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Project Report On
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
VISVESVARAYA TECHNOLOGICAL UNIVERSITY
BELGAUM
Submitted by
RAMA CHANDRA :1MV05ME085
LAKSHMAN R. RAJU :1MV05ME050
GIRISH H.N. :1MV05ME029
CHIRAG D.SONI :1MV05ME021
CERTIFICATE
This is to certify that the project work entitled “PICK AND PLACE ROBOT”
been submitted by RAMA CHANDRA (1MV05ME085), LAKSHMAN R RAJU
(1MV05ME50),GIRISH H.N. (1MV05ME029) AND CHIRAG D. SONI
(1MV05ME021) in partial fulfillment for the award of BACHELORS IN
MECHANICAL ENGINEERING by VISVESVARAYA TECHNOLOGICAL
UNIVERSITY , Belgaum, during the year 2008-2009.It is certified that all
corrections/suggestions indicated for internal assessment have been incorporated in the
report deposited in the department library. The project report has been approved as it
satisfies the academic requirements in respect to the project work prescribed for the
Bachelor of Engineering Degree.
Sir.M.V.I.T, Bangalore
1)___________________
2)___________________
ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task would be
incomplete without the mention of people who made it possible. It is their constant
guidance and encouragement that crowns all our effort with success.
We would like to mention our special thanks to all the teaching and technical staff
members of department of Mechanical Engineering, Sir MVIT, who helped us directly or
indirectly during the project work.
With a pressing need for increased productivity and the delivery of end products of
uniform quality, industry is turning more and more towards computer-based automation.
The industrial applications and atmospheres are diverse in nature, frequent, complex,
non-reachable or harmful to human beings. In all these cases the robot can be an
alternative to human hands.
The project is aimed to build a Pick and place robot, which can lift a payload of 200
grams to a maximum of 1 kilogram. It’s a third generation robot that provides fast,
efficient sample handling. Robot is a fully programmable robot with a mobile base.
Pick and Place Robot
INDEX
TITLE/CONTENT PAGE NO.
1. INTRODUCTION 1
1.1 What is a Robot? 2
1.2 Asimov’s Laws of Robotics 2
1.3 Robotics in science fiction 3
1.4 History 4
2. Fundamentals of Robot Technology 5
2.1 Robot anatomy 6
2.2 Classification of Robots 7
2.3 Robot Configuration 8
2.4 Components of a Robot 10
2.41 Manipulator 10
2.42 Actuators and drive 11
2.43 End effecter 12
2.44 Sensors 12
2.45 Controllers 13
2.46 Software 13
2.5 Some Terminologies 14
2.6 Specifications 15
3. DESIGN 16
3.1 Requirements 17
3.11 The ROBOT must be as LIGHT as possible 19
3.12 Determination of section thickness 20
3.2 Design a simple mechanism 21
8. References 59
8.1References 60
List of figures
TITLE PAGE NO.
Chapter 2
Robot manipulator
Fig (2.1) 6
Robot configurations
Revolute joints
Fig (2.7) 11
Fig (2.8) 11
Fig (2.9) 11
End effectors
Fig (2.13) 12
Fig (2.14) 12
Fig (2.15) 12
Chapter3
Fig (3.2) 20
Fig (3.3) 20
Fig (3.4) 21
Chapter 4
Fig (4.6) 39
Fig (4.7) 39
Chapter 5
INTRODUCTION
Chapter 1
INTRODUCTION
The term robot derives from the Czech word robota, meaning forced work or compulsory
service, or robotnik, meaning serf.
First used to describe fabricated workers in a fictional 1920s play called Rossum’s Universal
Robots by Czech author Karel Capek.
Definitions
“An automatic device that performs functions normally ascribed to humans or a machine
in the form of a human.”
-Webster’s Dictionary
A robot may not injure a human being, or, through inaction, allow a human being to come
to harm
A robot must obey orders given it by human beings, except where such orders would
conflict with the First Law.
A robot must protect its own existence as long as such protection does not conflict with
the First or Second Law.
Following the early instances of robots in plays and science fiction stories ,
robots then started to appear on television shows, like Lost in Space and then in
Hollywood movies.
In Lost in Space the robot demonstrated human characteristics such as feelings
and emotions.
Scientists today are still a long way off from programming robots which can
think and act like humans.
