Robotic Soldering Arm

Robotic soldering arm
CHAPTER NO.1 INTRODUCTION

Robots are primarily concerned with generating specific motion of the robot joints, simultaneously allowing tooling or sensors to perform certain functions, either when the arm is moving or at specific operational configurations. The arm and attached tooling may perform the operations themselves (such as Soldering) or carry parts to other devices which perform the operations. Robotics today is advancing to point, where many task that used to be for humans only, have been supplemented by machine that can do the same task faster and softer than human involvement factories are now shifting towards automated task with the help of robots. Nowadays such works like soldering, welding, drilling done through robot Robots are beginning to move out of the lab and into real environmental. In a hazardous environment application the operator cannot be physically near the robot to issue commands. Many researches in robotics believe that the low level functions of a robot should be controlled by a remote. These functions include reflective sensor based obstacle avoidance and basic motion primitives. However if these function are controlled by a remote it is necessary to allow a human operators. Soldering Robot, also known as automatic soldering machines, is applied to the solder welders bit different from the wave soldering, reflow furnace welding. Mainly used to replace the simple, repetitive manual welding equipment. Currently available mainly gantry robot type, foreign visible vertical articulated robot movement patterns. Robotic applications are widely used in research laboratories and industries to automate processes and reduce human errors. Some of the tasks performed by robots include assembly lines and motions that require force control with feedback to its controller. This paper describes my senior design project that examines both tasks using a robotic manipulator with five degrees of freedom.
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Fig.1.1 Basic robotic arm
1.1 Type of Robot
1. Cartesian robot
2. Cylindrical robot
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3. Scara robot
4. Polar robot
5. Spherical robot
6. Jointed arm
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1.2 FEATURES OF THE PROJECT
Features Robot arm material
Particulars Plastic
Specification It is lighter in weight and cheaper A combination of spur and spiral gears were used. Spiral
Gears
Spur gear were mostly used to amplify the motor torque
gear are used to achieve very high torque amplification within a relatively small space
Infrared communication module User Interface Software Soldering Gun Camera Power Supply Conveyor T.V.
Standard Standard Standard Standard infrared camera Standard Manufactured with DC motor Standard
RF-6 Combination circuit Keil 12 V Soldering Gun Checking correctness of operations 12 V Battery 10 rpm DC motor with timer circuit Standard for display
1.3 World Robotics Scenario 2013 Robotics market value: $8.7 billion; + software, peripherals, systems: $26 billion Year 2012 was second highest in sales (but -4% w.r.t. the record year 2011) industrial robot sales in 2012: 159K units (large variations in different areas) Americas: +7% (28K); USA: +9% (22K units) Asia/Australia: -5% (86K); Japan (28.7K), China (23K), Korea -24% (19.4K) Europe: -6% (41K); Germany -10% (17.5K), Italy -14% (4.4K)
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Increase in automotive, reduction in electronics (strong) and machinery. Forecast on operational stock of industrial robots: 1.5M units in 2015. Service robot sales in 2012: +2% (16K units) for professional use and +15% (3M units) for personal/domestic use, out of which 1.1M units for entertainment Professional use: defense (6.2K units, most UAV, 40% share), field robots (5.3K, 33%), medical/robot surgery (1300 units, but 44% in value). In the modern world, robotics has become popular, useful, and has achieved great successes in several fields of humanity. Robotics has become very useful in medicine, education, military, research and mostly, in the world of manufacturing. It is a term that has since been used to refer to a machine that performs work to assist people or work that humans find difficult or undesirable. Robots, which could be destructive or non-destructive, perform tasks that would have been very tedious for human beings to perform. They are capable of performing repetitive tasks more quickly, cheaply, and accurately than humans. Robotics involves the integration of many different disciplines, among them kinematics, signal analysis, information theory, artificial intelligence, and probability theory. These disciplines when applied suitably, lead to the design of a very successful robot. These are robots that perform particular tasks. They are usually in the form of robot arms and are normally stationary. In most cases, they are bolted at the shoulder to a specific position in the assembly line, and the robot arm can move with great speed and accuracy to perform repetitive tasks such as spot welding and painting. Manipulator robots are very much unlike the autonomous mobile robots whereby the intelligence provided to them does not make them adapt to the environment in which they are. In most cases, most manipulator robots are capable of handling many end-effectors in order to increase the versatility of their use. These various end-effectors can be used for several purposes such as welding, painting, screwing and assembling. Although manipulator robots can be very versatile, they suffer from a fundamental disadvantage, which is lack of mobility. A fixed manipulator robot has a limited range of motion that depends on where it is bolted down, in contrast to a mobile robot that is capable of moving about.
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CHAPTER NO.2 MECHANISM AND MOTION OF ROBOTS Mechanics deals with the analysis of the forces that cause a body to be in physical motion. The motion of the robot arm will be achieved with the use of dc motors as actuators. Since we will require knowing the exact position of the robot arm, the motors will be operated with remote. The dc motor is connected to the gear box in such a fashion that it triggers when specific positions of the output shaft of the motor are reached, thereby allowing us to know the exact position with relatively high accuracy. Since mechanics involves also the parts of the robot that are acted upon directly by the motors and the gears to achieve motion, the tensile strengths of those areas were designed to withstand the stresses generated due to friction and force of propulsion. 2.1 ROBOTIC ARM This functionality is best supported by a Joint class, which is used to create four Joint instances at run time (for the base, shoulder, elbow, and wrist). The class has several features: Each joint instance stores its current orientation; Each joint converts angles into timed rotations; Each joint knows the limits of its rotation, in both directions. The gripper could also be represented as a joint, but I'll continue to follow my decision in Arm Communicator and treat it as a binary device that is either open or closed. Manipulator is a fancy name for a robot or mechanical arm; hence it will be used intermittently with robot arm. A manipulator is an assembly of segments and joints that can be conveniently divided into three sections: the arm, consisting of one or more segments and joints; the wrist, usually consisting of one to three segments and joints; and a gripper or other means of attaching or grasping. Alternatively, the manipulator can be divided into only two sections, arm and gripper, but for clarity the wrist is separated out as its own section because it performs a unique function. Industrial robots are stationary manipulators whose base is permanently attached to the floor, a table, or a stand. In most cases, however, industrial manipulators are too big and use a geometry that is not effective on a mobile
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robot, or lack enough sensors (indeed many have no environmental sensors at all) to be considered for use on a mobile robot. There is a section covering them as a group because they demonstrate a wide variety of sometimes complex manipulator geometries. We will review the robot arm based on the three general layouts of the arm section of a generic manipulator, and wrist and gripper designs. It should be pointed out that there are few truly autonomous manipulators in use except in research labs. The task of positioning, orienting, and doing something useful based solely on input from frequently inadequate sensors is extremely difficult. In most cases, the manipulator is tele operated (remotely controlled using radio transmission technology).
