward
first wave of SCARA robots had only limited intelligence. kinematic equations. The DH convention provided a
Mohammed et al. [4] used ANFIS-based controllers for standardized way to determine realizable workspace limits
optimization the trajectory, while Tay et al. [5] emphasized the and the end-effector trajectories. The output of this step will
need to select an appropriate controller for the application be used to tune the joint parameters and modify the dexterity
within an Industry 4.0 architecture. AI and IoT's growing of the manipulator.
integration with SCARA robots is continuously extending
their landscapes of possibility, including some robots with To test real-world performance, we carried out motion
remotely operated and high-tech intelligent decisions. simulations using SolidWorks Motion and MATLAB. These
simulations created normal pick-and-place cycles while
The thrust area of research is mostly centred on adaptive testing the manipulator's ability to use both a horizontal and
control and overcoming nonlinear control. Garg's [6] studies vertical orientation. The tests also evaluated the smoothness
represent early work on handling parametric uncertainty. Lee and stability against various payloads.
et al. [7] extended this work into sliding mode control to
achieve robustness against disturbance.

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 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

Recorded the results from each testing stage in graphs,

tables, and images. In totality, these results provided a good
indication of how the design would perform in practice.

2.1. Modelling
The simulation of the modified SCARA manipulator
begins by modeling it in three dimensions in a CAD
environment. First, the individual links were modeled in the
SolidWorks Part environment and then assembled in the Fig. 4 Link 2
Assembly Environment to produce the full manipulator
assembly. Then the CAD Motion tool was used to define the
types of motion between joints, and to study how the system
behaved dynamically. At this point, detailed studies may have
been done to show how the manipulator was able to perform.

One important part of the design was the Base, as shown

in Figure 2. The Base provided structural support to the
manipulator and was the primary attachment point for Link 1
and other parts of the system. The Base was designed to ensure
that the manipulator was rigid, stable and aligned accurately. Fig. 5 Link 3
In the next section are the specifications of the Base.
In Figure 6, the component shown is Link 4, which allows
the drill bit flexibility, applied to end-effector adjustment. It is
modeled and designed based on the following dimensions.

Fig. 2 Base

Fig. 6 Link 4

The next component shown in Figure 7 is the end-

effector. The end-effector has two gripping links to hold the
object, which performs the pick and place operation, as shown
in the figure and dimensions in the table below: The end-
effector has a subassembly which has a gripper hub, gripper
finger, gripper link and gripper rotor link, whose dimensions
are shown below:

Fig. 3 Link 1

The second component is Link 1, shown in Figure 3, and

it allows the manipulator flexibility in the horizontal plane. It
is modeled and designed as per the following dimensions.
Figure 4 shows component Link 2, which gives the
manipulator flexibility in the vertical plane. It is modeled and
designed as per the following dimensions. Figure 5 shows
Link 3, which gives flexibility to the drill bit so that it can
change the drilling angle. It is modeled and designed as per
the following dimensions. Fig. 7 End-effector parts diagram

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 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

The end-effector assembly of the gripper is shown in 3. Mathematical Modelling

Figure 8, which defines the relationship between the The forward kinematics of the altered SCARA
components. The goal of the gripper is to hold and stabilize manipulator is defined according to the Denavit–Hartenberg
the object. The end-effector, which connects to the gripper, is (DH) convention. This convention allows for the specification
therefore a subassembly of the end-effector. of homogeneous transformation matrices for each joint,
leading to known end-effector position and orientation.

In order to preserve consistency in spatial depiction,

coordinate frames are systematically assigned according to the
axis of rotation for each joint. The kinematic structure of the
manipulator is then defined completely in terms of the DH
parameters.

Were,
link length, a = distance from zi to zi+1 measured along xi
Fig. 8 End-effector Assembly
Link twist, α = angle from zi to zi+1 measured about xi
Joint distance d distance from xi-1 to xi measured along zi
Joint rotation ɵ= angle from xi-1 to xi measured about zi

The simulations indicated that the proposed model

achieved broad workspace coverage and preserved accurate
trajectories during operation, both of which are necessary for
reliable manipulator operation.

With respect to the DH parameters, the link length is

decidedly the paramount parameter as it is most directly
related to the reach of the manipulator and overall
configuration of the workspace.

The Kinematic equations of the manipulator are given by

the DH Matrices.

Fig. 9 Assembly of the manipulator in different views

The manipulator's assembly uses an assembly

environment in CAD software. The parts are connected to
each other, and to assume different assembly mates includes
different types, as seen in Figure 9.

The work environment of the manipulator has an object

that has to be picked and placed in the rack. The environment
of the manipulator is shown in Figures 10, and 11.