1.4 History
Science fiction has no doubt contributed to the developments of robotics, by planting ideas
in minds of young people who might embark on careers in robotics, and by creating awareness
among the public about this technology. We should also identify certain technological
developments over the years that have contributed to the substance of robotics.
The below table presents a chronological listing which summarizes the historical developments
in the technology of robotics.
Chapter 2
Fundamentals of Robot Technology
Robot anatomy is concerned with the physical contraction of the body, arm, and wrist of the
machine. The body is attached to the base and the arm assembly is attached to the body. At the
end of the arm is the wrist. The wrist consists of a number of components that allow it to be
oriented in a series of joints. The body, arm and wrist assembly is sometimes called the
manipulator.
1. Degrees of freedom
2. Kinematic structure
– Parallel (closed)
– Hybrid
3. Drive technology
5. Motion characteristics
– Planar
– Spherical
– Spatial
6. Control method
– Point-to-point
– Continuous path
Prismatic (P)
Revolute (R)
Spherical (S)
Robot configurations:
– Cartesian/rectangular/gantry (PPP)
– Cylindrical (RPP)
– Spherical (RRP)
– Articulated/anthropomorphic (RRR)–
–
Fig (2.2) Fig(2.3)
Fig(2.4) Fig(2.5)
Fig (2.6)
Manipulator (arm)
– Hydraulics
– Pneumatics
– Gearbox
Software
Base
- Fixed
2.41 Manipulator
Is the main body of the robot and consists of links, the joints and other structural elements.
Relative motion permitted by a joint is governed by form of contact surfaces between the
members
Revolute joints
Common types
• Servomotors – power driven mechanism that help main controller operates using low force
Hydraulic cylinders – moved by, or operated by a fluid, especially water, under pressure.
In most cases the action of the end effecter is either controlled by the robot’s controller or the
controller communicates with the end effectors controlling device
The end effectors may be: a Gripper, Suction/Vacuum, Glue, Hooks, Rack and Pinion, Screw
and Fastener Devices
2.44 Sensors
Sensors are used to collect information about the internal state if the robot to communicate with
outside environment. Sensors that tell the robot position/change of joints: odometers, speedometers,
etc.Force sensing. Enables compliant motion—robot just maintains contact with object. Sensors used
in robotics are tactile sensors or nontactile sensors; proximity or range sensors; contact or non contact
sensors, or a vision system. For manipulator motion control, joint-link positions, velocities, torques,
or forces are required to be sensed.
Table 2
2.45 Controllers
2.46 Software
Work volume:
It is the term that refers to the space with in which the robot can manipulate its wrist end. The
convection of using the wrist end to define the robots work volume is adopted to avoid the
complication of different sizes of end effectors that might be attached to the robot wrist.
The work volume is determined by the following physical characteristics of the robot:
• The robot’s physical configuration.
• The sizes of the body, arm and wrist components.
• The limits of the robot joint movements.
Accuracy:
It is the robots ability to position its wrist end at a desired target point within the work
volume.
Repeatability:
The ability to position its wrist or an end effectors attached to its wrist at a point in space
that had previously been taught to the robot.
2.6 Specifications
DESIGN
Chapter 3
DESIGN
The robot design is the most important part in the process of constructing the robot. Here we
develop new ideas for the construction of the robot and express these ideas in the form of plans and
drawings.
Material selection
Design of mechanism
Preliminary design
Revision of design
Final drawings
3.1 REQUIREMENTS
The mechanism must be simple such that the manufacturing process is simplified.
Since we want the robotic arm to be as light as possible we have chosen aluminum as material for
this robot.
PROPERTIES OF ALUMINIUM
DENSITY
Light weight is perhaps aluminum’s best known characteristic and with a density of 2.7 x 103
kg/m3 is approximately 35% that of steel. This feature together with other characteristics such as
corrosion resistance and tensile strength has led to it replacing steel in many applications.
TENSILE STRENGTH
Commercially pure aluminum has a tensile strength of approximately 90MPa and can be
improved to around 180MPa by cold working. The heat treatable grades can develop a tensile
strength of around 570MPa and even higher in some alloys (7001). This figure compares favorably
with mild steel which has a tensile strength of approximately 260MPa.