Fig. 2.1.1 Robotic arm
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Fig.2.1.2 Robotic arm
Robot Tooling: The tools which are grasped by mechanical grippers include the soldering gun. Soldering Gun: General purpose industrial robot can maneuver and operate a soldering gun to place a series of soldering on flat, simple-curved, or compound-curved surfaces. In production line operations on appliances or auto bodies, stop-and-go rather than continuous line motion is preferred. When the time available is too short for one robot to make all the sold within its reach, the number of sold points can be divided among two or more robots, as is done in the
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automotive industry. Similarly, if all of the sold are not of the same type, there must be a different gun and so a different robot for each. The robot can position soldering within 0.250 in., but the line must position the work accurately. 2.2 POSITIONING, ORIENTING AND DEGREES OF FREEDOM
Fig. 2.2.1 Degree of freedom The rotation limits are specified in degrees, and the times are for a single rotation from one limit to the other. For example it takes the base 15.3 seconds to rotate from its right hand limit over to the left limit (and the same time in the other direction). We'll use the timing and limit information to calculate a rotation rate for each joint: rotation rate = ((positive angle limit) - (negative angle limit))/ rotation time
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This rate is divided into a user-supplied angle offset (e.g. turn by 30 degrees) to convert it into a rotation time (30 / rotation rate). Another problem is that the gear wheels slip when they start rotating, effectively causing the arm to move faster for the first few milliseconds. The gears also take a few milliseconds to stop moving when a joint is told to stop. These millisecond inaccuracies build up if the joints are rotated using many small angle changes as opposed to a single large adjustment.
Fig.2.2.2 Rotation of arm The human arm is considered to have seven degrees of freedom. These consist of three rotations at the shoulder, one at the elbow, and three rotations at the wrist. The motors that control the shoulder and, to a lesser degree, the elbow have to carry the load of the entire arm, hand, and payload. These motors must be capable of producing substantially greater torque than motors at other joints. To reduce the number of high-torque motors required, the shoulder is designed with only two DOFs. Although the wrist does not have to carry a high load like the shoulder, space at this point on the arm is limited. For this reason, the wrist is given only two DOFs. This leaves a total of five degrees of freedom for the arm instead of seven. The human hand has twenty seven degrees of freedom, most of which are associated with the fingers. To grasp a simple object, the motions of the fingers are not needed. This assumption allows the hand to be designed with one degree of freedom, thus greatly simplifying the design. A simple representation of the arm is shown in the Figure
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below. The red arrows represent the axis that each DOF can rotate about. Although the hand is shown, its DOF is not labelled. 2.3 GRIPPERS
Fig.2.3.1 Gripper The distance from the wrist to the gripper ends at the midpoint of the gripper prongs when they're closed. If you're looking for precision-tooled robotics hardware, with movements accurate to millimetres, then the OWI isn't for you. But, considering the price, OWI Robotics has produced an amazingly fun product. One problem is that the gear wheels tend to slip due to the weight of the arm, or if the arm is rotated into a hard obstacle, or beyond a joint's rotation limit. Gravity also means that the arm's rotational velocity isn't constant -- for example, rotating the shoulder joint downwards takes less time than rotating it upwards by the same amount. Another factor is the battery power supply as the batteries fade, so does the arm's speed.
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CHAPTER NO.3 DESIGN OF ROBOTIC ARM 3.1 DESIGN 3.1.1 Design selection of robotic arm: In choosing the materials and the shape for the robotic arm, the following were taken into consideration: 1. The ease of manufacturing 2. The mode of manufacturing 3. Ease to assemble 4. Strength and durability of the parts 5. Weight of robot 6. Cost 3.1.2 The principle requirements for power transmission of robots are: 1. Small size 2. Low weight and moment of inertia 3. Accurate and constant transmission ratio 4. Low energy losses and friction for better responsiveness of the control system. Hence, combination of these factors has greatly influenced all the choices made in the design selection of the Robotic arm In the design of systems, there are generally two methods of approach namely: Top-down method Bottom-Up method The top-down method is usually applied in designing a system from the scratch while the down-top method is used for reverse designing of an already existing system or functional design as in software engineering. We employed the top-down approach in the design of the robot arm.
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Figure 3.1.2: Sketch of the Robot Arm We employed the top-down approach in the design of the robot arm.
MECHANICAL ARM
ELECTRONIC HARDWARE
SOFTWARE
SYSTEM INTEGRATION
ROBOT ARM/ MANIPULATOR
Fig.3.1.3 Robot Arm System Design (Top-Down Approach)
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A robot arm or manipulator is composed of a set of joints, links, grippers and base part. The joints are where the motion in the arms occurs, while the links are of fixed construction. Thus the links maintain a fixed relationship between the joints. The joints actuated by motors. A revolute joint is one that allows rotary motion about an axis of rotation. An example is the human elbow.
Fig. 3.1.2 linkages of Arm Design of the arm is to define its degrees of freedom. A degree of freedom, or DOF, is an independent displacement associated with a particular joint. Joints can be ether prismatic or revolute, or both. Prismatic joints are capable of linear motions while revolute joints are capable of rotating. In this case each of the arms joints is revolute, and thus, each degree of freedom is a rotation. Each of these DOFs is controlled by motors.