Fig. 11 Modified SCARA in another view

The link transformation matrix is given by:

i-1
Ti
𝑐𝑜𝑠𝜃𝑖 −𝑠𝑖𝑛𝜃𝑖 𝑐𝑜𝑠𝛼𝑖 𝑠𝑖𝑛𝜃𝑖 𝑠𝑖𝑛𝛼𝑖 𝑎𝑖 𝑐𝑜𝑠𝜃𝑖
𝑠𝑖𝑛𝜃𝑖 𝑐𝑜𝑠𝜃𝑖 𝑐𝑜𝑠𝛼𝑖 −𝑐𝑜𝑠𝜃𝑖 𝑠𝑖𝑛𝛼𝑖 𝑎𝑖 𝑠𝑖𝑛𝜃𝑖
[ ] …(1)
0 𝑠𝑖𝑛𝛼𝑖 𝑐𝑜𝑠𝛼𝑖 𝑑𝑖
Fig. 10 Modified SCARA manipulator with work part 0 0 0 1

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 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

Table 1. DH parameters of modified SCARA manipulator 𝑐3 0 𝑠3 𝑙3 ∗ 𝑐3

link(i) a α (degrees) d ɵ 𝑠 0 −𝑐3 𝑙3 ∗ 𝑐3
2
T3= [ 3 ] (4)
base (0) 0 -90 d1 ɵ1 0 1 0 0
1 0 -90 d2 ɵ2 0 0 0 1
2 0 90 0 ɵ3 𝑐4 −𝑠4 0 0
ɵ4 𝑠 𝑐4 0 0]
3 l3 0 0 3
T4= [ 3 (5)
0 0 1 0
4 0 0 d5 0 0 0 0 1

The transformation matrices obtained for each link are as 𝑐5 −𝑠5 0 0

follows 𝑠 𝑐4 0 0]
4
T5 = [ 5 (6)
𝑐1 0 −𝑠1 0 0 0 1 𝑑5
0 𝑠1 0 𝑐1 0 0 0 0 1
T1 = [ ] (2)
0 −1 0 0
0 0 0 1 The final transformation for the manipulator is obtained
by multiplying (2), (3), (4), (5) and (6).
𝑐2 0 𝑠2 0
0
𝑠 0 𝑐2 0 T5 = 0T11T22T33T44T5
1
T2 = [ 2 ] (3)
0 −1 0 0
0 0 0 1

(s1 s3 + c1 c2 c3 )c4 -s2 s4 c1 -(s1 s3 + c1 c2 c3 )s4 -s2 c1 c4 -s1 c3 + s3 c1 c2 -d5 (-s1 c3 + s3 c1 c2 ) + l3 (s1 s3 + c1 c2 c3 )
(s c c -s c )c -s s s -(s1 c2 c3 -s3 c1 )s4 -s1 s2 c4 s1 s3 c2 + c1 c3 d5 (s1 s3 c2 + c1 c3 ) + l3 (s1 c2 c3 -s3 c1 )
0
T5= [ 1 2 3 3 1 4 1 2 4 ]
-s2 c3 c4 -s4 c2 s2 s4 c3 -c2 c4 -s2 s3 -(d5 s3 + l3 c3 )s2
0 0 0 1
(7)
4. Structural Analysis In a nutshell, rigid body dynamics is the study of bodies
With SCARA manipulators, rigid body analysis is that do not deform from their shape. Rigid body dynamics
performed using CAD-based simulation packages, generally focuses on the motion of particles in a body that maintain a
in the context of transient structural analysis or using the rigid fixed relative distance. While a rigid body is subject to
dynamics module. The manipulator model will depend on the external forces or during the actuation of the end-effector
configuration of the SCARA, but once the model is generated, body, each manipulator link is modelled as a rigid body with
its motion and load characteristics can be assessed accurately. the Base as a fixed body, allowing it to be stable. This analysis
This is an important piece of analysis because it can give was intended to simplify the yaw angle and configuration
useful output on parameters like resultant displacement and analysis while still being reasonable in how it looked to
system responses with changing conditions. function in the real world.

The analysis was for the rigid body of the manipulator

under applied loads of 100N. The final evaluation for the
maximum stress was 1.81e+07 N/m2, and the final evaluation
for the resulting displacement was 0.24 mm.

Fig. 12 Force application on the assembly of the modified SCARA

The Base of the manipulator remains stationary to analyze

the stress and resultant displacement of the manipulator with
a load of 100N acting on the end-effector, which is shown in
Figures 12, 13, and 14.
Fig. 13 Fine mesh generation of the manipulator in CAD

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 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

Fig. 14 Stress analysis

Fig. 17 Placing position in the vertical plane

Figures 17 and 18 demonstrate the manipulator modelling

in SolidWorks 2023 and the end effector coordinates,
respectively. The kinematic analysis is done in SolidWorks;
the end-effector trajectory is illustrated in Figure 18.