CORROSION RESISTANCE
Aluminum has a good resistance to corrosion. This is attributable to a thin oxide film which
forms and protects the metal from further oxidation: unless exposed to some substance or condition
which destroys this protective coating the metal remains protected from corrosion.
The arm is designed to withstand forces generated due to own body weight, object weight, forces
due to velocity and centrifugal forces.
Fig 3.1
Free body diagram
After making the preliminary drawings of each link, the weight of the link is calculated by
ρ=M/V
M is the mass in kg
V is the volume in m3
60
200 200
Mb = F*e
= 29.4*200
= 5880N-mm
I = (b*d^3)/12
= (b*60^3)/12
= 29.4/(60*b) + (5880*30)/((b*60^3)/12)
b = .571mm
200 200
Payload = 2*9.81
200
100
Fig (3.4)
= 9195.5 N-mm
= 24.52/A
= 15.47/b.
Working stress = Total stress/FOS (Where FOS stands for factor of safety)
b = 0.874 ~ 0.9mm
To reduce the design procedure for calculating inertia forces and forces due to change in
velocity we use spacers. Spacers not only help in withstanding these forces, but also provide
rigidity for the robotic arm.
To reduce the manufacturing work we are fixing the arm to the shaft by means of fastening,
otherwise we have to use keys and slots to fix the shaft to the arm which consumes lot of time in
designing the keys and slots. We designed the robot to work using simple chain drives. The chain
drives are from automobile engines. Using these chains also reduces the cost of the chain drive and
also these chains operate silently.
Preliminary drawings of all the parts are made. An inventor model of the robot with all the links
is prepared, which gives insight of how the arm is to be assembled and how the arm looks after the
assembly.
These drawings are subject to changes in manufacturing process depending on the availability of
the materials.
The entire design is reviewed for defects; suitable corrections are made to suit the requirement.
The design can be changed as per the torque requirement. Referring to the fig 1 the torque required
is calculated as shown below
T3=W7*L3+ (W6*L3)/2+M3*L4+M2*L5
=9.81*0.2+ (0.4*0.2)/2+0.2*0.1+0.2*.05
=2.005 N-m
=(0.2+0.2)*9.81+(0.2+0.1)0.4+(.4*.2)/2+0.2(0.2+0.1)+0.2*(0.2+0.05)
= 4.194 N-m
(L1+L2+L5)*M1+ (W2*L1)/2
= (0.2+0.2+0.1)*9.81+(0.2+0.2+0.1)*0.4+(0.2+0.1)0.4+(0.2+0.2+.1)*0.2+
(0.2+0.2+0.05)*0.2+ (0.4*0.2)/2
=5.455 N-m
By referring the above equations we can see that the torque required is a function of weight of the
links, weight of the motor, length of the link. The design can be altered if torque requirement is very
high, the length can be minimized to reduce the torque requirement.
As per the requirements the design is changed and final drawing is made. These drawings are taken
to the workshop to manufacture various parts which are then assembled as per the inventor model.
From all the above gripper mechanisms we are adopting power screw mechanisms because of
its strong holding property, simple mechanism hence easy to construct and it is cost efficient.
The force required to grip an object is to be calculated. Here a small illustration is shown,
where the robot is supposed to grip an object and that object is a human neck in this case.
There are two kinds of friction coefficients that are to be taken into consideration they are
1) Static friction
2) Kinetic friction
The kinetic coefficient of friction is when the materials are already in motion
Since our robot is used to move only stationary objects, we are considering only static
friction.
Table 3
The robotic arm is placed over the mobile base. The mobile base gives additional two more
degrees of freedom to the arm. The base is made up of aluminum to reduce the weight of the
robot.
1) Aluminum frame
3) Aluminum shaft
4) Aluminum pulleys
5) Drive motors
6) Chain drive
3.41 Frame
The frame of the robot is the basic structure to which we attach everything else. It is
probably the largest part of the robot, so we make sure it is made of a light weight rigid
material such as aluminum.
Aluminum plates are attached to the frame, which forms the body of the mobile base. The
plates must house the bearings in which the shafts are housed and also it houses the
motor, which drives the shafts.
We wanted to mobile base to appear like a tanker, so we have used belt drives to give the
tank look. We have used teethed belt for this purpose. This belt has better traction
capacity as compared to normal flat belts.
The shaft and pulleys are made up of aluminum to reduce the weight. The pulleys are
given toothed profile to grip the belt properly and prevent it from slipping.