Fig, 3.1.3 Degrees of freedom
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3.2 MATERIAL SELECTION In manipulator structures, stiffness-to-weight ratio of a link is very important since inertia forces induce the largest deflections. Therefore, an increase in the Elastic modulus, E would be very desirable if it is not accompanied by an unacceptable increase in specific density, . The Elastic modulus is an indication of the materials resistance to breakage when subjected to force. The best properties are demonstrated by ceramics and beryllium but ceramics have a problem of brittleness and beryllium is very expensive. Factors like ageing, creep in under constant loads, high thermal expansion coefficient, difficulty in joining with metal parts, high cost and the fact that they are not yet commercially available make the use of fiber-reinforced materials limited though they have good stiffness-to-weight ratios. However, with advances in research, some of the mentioned setbacks have been significantly reduced. Hence, the use of fiber-reinforced materials (known as composites) is becoming more attractive. Therefore the materials recommended for use in this project are Plastic Fiber Glass-reinforced Plastic
The links have an internal hollow area, which provides conduits for power transmitting components i.e. gears in this case, and the DC motors. At the same time, their external dimensions are limited in order to reduce waste of the usable workspace. They are as light as possible to reduce inertia forces and allow for the highest external load per given size of motors and actuators. For a given weight, links have to possess the highest possible bending (and tensional) stiffness. The parameter to be modified to comply with these constraints is the shape of the cross-section. The choice is between hollow round and hollow rectangular cross-section. From design standpoint of view, the links of square or rectangular crosssection have advantage of strength and machinability ease over round sections. After more research and consultations with our supervisor and some lecturers in the Mechanical Engineering department, who are experts in the field, we settled for Plastic mainly on grounds of cost and workability.
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3.3 GEAR SYSTEM Robot gears are large reduction in few steps, low inertia, low friction, zero backlash, high stiffness, low lost motion and low weight. Compact speed reducers based on cycloid gearing are therefore an attractive alternative for robot manufacturers. Speed reducers based on cycloid gearing are specified by a rated torque which corresponds to the stamina of the speed reducer, i.e. the larger the rated torque the longer the lifetime under constant load conditions. Together with the rated torque, a rated speed is also included in the equation for predicting lifetime. Gear box: These are chosen discretely from a list. Each gearbox is modelled as a point mass with transmission inertia and friction. The most important criterion for the gearboxes is the number of possible cycles before they break down.
Fig.4.3.1 Gear In this work, we have chosen the bevel, spur types of gears. These were readily available from scrap machines (photocopiers). Spiral gears have the advantage of high torque amplification within a relatively small space. The necessary data for the selection and choice of the gear arrangements at each joint are: i. ii. iii. Power transmitted, P = TW Transmitted speed, ( rad/s) Torque developed , T ( Nm)
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iv. v. vi. vii. viii. ix.
Lewis form factor, Y Bending stress, ,( ultimate tensile strength) Ultimate tensile strength, ut Factor of safety, n Module of gear, m Number of teeth, N
The equations below show the relationship between these parameters. They led to the selection of the gears. i. Gear diameter, d mN
V
ii. Pitch line velocity,
d 60
iii.
Transmitted load, W
p V
iv. Velocity , KV
6 6 V
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3.4 FORCE CALCULATION FOR JOINT
Choose parameters: 1. Weight of each arm 2. Weight of each joint 3. Weight of soldering gun 4. Length of each arm Next does a moment arm calculation, multiplying downward force times the linkage lengths. This calculation must be done for each lifting actuator. This particular design has just tow DOF that requires lifting, and center of mass of each linkage is assumed to be length/2
Torque about joint 1: M1 = L1/2 * W1 + L1 * W4 + (L1 + L2/2) * W2 + (L1 + L3) * W3 Torque about joint 2: M2 = L2/2 * W2 + L3 * W3 Using above formula, calculate torque at joint 1: M1 = L1/2 * W1 + L1 * W4 + (L1 + L2/2) * W2 + (L1 + L3) * W3
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Where, 1. L1 2. L2 3. L3 4. W1 5. W2 6. W3 7. W4 We get, M1 = L1/2 * W1 + L1 * W4 + (L1 + L2/2) * W2 + (L1 + L3) * W3 M1 = (110/2) * 200 + (110*170) + (110+ (90/2)) + (110+110)* 100 M1 = 51845gm-mm Using above formula, calculate torque at joint 2: M2 = L2/2 * W2 + L3 * W3 M2 = ((90/2)*90) + (110*100) M2 = 15050 gm-mm Therefore, TORQUE = FORCE * PERPENDICULAR DISTANCE FORCE = TORQUE / PERPENDICULAR DISTANCE F1 = 51845/110 F1 = 471.31 gm F1 = 472 gm Weight lifted by robotic arm: F2 = 15050 /90 F2 = 167gm
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= 110 mm = 90 mm
= 110 mm = 200 gm = 90 gm
= 100 gm = 170 gm
CHAPTER NO.4 ROBOTIC ARM MOTION A robot's motion is constrained by its physical construction as well as the environment in which it must work. For example, when designing a robotic arm to play a game of chess against a human opponent, an engineer must design a physical shape and write an intelligent computer program that together allow the robot to pick up any piece on the board, without knocking over other pieces or poking its opponent in the eye. There are many ways to approach these sorts of problems. A robot may have pre-programmed knowledge of many deferent possible con gyrations, and pick one most suitable to its current task. It may learn to move through its environment by trial and error, or it may be built in such a way that the motion required for any task is trivially obvious. Each method has its beets: elevators, for example, were designed using the third approach, and not the second, for good reasons.
Fig 4.1 Motion of Arm

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The project is limited to manually controlling each degree of freedom. The operator moves each joint to a new angle and this places the arm in a new configuration. For each configuration the hand is moved to a specific location and orientation. The equations that relate the arms configuration to the hands location and orientation are called the forward kinematic equations for position. What is more useful however, is the ability to determine the arm configuration that will achieve a desired hand location and orientation. In other words, the position and orientation of the hand must be defined in terms of the joint angles. This is called inverse kinematics. The forward kinematic equations for the arm are developed below followed by some possible solution techniques for the inverse kinematic problem. Developing these equations is the first step to implementing a more sophisticated method of motion control. Although this development is not an exhaustive description of the mathematics involves, it highlights the basic concepts.
4.2 Position Control: Currently there are encoders attached to the two DC motors which control the shoulder and elbow vertical movements however they are not used. The encoders cause difficulty with the motors because the motors resist instantaneous position correction and they lock-up. Currently all position control is manual and user-operated through a RF wireless joystick controller.