Fig. 15 Resultant displacement

5. Motion Analysis
The manipulator is oriented in the initial position, as
shown in Figure 16. Each joint of the manipulator uses a motor Fig. 18 Path of the end effector
simulated through CAD to make the movements of the
manipulator. The angular displacement is input for the first 6. Results
three rotational joints. For the fourth rotational joint, angular 6.1. Angular Displacement, Angular Velocity and Angular
velocity is input, and for the prismatic joint, linear Acceleration Plots of Each Joint for the Path
displacement is input. 6.1.1. Joint 1
The first revolute joint demonstrated smooth angular
kinematics, with consistent displacement propagation in a
uniform manner based on what motion was applied to the
input during the simulation cycle (Figure 19). The angular
velocity and acceleration plots showed the same thing for
input motion (Figures 20 and 21) while the linear velocity
trajectory (Figure 22) seemed to show few drastic
performance spikes.
Angular Displacement_Joint1 (deg)

76

56

36

15

-5
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )

Fig. 16 Pick up point in horizontal plane Fig. 19 Angular displacement of joint-1

42
 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

21 871

Linear Displacement2 (mm)

16 816

10 760

5 704

0 648
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20 0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )
T im e ( sec )

Fig. 20 Angular velocity of joint-1 Fig. 26 Linear velocity of joint-2

6.1.3. Joint 3
11
Figures 27–29 illustrate the motion response of joint 3.
8 Compared to the earlier joints, the acceleration shifted more
6 noticeably, which implies that careful tuning of this joint is
3 significant for smooth trajectories.

Angular Displacement_Joint3 (deg)

-14
0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec ) -34

Fig. 21 Angular acceleration of joint-1 -54

-75
1846
-95
1764 0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )

1683
Fig. 27 Angular displacement of joint-3
1602 21
Angular Velocity_Joint1 (deg/sec)

1521 16
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )
10
Fig. 22 Linear velocity of joint-1
5

6.1.2. Joint 2 0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
Figures 23-26 showed that joint 2 underwent a negative T im e ( sec )

angular displacement, which shows a counter-rotation of joint Fig. 28 Angular velocity of joint-3
Angular Acceleration_Joint3 (deg/sec**2)

1. The gentle slope of the velocity and acceleration curves also 23

demonstrates the joint motion control that was acting on joint 17

2, and there is still some level of accuracy that can be attained 11

with multi-axial coordination. 6

0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
-14 T im e ( sec )

-34
Fig. 29 Angular acceleration of joint-3
-54
6.1.4. Joint 4
The final revolute joint (Figures 30–33) had a greater
-75
angle of motion and greater velocity changes, as might be
-95
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
expected for joints toward the end of the manipulator. The
T im e ( sec )
motion was still stable during the tests, and no inconsistencies
Fig. 23 Angular displacement of joint-2 were observed after a number of repetitions.
21
11
Angular Displacement_Joint4 (deg)

16
-34
10
-80
5
-126
0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20 -171
T im e ( sec ) 0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )

Fig. 24 Angular velocity of joint-2

Fig. 30 Angular displacement of joint-4
12
Angular Velocity_Joint4 (deg/sec)

34
9
25
6
17
3
8
0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20 0
T im e ( sec ) 0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )

Fig. 25 Angular acceleration of joint-2

Fig. 31 Angular velocity of joint 4

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 PVS Subhashini & Bharadwaj Aditya Singh / IJME, 12(9), 37-45 2025

20 11

15 -34

YAW (deg)
-80
10

-126
5
-171
0 0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec )
Fig. 36 Yaw Vs Time
Fig. 32 Angular acceleration of joint-4
7. Conclusion
313
This paper introduces an innovative 5-DOF SCARA
235
manipulator developed to increase efficiencies in pick-and-
place operations in both vertical and horizontal positions. The
157
system was modeled using CAD, motion analyses and a
78
detailed study of the kinematics.
0
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
T im e ( sec ) The Denavit–Hartenberg (DH) convention was used to
Fig. 33 Linear velocity of joint-4 develop the forward kinematic equations used in the
kinematics study. Structural testing was completed at a load of
6.2. Roll, Pitch and Yaw Plots of Each Joint for the Path 100 N. The manipulator remained steady under load and
The Roll, Pitch, and Yaw plots of every joint are the plots showed it would be able to withstand stresses without failure.
of the orientation of a robotic joint in the form of its rotational The experienced stresses were close to the maximum
motion around each axis. In order to analyze how every joint allowable stress of 1.81 x 10⁷ N/m² and a negligible amount of
accounts for the joint motion of the robot, the roll, pitch and displacement with a maximum of 0.24 mm, indicating great
yaw plots of the manipulator were examined and displayed in structural reliability. The simulations showed consistent
figures 34, 35, 36, respectively. motion in each of the five joints.

179 In contrast with standard SCARA architectures, the

90
present architecture provides real advantages in more confined
constrained environments, higher accuracy in conjunction
Roll (deg)

1
with multi-axis movements and improved flexibility in
-88 operations. These outcomes indicate that the manipulator
-177 could be applicable in contemporary manufacturing
0.00 0.92 1.84 2.76 3.68 4.60
Tim e ( sec )
5.52 6.44 7.36 8.28 9.20
environments to execute horizontal and vertical operations.
Fig. 34 Roll Vs Time Generally, the modified SCARA manipulator has
demonstrated a practical, lower-cost alternative to flexible
10 automation.
5

Acknowledgments
Pitch

1
We are deeply thankful to everyone who contributed to
-4
turning an idea into a tangible application. We extend our
-8 sincere gratitude to the Management of Vasavi College of
0.00 0.92 1.84 2.76 3.68 4.60 5.52 6.44 7.36 8.28 9.20
Tim e ( sec ) Engineering, Hyderabad, for their support in carrying out this
Fig. 35 Pitch Vs Time work.

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