Wheel diameter: When making the wheels we want to put our motor into consideration.
For a start, there is torque and velocity. Large diameter wheels give the robot low torque
but high velocity. Since we already have a very strong motor, we can use wheels with
larger diameters. Lower diameter wheels have low velocity but high torque.
While selecting the diameter of the pulley we also had to check frame width and the
ground clearance.
Manufacturing
Chapter 4
Manufacturing
Some of the important factors to be considered are:
1. Shape to be produced
2. Type of material
6. Dimensional tolerance
7. Economic considerations
1. Major base.
2. Minor base.
3. Chest/casing.
4. Arm1 (Tapered).
5. Arm2 (I-shape)
6. Long Shaft.
7. Moderate shaft.
8. Short shaft.
9. H-type bush.
12. Spacers.
• Metal cutting
Slot creation
Using the vertical milling machine and the end milling cutter the hole was made .
To fix both casings/chest as per the design center punch was marked at the required
dimensions and using 5.1mm drill bit holes were drilled as shown in the previous slide.
4.3 Casings/chest
Using hand shear, aluminum plate was cut for required size of casings.
• After obtaining the size for casing the aluminum plate was subjected to bench press to
obtain “L”-shape as shown in previous slides
• To fix both casings/chest as per the design center punch was marked at the required
dimensions and using 6 mm drill bit holes were drilled as shown in the previous slide
• According to the dimension of the shaft of the motor marking was made on the casing
plate and hole for shaft diameter was drilled and using the round file the finishing was
obtained.
• With respect to center of the thus drilled hole the PCD hole marking were made and was
drilled accordingly.
• To connect the casings using shaft and bearing arrangement a hole was drilled to
diameter of step bearing.
• As per the design markings were made on the aluminum plate and using hand shear the
plate was cut on the marking.
• To obtain the proper finishing on the cut surface grinding was done using the portable
hand grinding machine.
• To connect this arm to casing via bearing and shaft, holes were drilled as per the
dimension of the bearing and to fix the bush to the arm through fasteners countersunk
holes were created at the surface as shown in the previous slides.
• To connect this tapered arm to arm2 (I-shape) one more hole is drilled at the other end of
the arm which is according to the dimensions of the arrangement of “moderate sized shaft
and step bearing”.
• As per the design markings were made on the aluminum plate and using hand shear the
plate was cut ton the marking
• To connect this arm to arm1 (tapered) via bearing and shaft, holes were drilled as per the
dimension of the bearing and to fix the bush to the arm through fasteners countersunk
holes were created at the surface as shown in the previous slides.
• After obtaining the “I” shape to connect both the arms through the “short shaft &
bearing” arrangement, holes of the required size were drilled accordingly.
• The holes were filed using the round file to obtain the smooth radial finish.
• It was so finished such that it fits into the bearing, situated in the casing rigidly.
• Similarly other two shafts “MODERATE SHAFT & SHORT SHAFT” of the required
dimensions were machined to connect the arm1 & arm2 respectively.
Step Bush
• An aluminum rod of dimension greater than the requirement was obtained, and required
length was cut to make the bushes
• In the robot Shape of bush is h type so as to insert 2 bearings at both side of it which will
allow free movement of sprockets on the shaft to complete sprocket chain mechanism.
• Higher accuracy was required in the machining of this bush as otherwise lead to
misalignment and would not support the bearing and sprocket properly.
• PCD holes were then drilled to fix the driving sprocket to the bush and a radial hole was
drilled to ground the bush on longest shaft.
• An aluminum rod of dimension greater than the requirement was obtained, and required
length was cut to make the bushes
• In the robot Shape of bush is step type so as to fix the arm1 to casing and further to join
arm1 to arm 2 and support them on the shaft
• One more application of the step bush is to support the driven sprocket fixed on
moderate shaft so as to drive the arm2.
• Higher accuracy was required in the machining of even this bush as otherwise lead to
misalignment and would not support the arms and casing on respective shafts.
• PCD holes were then drilled to fix the driven sprocket to the one of the step bushes and
also to attach them to end of arms and casings.
4.7 Spacers
An aluminum rod of square cross section and dimension greater than the requirement was
obtained, and required length was cut to make the spacer
• Using Hacksaw the aluminum rod was cut to the required size providing certain
tolerance on both the sides.