4.3 DC Motor Driver: The driver IC used for the dc motor is the L298 Dual Full-Bridge Driver. The L298 is an integrated monolithic circuit in a 15-lead multi watt package. It is a high voltage, high current dual full-bridge driver designed to accept standard TTL logic levels and drive inductive loads such as relays, solenoids, DC and stepper motors. Two enable inputs are provided to enable or disable the device independently of the input signals. The emitters of the lower transistors of each bridge are connected together and the corresponding external terminal can be used for the connection of an external sensing resistor. An additional supply input is provided so that the logic works at a lower voltage.
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CHAPTER NO.5 MOTORS AND MOTION CONTROLS 5.1 MOTORS 5.1.1 DC MOTOR The dc motors are most easy to control .One dc motor will require only two dc signals for its operation , if we want to change the direction then we just need to change the polarity of the power across it . We can vary speed by varying the voltage across the motor by making use of gears. The dc motor does not have enough torque to derive a robot directly by connecting wheels to it, gears increases the torque. Mathematical interpretation
Rotational power (p) = Torque (t)*Rotational speed (s), T = P/s P is constant for dc motor with constant electrical power. Thus the torque is inversely proportional to the speed, T 1/s By using two motors we can move robot in any direction, the steering mechanism of robot is called as differential drive. DC motors come in a variety of shapes and sized although most are cylindrical. They feature an output shaft which rotates at high speeds usually in the 5000 to 10,000 rpm range. Although DC motors rotate very quickly in general, most are not strong (low torque). In order to reduce the speed and increase the torque, a gear can be added. To incorporate a motor into a robot, you need to fix the body of the motor to the frame of the robot. For this reason motors often feature mounting holes which are generally located on the face of the motor so they can be mounted perpendicularly to a surface. DC motors can operate in clockwise (CW) and counter clockwise (CCW) rotation. The angular motion of the turning shaft can be measured using encoders or potentiometers.
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5.1.2 Control of DC Motors Controlling the D.C. motor is done using the principle of the H-bridge. The H-bridge is shown in the fig 2.3 below: Assuming switches A and D are closed, current flows through the motor in one direction and the motor rotates in a clockwise direction. If switches B and C are closed, current flows in the opposite direction and the D.C. motor rotates in a counterclockwise direction. If A and B OR C and D are closed, the motors terminals are at the same potential and no current flows, hence the motor brakes.
12V 12V
A
d.c. Motor
+88.8
THE H-BRIDGE
Fig. 5.1.1 DC Motor control The H-bridge is represented by the transistor network Terminals A and B is connected to the digital outputs of the microcontroller. The LHS network is a mirror image of the RHS network. This makes bi-directional control possible. Controlling the motor can be analyzed considering four scenarios: The first is when A is LOW and B is HIGH. On the LHS, Q1 is turned on eventually making Q3 to on and conduct. Q2 is turned off, eventually turning off Q4. On the RHS, Q5 is turned off, thereby turning Q7 off also. Q6 is turned on causing Q8 to conduct current. As a result, current flows through Q8, to the D.C. motor and finally to ground through Q3, causing the motor to rotate counter-clockwise. The second is when A is HIGH and B is LOW. On the LHS, Q1 and Q3 are off while Q2 and Q4 are on. On the RHS, Q5 and Q7 are on while Q6 and Q8 are off. Current flows through the D.C. motor from Q4 to Q7, causing the motor to rotate clockwise.
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The third is when A is LOW and B is LOW. On the LHS, Q1 and Q3 are on while Q2 and Q4 are off. On the RHS, Q5 and Q7 are on while Q6 and Q8 are off. The motor terminals are then at 0V and the motor brakes. The fourth is when A is HIGH and B is HIGH. On the LHS, Q1 and Q3 are off while Q2 and Q4 are on. On the RHS, Q5 and Q7 are off while Q6 and Q8 are on. The motor terminals are then at 12V and the motor brakes. Specifications: VOLTAGE MODEL NO LOAD AT MAXIMUM EFFICIENCY
NOMINAL SPEED CURRENT SPEED CURRENT TORQUE OUTPUT V r/min 1200 A 0.026 r/min 980 A 0.17 g.cm mN.m 25.3 2.48 W 1.25
RX-RF370CH-15370
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Fig. DC Motor geometry 5.2 THE WIRELESS COMMUNICATION SYSTEM The user interacts with the robot through a graphic user interface on a remote, hence the need for some form of communication between the remote and the receiver. We chose a wireless communication mode for reasons of flexibility, and we established communication between the remote and the robot via infrared. After some research, we decided to use a one-chip solution in the form of an infrared transmitter/receiver IC (ST12 CODEC). ST12 CODEC is a radio frequency and infrared encoder/decoder IC for remote
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control applications having unique features and flexibility not available with other remote control encoder decoder ICs. ST12 is truly a single-chip remote control solution. The ST12 combines the functionality of both encoder and decoder in a single package with several unique features for enhanced operation and a reduced component count for transmitter and receiver circuits. However, we could not lay our hands on this IC because it was not readily available. We needed to import it. This led to more research on alternatives that would approximate the desirable qualities of the ST12. We eventually arrived at a microcontroller solution for encoding the intelligence signal at the PC end and decoding it at the base of the robot for appropriate arm control.The command controller generates an 8-bit command code corresponding to the desired action and sends it to the parallel port. The receiver at the base of the robot reads this command code and uses it to modulate the carrier signal coming from the carrier generator. A IC configured in a stable mode was used to generate a carrier signal of 38kHz, since the IR receiver is sensitive to signals at this frequency. The IR receiver is a TSOP infrared receiver IC. It sees a 38kHz square wave of an infrared signal as a logic 1, inverts it and places a logic 0 on its output pin. When there is no incident IR signal, it sees it as logic 0, inverts it and places logic 1 on its output pin. Hence, any binary sequence can be transmitted serially by activating or deactivating the frequency generator appropriately in sequence. The range of the IR transmitter can be increased by increasing the current at the transmitter. Also, using more than one transmitter will increase the range. The transmitter is simply an infrared light emitting diode (LED) and we were able to achieve a range of about 6 meters line of sight.