• Since perfect flat surface is required at the ends the, spacers were machined using
“universal milling machine”.
Drilling
• To fix spacers as per the design center punch was marked at the required
dimensions and using 4 mm drill bit holes were drilled
Need of spacers
Spacer is an element which is used to maintain uniform distance between two plates
Use of spacers in between two plates prevents from bending due to inertia forces
generated due to movement of arm.
• Then it’s fastened rigidly to the major base which consisting of robotic arm.
• Gear cutting operation is used for the manufacturing of pulley according to number of
teeth and other considerations.
• Depending on the number of teeth and centre distance the belt which rotates along the
pulley is purchased
• Machining of the casing is done so that the motor can be attached to it.
• Sprocket and chain mechanism is used to transfer the power of motor to the shaft and
rotating the pulley.
Collar bearing
Thrust bearing
2. Sprockets
3. Timing chain
4. Pulley
5. Belt
6. Fasteners
Controller
Chapter 5
Controllers
5.1 INTRODUCTION
A micro controller is a microcomputer on a single chip I.e., it is a integration micro process
with memory and input/output interfaces (ports) and other peripherals such as timer etc on a
single chip.
They are programmable, cheap, small, can handle abuse, require almost zero power, and there
are so many varieties to suit every need. This is what makes them so useful for robotics - they are
like tiny affordable computers that you can put right onto the robot.
• The three dimensional objects with different physical properties are to be manipulated.
• The processing and the analysis of the digital data from sensors and vision system have to
be done in real time.
5.21 Transistors
A transistor is a semiconductor device commonly used to amplify or switch electronic
signals. A transistor is made of a solid piece of a semiconductor material, with at least three
terminals for connection to an external circuit. A voltage or current applied to one pair of the
transistor's terminals changes the current flowing through another pair of terminals.
There is variety of transistors available in the market, but the transistor we have selected
for our microcontroller is a MOFSET transistor. The metal–oxide–semiconductor field-effect
transistor (MOSFET, MOS-FET, or MOS FET) is a device used to amplify or switch electronic
signals.
5.23 Relays
A simple electromagnetic relay, is an adaptation of an electromagnet. It consists of a coil
of wire surrounding a soft iron core, an iron yoke, which provides a low reluctance path for
magnetic flux. Relays are used to control the motor speed.
Working principle
When an electric current is passed through the coil, the resulting magnetic field attracts the
armature, and the consequent movement of the movable contact or contacts either makes or
breaks a connection with a fixed contact.
The type relay used in our microcontroller is Pole and throw type relay.
DPDT - Double Pole Double Throw. These have two rows of change-over terminals.
Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has eight
terminals, including the coil.
In this robot the relays are used to control the speed of the motor.
The push button switches are the means by which we control the robot motion. By pressing a
particular switch a motor is activated and the motion is provided to the respective part of the
robot. The motion can be provided to a joint or a wheel of the robot.
The device is manufactured using Atmel’s high density nonvolatile memory technology.
The Onchip ISP Flash allows the program memory to be reprogrammed in-system through an
SPI serial interface, by a conventional nonvolatile memory programmer, or by an On-chip Boot
program running on the AVR core. The boot program can use any interface to download the
application
Motor circuit
Chapter 6
Machine Loading/Unloading
Assembly
Inspection/Testing
6.2 Advantages
• Flexibility is more.
• Track mechanism of the mobile base provides simple steering system and can be
Chapter 7
CONCLUSION
FUTURE SCOPE
Since our robot has majorly two applications such as “pick and place” and “moveable”.
DEVELOPMENT
By the use of different kinds of end effectors we can make the robot to perform variety of
operation. Example drilling spray painting, fastening, spot welding etc.
By modifying the present program we can achieve flexible controlling of the robot.
Since the robot uses track configuration for movement it can used in all types of terrains.
Therefore it can be used for excavation.
REFRENCES
CHAPTER 8
REFERENCES
• www.robotics.org
• www.lynxmotion.com
• www.societyofrobots.com
• www.space.gc.ca
• www.nasa.gov
• http:robotz.org
• www.fanucrobotics.com
• http://asimo.honda.com
• www.bbc.co.uk/science/robots/rooteers/index.shtml
• Industrial Robotics by Groover, TATA Mc-GRAWHILL publications.