Modulated IR receiver Carrier frequency IR transmitter Remote Transmitter Microcontroller
Fig. 5.2 wireless communication system
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CHAPTER NO 06 ELECTRONICS HARDWEARE SELECTION 6.1 Transmitter Remote Transmitter based on Holtek HT12E 8 button, each individually controlled 8 bit user settable Address (0~255) Transmit Data Indicator LED Transmitter operating range up to 100 to 200 m under open field conditions Operating frequency 434 MHZ Low power and high noise immunity CMOS technology Low standby current ; 0.1uA(typ)@ VDD = 5V
6.2 Receiver 8 channels, each individually controlled 8 bit user programmable address (1~255) Relay output-3A rated changeover contacts (Refer the data sheet of relay) Relay Indicator LED On board power LED indicator Operating frequency 434MHZ Receiver operates from 12V DC power supply On board leam and store address switch HK-BB decoder has internal flash Memory to Store Address Selectable mode, Toggle or momentary
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1. 2.
Toggle: Press > on; Press again > off Momentary: Press and hold > On; Release >off
Power supply input and Relay contact are brought out as Screw Terminals
6.3 RF Transmitter Transmitter USES RF Encoder HT12E IC from Holtek. Each key pressed Transmits 12 bits containing 8-bit address and 4 bit data. RF sends the transmitted information with 434 MHz RF transmitters. HT12E works on 5V to 12V, which is powered by 9V to 12V Battery. Diode D2 provides
protection in case battery is connected reverse. LED L 1 is visual indication to transmitter status (on/ off). 6.4 RF Receiver Receiver uses HK-8B in RF Decoder Chip. All eight outputs are taken to eightchannel relay driver stage. Single jumper sets the receiver in latching or momentary output mode. HK-8B chip has internal flash memory to learn and store the address. Output can be set to momentary mode or latch mode. The setting of jumper decides which channel remains in momentary or latch mode. Make sure you discontinue the power supply while setting the modes; since this pin is read during power up. Momentary mode means the relay is operated (on) while the corresponding button on the remote is being pressed. Releasing the button releases the relay (turns it off) Toggle (Latch) mode means that separate key presses are needed to turn the relay on and off. The first press of the button turns the relay on (if it was off). The relay stays on when the button is released. Pressing the button against turns the relay off. Each button press toggles the state of the relay. Relay contacts are brought out as PCB mounted screw terminals, enabling external equipment to be controlled. The relay outputs are rated to switch up to 240VAC mains voltage. Extreme care should be taken when switching mains voltage.
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6.5 Relay Driver Relay output stage schematic using ULN2803, which is an 8 Darlington transistor array with internal base resistor and coil reverse protection diodes. Using this chip simplified driving of relays and LEDs. 1 K resistors provide current limiting to LEDs to be powered from 12V. Relay from Good Sky or HK are found suitable since it only consumed 1.6 mA when switched on. 6.6 Diodes To ensure unidirectional flow of the liquids we use mechanical valves in its path. By properly arranging these valves in a system we get useful device such as pumps and locomotives. In the field of electronics too we have called semiconductor diode for
controlling flow of electric current in one direction but we use diodes in circuits for limited purpose like converting AC to DC by passing back E.M.F. etc. A diode allows current to pass through it provided it is forward biased and the biasing voltage is more than potential barrier of the diode. All diodes are general purpose silicon or germanium diodes. 6.6.1 General characteristics 1. Case 2. Voltage Rating 3. Current Rating 4. Junction Capacitance 5. Forward Breakdown voltage 6. Forward Breakdown current 7. Switching Time 6.7 Resistors A resistor is two terminal electronic component designed to oppose an electric current by producing a voltage drop between its terminal in proportion to the current, that is in accordance with Ohms law V = IR. The resistance R is equals to the voltage drop V across the resistor divided by the current I through the resistor. SD-5 75V 75 ma 4pF 1V 10 ma 0.1 Ns
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Resistors are characterized primarily by their resistance and the power they can dissipate other characteristics include temperature coefficient, noise and inductance. Practical resistor can be made of resistive wire and various compounds and films they can be integrated into hybrid and printed circuits. Size and position of leads are relevant to equipment designers resistors must be physically large enough not to overheat when dissipating their power. Variable resistors adjustable by changing the position of a tapping on the resistive element, and resistors with a movable tap (Potentiometers), either adjustable by the user of equipment of contained within, are also used. Resistors are used as part of electrical networks and electronic circuits.
6.7.1 Color code system of Resistor is shown in below figure.
Fig.6.7.1 Resistor color code system
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6.8 IC 555
Fig. 6.8.1 IC 555 Pin 1 (Ground): Connects to the 0v power supply.
Pin2(Trigger): Detects 1/3 of rail voltage to make output HIGH. Pin 2 has control over pin 6. If pin 2 is LOW, and pin 6 LOW, output goes and stays HIGH. If pin 6 HIGH, and pin 2 goes LOW, output goes LOW while pin 2 LOW. This pin has very high impedance (about 10M) and will trigger with about 1uA.
Pin 3 (Output): (Pins 3 and 7 are "in phase.") Goes HIGH (about 2v less than rail) and LOW (about 0.5v less than 0v) and will deliver up to 200mA.
Pin 4 (Reset): Internally connected HIGH via 100k. Must be taken below 0.8v to reset the chip.
Pin 5 (Control): A voltage applied to this pin will vary the timing of the RC network (quite considerably).
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Pin 6 (Threshold): Detects 2/3 of rail voltage to make output LOW only if pin 2 is HIGH. This pin has a very high impedance (about 10M) and will trigger with about 0.2uA. Pin7(Discharge): Goes LOW when pin 6 detects 2/3 rail voltage but pin 2 must be HIGH. If pin 2 is HIGH, pin 6 can be HIGH or LOW and pin 7 remains LOW. Goes OPEN (HIGH) and stays HIGH when pin 2 detects 1/3 rail voltage (even as a LOW pulse) when pin 6 is LOW. (Pins 7 and 3 are "in phase.") Pin 7 is equal to pin 3 but pin 7 does not go high - it goes OPEN. But it goes LOW and will sink about 200mA. Pin 8 (Supply): Connects to the positive power supply (Vs). This can be any voltage between 4.5V and 15V DC, but is commonly 5V DC when working with digital ICs. The 555 monolithic timing circuits is a highly stable controller capable of producing accurate time delays, or oscillation. In the time delay mode of operation, the time is precisely controlled by one external resistor and capacitor. For a stable operation as an oscillator, the free running frequency and the duty cycle are both accurately controlled with two external resistors and one capacitor. The circuit may be triggered and reset on falling waveforms, and the output structure can source or sink up to 200mA.
Inside the 555 timer chip or what makes it work. Well, the 555 timer chip an Integrated Circuit (IC) and therefore it contains a miniaturized circuit surrounded by silicon. Each of the pins is connected to the circuit which consists of over 20 transistors, 2 diodes and 15 resistors.
Fig.6.8.2 IC555 inside
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FEATURES: Turn-off time less than 2s Max. Operating frequency greater than 500 kHz Timing from microseconds to hours Operates in both a stable and monostable modes High output current Adjustable duty cycle TTL compatible Temperature stability of 0.005% per C
APPLICATIONS: Precision timing Pulse generation Sequential timing Time delay generation Pulse width modulation
6.9 Capacitor Any arrangement of two conductors separated by an electric insulator (i.e. dielectric) is a capacitor. An electric charge deposited on one of the conductors induces an equal charge of opposite polarity on the other conductor. As a result, an electric field exists between the two conductor surfaces and there is a potential difference between them. The electric field anywhere between the conductor surfaces is directly proportional to the magnitude of the charge Q on the conductors. And the potential difference V is also directly proportional to the charge Q. The ratio Q/V is thus a constant for any electric field distribution as determined by the shape of the conductors, the distance of separation, and the dielectric in which the field exists.
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The ratio Q/V is called the capacitance, C, of a particular arrangement of conductors and dielectric. Thus, C = Q/V, Where, Q and V are in units of coulomb and volt. C has the units Farad (F)
The simple theoretical expression for the capacitance value of a parallel plate capacitor is where, A = plate area [m2] = cross section of electric field, d = distance between plates [m], o = permittivity of free space = 8.854 x 10-12 F/m and r = relative permittivity of the dielectric between the plates [dimension less].
This calculated value is based on the assumption that the charge density on the plates is uniformly distributed. In practice there is always a concentration of charge along the edges. This charge concentration is at the sharp corners of the plates. Thus for a given voltage, the actual total charge is always greater than the theoretical total charge.
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CHAPTER NO 07 CONVEYOR SYSTEM A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. Many kinds of conveying systems are available, and are used according to the various needs of different industries. There are chain conveyors (floor and overhead) as well Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys .
Fig.7.1 Simple conveyor Industries that use conveyor systems: Conveyor systems are used widespread across a range of industries due to the numerous benefits they provide.
Conveyors are able to safely transport materials from one level to another, which when done by human labor would be strenuous and expensive.
They can be installed almost anywhere, and are much safer than using a forklift or other machine to move materials.
They can move loads of all shapes, sizes and weights. Also, many have advanced safety features that help prevent accidents.
There are a variety of options available for running conveying systems, including the hydraulic, mechanical and fully automated systems, which are equipped to fit individual needs.
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Conveyor systems are commonly used in many industries, including the automotive, agricultural, computer, electronic, food processing, aerospace, pharmaceutical, chemical, bottling and canning, print finishing and packaging. Although a wide variety of materials can be conveyed, some of the most common include food items such as beans and nuts, bottles and cans, automotive components, scrap metal, pills and powders, wood and furniture and grain and animal feed. Many factors are important in the accurate selection of a conveyor system. It is important to know how the conveyor system will be used beforehand. Some individual areas that are helpful to consider are the required conveyor operations, such as transportation, accumulation and sorting, the material sizes, weights and shapes and where the loading and pickup points need to be. A conveyor belt (or belt conveyor) consists of two or more pulleys, with a continuous loop of material - the conveyor belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler. There are two main industrial classes of belt conveyors; those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport industrial and agricultural materials, such as grain, coal, ores, fines, and lumps material. Today there are different types of conveyor belts that have been created for conveying different kinds of material available in PVC and rubber materials. The belt consists of one or more layers of material. They can be made out of rubber. Many belts in general material handling have two layers. An under layer of material to provide linear strength and shape called a carcass and an over layer called the cover. The carcass is often a woven fabric having a warp & weft. The most common carcass materials are polyester, nylon and cotton. The cover is often various rubber or plastic compounds specified by use of the belt. Covers can be made from more exotic materials for unusual applications such as silicone for heat or gum rubber when traction is essential. Material flowing over the belt may be weighed in transit using a belt weighed. Belts with regularly spaced partitions, known as elevator belts, are used for transporting loose materials up steep inclines. Belt Conveyors are used in self-unloading bulk freighters and in live bottom trucks. Conveyor technology is also used in conveyor transport such as moving
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sidewalks or escalators, as well as on many manufacturing assembly lines. Stores often have conveyor belts at the check-out counter to move shopping items. Ski areas also use conveyor belts to transport skiers up the hill. A wide variety of related conveying machines are available, different as regards principle of operation, means and direction of conveyance, including screw conveyors, vibrating conveyors, pneumatic conveyors, the moving floor system, which uses reciprocating slats to move cargo, and roller conveyor system, which uses a series of powered rollers to convey boxes or pallets.
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CHAPTER NO 08 POWER SUPPLY In this project we use power supply from battery. Below gives details of battery The use of sealed lead acid batteries has been increasing steadily due to the low prices versus capacity combined with ease of use. However, it is critical that storage, charging and discharging requirements are adhered to so as to avoid failure of the product. Charging: The ideal charger for these batteries is the constant voltage type where a voltage of between 13.50 and 13.80 volts is maintained across the terminals with an initial current limit of 0.2C (where C is the capacity of the battery, hence this value is 1.4A for the 12V 7.0 Ah battery). Remember to observe polarity when charging. The Securi-Prod Part No. PS04 is a suitable charger for the 12V 1.3 Ah battery
Discharging: The discharge capacity of a battery varies and is dependant on the discharge current. The rated capacity as represented on the product is the 20 hour rate i.e. the capacity of the battery discharged for 20 hours to a final voltage of 10.50 volts at a temperature of 25C (in other words 250mA for a 12V 7.0 Ah battery).
Short circuiting: All effort should be made to avoid short circuiting the battery.
Deep discharge: Securi-Prod batteries are recoverable if deep discharged, ie. Below 10.5V, but this practice should be avoided as there is a measure of loss each time this occurs.
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Installation and mounting: When installing a battery into housing ensure adequate ventilation. Whilst the battery is sealed, a certain amount of acid fumes are emitted which may cause a minimal amount of corrosion to PC boards.
Fig. 8.1 CAD-CAM diagram of Lead-Acid battery The power supply unit provides four voltage levels for the robot control. The dc motor requires 12Vdc, the TTL ICs require 5Vdc, and -12Vdc was provided in anticipation of possible need of signal amplification with an operational amplifier. The ac voltage from the mains is stepped down by a centre tapped transformer. The low voltage ac is converted to dc by a bridge rectifier, filtered by capacitors and passed through appropriate voltage regulator ICs to obtain the required dc voltage levels. The 7815, 7812, 7805 and 7912 voltage regulators were used to obtain regulated outputs of 15V, 12V, 5V and -12V dc, respectively.
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Positive plates: Positive plates are plate electrodes of which a grid frame of lead-tin-calcium alloy holds porous lead dioxide as the active material.
Negative plates: Negative plates are plate electrodes of which a grid frame of lead-tin-calcium alloy holds spongy lead as the active material.
Electrolyte: Diluted sulphuric acid is used as the medium for conducting ions in the electrochemical reaction in the battery.
Separators: Separators, which retain electrolyte and prevent shorting between positive and negative plates, adopt a non-woven fabric of fine glass fibbers which is chemically stable in the diluted sulphuric acid electrolyte. Being highly porous, separators retain electrolyte for the reaction of active materials in the plates.
Valve (One way valve): The valve is comprised of a one-way valve made of material such as neoprene. When gas is generated in the battery under extreme overcharge condition due to erroneous charging, charger malfunctions or other abnormalities, the vent valve opens to release excessive pressure in the battery and maintain the gas pressure within specific range (7.1 to 43.6 kPa). During ordinary use of the battery, the vent valve is closed to shut out outside air and prevent oxygen in the air from reacting with the active material in the negative electrodes.
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Positive and negative electrode terminals: Positive and negative electrode terminals may be fasten tab type, bolt fastening type, threaded post type, or lead wire type, depending on the type of the battery. Sealing of the terminal is achieved by a structure which secures long adhesive-embedded paths and by the adoption of strong epoxy adhesives. For specific dimensions and shapes of terminals, see page 70. Battery case materials: Materials of the body and cover of the battery case are ABS resins, unless otherwise specified.
Fig.8.2 Construction of battery Chemical Reaction of Battery as follow
Fig.8.3 Chemical reaction
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CHAPTER NO 09 CONCLUSION The project was time-consuming, work-intensive and economically tasking. However, we are proud as a group to have achieved for the first time, the control of a 6degree of freedom robotic arm The possibilities are endless. Robotics is a relatively untapped field in Nigeria and it has many prospects. Starting with our community, we can, step by step, create robots that will ultimately be used to perform some pertinent tasks that are too bothersome for human beings. The fact that it also combines various disciplines of engineering is also notable. Control can be improved by using a remote control to manipulate the robot instead of devoting a whole wireless system to it. The use of printed circuit boards (PCB) to do the circuits. This reduces the errors due to faulty connections and wiring usually found on other boards. Use of DC motor at the base the output torque of the DC motor is higher than that of the stepper motors. Using DC motor at this joint brought us a step closer to solving the problem of insufficient torque to carry the arm. The weights of all the motors were put into consideration when calculating the torque at each joint. This is to make sure the gears are arranged in a way that will produce enough torque to carry the succeeding load. Starting with our community, we can, step by step, create robots that will ultimately be used to perform some pertinent tasks that are too bothersome for human beings. The fact that it also combines various disciplines of engineering is also notable.
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CHAPTER NO 10 FUTURE DEVELOPMENT Mobility and navigation: future robots will be mobile, able to move under their own power and navigation systems. Universal gripper: robot gripper design will be more sophisticated, and universal hands capable of multiple tasks will be available. Systems integration and networking: robots of the future will be user friendly and capable of being interfaced and networked with other systems in the factory to achieve a very high level of integration. Sensors: Future work that can be performed on this mechanical arm includes adding sensors. These could include sonar range finder, or even an experimental smell detector. This would allow automation of the entire robot Specify End-effecter Position: Additionally, and more specifically for the mechanical arm, future work could involve solving the inverse kinematic equations for all degrees of freedom in the arm. This would allow the user or an automated intelligent program utilizing sensors to specify a position and orientation that the hand should be in. All the angles of rotation for each motor and servo would be automatically calculated and moved to that position. Image processing: Image processing would be an essential upgrade with vision sensors so that the incoming data could be interpreted properly. Intelligent processing would allow more accurate readings and would provide optimized responses. Increasing the degrees of freedom of the robotic arm by implanting more servos motors. Artificial Intelligence Perhaps the most dramatic changes in future robots will arise from their increasing ability to reason. The field of artificial intelligence is moving rapidly from university laboratories to practical application in industry, and machines are being developed that can perform cognitive tasks, such as strategic planning and learning from experience. Increasingly, diagnosis of failures in aircraft or satellites, the management of a battlefield, or the control of a large factory will be performed by intelligent computers. Like the term "robot" itself, artificial intelligence is hard to define. Ultimate AI would be a
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recreation of the human thought process -- a man-made machine with our intellectual abilities. This would include the ability to learn just about anything, the ability to reason, the ability to use language and the ability to formulate original ideas. Robotics are nowhere near achieving this level of artificial intelligence, but they have had made a lot of progress with more limited AI. Today's AI machines can replicate some specific elements of intellectual ability. Virtual Travel - People will be able to visit each other without traveling. They will do this by taking control of a robot at their desired vacation destination, and use the Internet to transmit all the sensory information back and forth. What will this mean? Doctors will make "house calls" again. Long distance relationships will never be the same. Families spread across the globe can play games together. And perhaps most importantly, people will think nothing of having a satisfying conversation with a mechanical contraption made of aluminum, plastic, and silicon Housekeeping by Choice: The physical environments we live in will take care of themselves. Machines will do the routine chores around the house. We will choose when it is time for the extraordinary. Our houses and apartments will keep themselves swept and scrubbed clean. There will be no piles of laundry, and your basic dinner will be moments away. Machines will not have replaced us. But they will give us the opportunity to build on the routine and create the unusual, brilliant, or just different. Robots will raise the standard upon which we will build. They will give us a chance to dream and the time to live life to the fullest Artificial Intelligence: Perhaps the most dramatic changes in future robots will arise from their increasing ability to reason. The field of artificial intelligence is moving rapidly from university laboratories to practical application in industry, and machines are being developed that can perform cognitive tasks, such as strategic planning and learning from experience. Increasingly, diagnosis of failures in aircraft or satellites, the management of a battlefield, or the control of a large factory will be performed by intelligent computers. Like the term "robot" itself, artificial intelligence is hard to define. Ultimate AI would be a recreation of the human thought process -- a man-made machine with our intellectual abilities. This would include the ability to learn just about anything, the ability to reason, the ability to use language and the ability to formulate original ideas
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CHAPTER NO 11 COST ESTIMATE No. 01 02 Name of Elements Robotic arm body Battery Material Standard 12 V 9V 03 04 05 06 Gear Conveyor wheels Conveyor belt DC Motors Plastic Standard Standard 200 rpm 3.5 rpm 1200 rpm 07 08 09 10 11 12 13 14 15 Soldering gun Camera Relay RF Transmitter RF Receiver Resistors Capacitors Screw Serial ports (pin connectors) 16 17 18 19 20 21 22 23 LEDs Connection wire Control switches IC 555 Solder wire Base (chassis) Workshop charges Travelling Standard Standard Standard Standard Standard Standard --10 9 feet 02 01 01 01 --Total (Rs.) 50 200 50 700 20 150 1000 2000 18210.00 Standard Standard Standard Standard Standard Standard Standard Standard Standard Qty. Of parts 01 01 01 08 02 01 01 01 05 01 01 08 01 01 15 15 50 02 Cost (in Rs) 3500 650 150 240 50 80 250 380 1000 200 2200 95 2500 2500 25 20 50 150
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CHAPTER NO 12 REFERENCES 1. L. Feng, J. Borenstein, D. Wehe A Completely Wireless Development System for Mobile Robots, Proceedings of the ISRAM Conference, Montpellier, France, May 27-30, 1996, pp. 571-576 2. Dragos Mihai POSTELNICESCU, Constantin NEGRESCU, WIRELESS
CONTROL OF MOBILE ROBOTS. UPB Sci. Bull., Series C Vol. 70, No. 2, 2008, ISSN 1454-234x 3. George M. Calhoun Third Generation Wireless Systems, Ed. Artech House, Inc., 2003 4. Dr. S. Bhargavi, S.J.C.I.T., Design of an Intelligent Combat Robot for war fields, (IJACSA) International Journal of Advanced Computer Science and Applications, Vol. 2, No. 8, 2011 5. M. A. Meor Said, M.A.Othman, M. M. Ismail, H. A. Sulaiman, M. H. Misran, Z.A. Mohd Yusof, Wireless Controlled Omnidirectional Monitoring Robot With Video Support, International Journal of Engineering Research and Applications
(IJERA) ISSN: 2248-9622, Vol. 2, Issue4, July-august 2012, pp.2228-2232. 6. Yoshikazu K., Takayuki K., Yasuyuki S., Kiyoshi K., and Hiroshi I., An Approach to Integrating an Interactive Guide Robot with Ubiqu itous Sensors, In the Procee dings of the IEEE/RSJ Interna tional Conference on Intelligent Robots and Systems (IROS), pp. 2500-2505,2004 7. Bahaa Ibraheem Kazem, Ali Ibrahim Mahdi and Ali Talib Oudah, Motion Planning for a Robot Arm by Using Genetic Algorithm, Jordan Journal of Mechanical and Industrial Engineering, Volume 2, Number 3,Sep. 2008 ISSN 1995-6665 Pages 131 136. 8. Chun Htoo Aung, Khin Thandar Lwin, and Yin Mon Myint, Modeling Motion Control System for Motorized Robot Arm using MATLAB, World Academy of Science, Engineering and Technology 18 2008
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CHAPTER NO 13 OPERATION AND FLOW CHART OF PROJECT Order of operation for project creation:
Fig.13.1 Order of operation for project creation
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Flow Chart of project working:
Fig.13.2 Flow Chart
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CHAPTER NO 14 CAD CAM DRAWING OF ROBOTIC ARM
CAD CAM drawing of robotic arm:
Fig.14.1 CAD CAM diagram of robotic arm
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Description of Robotic arm:
NO
No. Of parts
Description
Material
Dimension
J H
1 1
WRIST JOINT MOTOR ELBOW JOINT MOTOR SHOULDER JOINT MOTOR THE GRIPPER THE WRIST THE FORE ARM THE UPPER ARM THE SHOULDER THE WAIST
DC motor DC motor
87mNm 155mNm
DC motor
155mNm
F E D C B A
1 1 1 1 1 1
Plastic Plastic Plastic Plastic Plastic Plastic
100150 250440 250500 400500 480550 310710
Table 14.1 Robotic arm description
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CHAPTER NO 15 CIRCUIT DIAGRAM
Power supply unit:

Q4
TIP125
TR1 MAINS
220V/240V 50/60Hz
BR1
KBP2086
U17 R8
10k 7815 1 VI D N G 2 VO 3
(D.C. Motor Line)
C12
TRAN-2P3S 100uF
C13
100uF
(35V)
(25V)
U18
7812 1 VI D N G 2 VO 3
(Stepper Motor Line) 1

2 3 4
J1 A B C D
CONN-SIL4
C14
100uF
(16V)
J2
1 2 3 4
GND
CONN-SIL4
U19
7805 1 VI D N G 2 VO 3
(IC Line)
C15
100uF
OUTPUT SPECIFICATIONS
(10V)
U20
7912 2 VI D N G VO 3
(-ve Voltage Line)
A: +15V, 3.75A
C16
B: +12V, 1.35A C: +5V, 1.35A D: -12V, 1.35A
100uF
C17
100uF
(35V)
16V
Fig.15.1 The Power supply unit
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Transmitter:
Fig.15.2 Circuit diagram of Transmitter
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Receiver:
Fig.15.3 Receiver circuit diagram
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CHAPTER NO 16 PICTURES OF ROBOTIC SOLDERING ARM
Image 1: Robotic arm and Conveyor Belt
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CHAPTER NO.1 INTRODUCTION