(A) Components assembling

The arm control by robotics is very popular in the world of robotics. The essential part of the robotic
arm is a programmable micro controller based brick capable of driving basically Two servos & a dc
motors design to form an anthropomorphic structure.
Our primary objective is to make the Robotic arm, having two servo motors & a dc motor to
interface with the In!evelopment of a "icrocontroller #ased Robotic $rm. It provides more
interfaces to the outside world and has larger "emory to store many programs
$pproach%
&e were able to perform a detailed study of the robotic arm and the microcontroller. &e Tested the
built robotic arm, and the servo motors & dc motors when the robot is loaded. &e also learnt and
familiari'ed with the microcontroller
using assembly language, and
converting the assembly language
codes to he(adecimal codes using a
development board.
Mechanical Structure of the Arm:
In constructing our arm, we made use of Two servo motors and a dc motors and gears since our
structure is a three dimensional structure. $ typical prototype that we employed is as shown in
)igure. There is a servo motor at the base, which allows for circular movement of the whole
*tructure+ another at the shoulder which allows for upward and downward movement of the $rm+
while at last dc motor at the wrist allows for the picking of objects by the magnetic hand.
39
Micro-Controller:
The various components of the ",- shown in )igure . are e(plained below%
Random $ccess "emory (RAM): R$" is used for temporary storage of data during runtime.
RO"% RO" is the memory which stores the program to be e(ecuted.
*)R Registers% *pecial )unction Registers are special elements of R$".
/rogram ,ounter% This is the 0engine0 which starts the program and points to the memory address of
the instruction to be e(ecuted. Immediately upon its e(ecution, value of counter increments by 1.
,ontrol 2ogic: $s the name implies, it which supervises and controls every aspect of operations
&ithin ",- and it cannot be manipulated. It comprises several parts,
The most Important ones including% instructions decoder, $rithmetical 2ogic -nit 3$2-4 and
$ccumulator.
$5! ,onverter: $5! stands for analog to digital. They convert analog signals to digital signals.
I5O /orts% To be of any practical use, microcontrollers have ports which are connected to the pins on
its case. 6very pin can be designated as either input or output to suit user7s needs.
Oscillator: This is the rhythm section of the ",-. The stable pace provided by this instrument
allows harmonious and synchronous functioning of all other parts of ",-.
Timers: timers can be used for measuring time between two occurrences and can also behave like a
counter. The &atchdog Timer resets the ",- every time it overflows, and the program e(ecution
starts anew 3much as if the power had just been turned on4.
/ower *upply ,ircuit: this powers the ",-.
Methodology:
The method employed in designing and constructing the robotic arm are based on the operational
,haracteristics and features of the microcontrollers, stepper motors, the electronic circuit diagrams
and most importantly the programming of the microcontroller and stepper motors.
40
Block Diagram
The block diagram of our work is as shown in )igure
(B) orking of the robotic arm
This work is able to successfully accomplish the defined functionality. $ sample robot which can
rotate, magneti'e an object, lower and raise its arm, by being controlled by the microcontroller is
built successfully. The development board is soldered and it used the re8uired procedure for the
correct operation of the controller. The development board has been interfaced to the servo & dc
motors such that the anthropomorphic like structure can be controlled from the buttons at the base of
the structure 3robotic arm4.
&hen signal come to robotic arm, it will activated and then it searching for the code object in storage
area when it get confirmation of availability thus it call $9: to collect and dispatch that object to its
destination of call at the instant of getting signal inbuilt program in $:R controller activate and
41
READY AND
CALLING AGV
VIA REQUEST
SIGNAL
SERVO WORK WITH
PERTICULAR
PROGRAMED
OBJECT FOR PICK
PICKING OBJECT
BY CLAW AND
DROP ON AGV
WITH WORK
DONE SIGNAL
CODE
FROM
ASSEMBLY
AREA TO
MOTOR
DRIVER l93D
PWM
GENARATE BY
AVR TIMER
WORK
DONE
TRANSMIT
SIGNAL
VIA RF
MODULE
VCC!00
check signal status incoming signal on -*$RT terminal via R) module thus programmed $:R drive
the servos with fi( degree which have been place in programming for particular objects ,end effecter
as a claw made up of dc geared motor and spar gear assembly with $:R via 2.;<! motor driver h
bridge I, collect the object lift up and drop on $9: and its come back its original position which is
mention in its program.
(C) !urpose of the robotic arm
This robot is a mechanical arm, a manipulator designed to perform many different tasks and capable
of repeated, variable programming.
To perform its assigned tasks, the robot moves parts, objects, tools, and special devices by means of
programmed motions and points. The robotic arm performs motions in space. Its function is to
transfer objects or tools from point to point, as instructed by the controller
In manufacturing industry and nuclear industry, a large fraction of the work is repetitive and
judicious application of automation will most certainly result in optimum utili'ation of
machine and manpower.
$ pneumatic =/ick and /lace> Robot has been developed to achieve automation in
applications where great sophistication is not needed and simple tasks like picking up of
small parts at one location and placing them at another location can be done with great ease.
3)4 Scope of the robotic arm
The machine will be of great use to perform repetitive tasks of picking and
placing of small parts 3up to ?@@ gms4 in an industrial production line.


Its use can be e(tended and e(ploited by few modifications to do difficult
and ha'ardous tasks for industrial applications.

It can be used to do small assembly work effectively due to its great added
accuracy for placement of parts, which is further e(tended scope of our
project
The machine provides motion to the end effectors in the theta and A directions. The end effecter can
be a pair of pneumatic grippers, a set of multiple grippers, magnetic pickup, vacuum pickup etc.
The device has its own inbuilt logic and all the movements of the device are controlled by the
combination of control valve and reversible valve which form the vital part of the machine. $ single
pulse of air given to the control valve activates the reversible valve and admits air alternately to the
two pneumatic cylinders during one cycle. This causes to and fro linear motion of the common rack
4
which is converted into the rotary motion of the pinion and ultimately imparts angular sweep 3theta4
and vertical motion 3A4 at the end of each stroke to the head carrying the pickup arm with the end
effecter. $ngular sweep 3theta4 as well as the vertical motion 3A4 is adjustable by means of
mechanical stoppers. The operating speed of the pickup arm can be varied to suit the re8uirement by
operating the flow control valves provided on the two cylinder heads. !uring one operating cycle the
pickup arm carrying the end effecter starts from its home position, goes to the other end, picks up the
part and returns to its original home position. The picked up part is delivered to the home position
when the ne(t cycle is triggere
"# A$%&MA%'D ($)D'D *'+)C,'
Definition
$n automated guided vehicle or automatic guided vehicle 3$9:4 is a mobile robot that follows
markers or wires in the floor, or uses vision or lasers. They are most often used in industrial
applications to move materials around a manufacturing facility or a warehouse. $pplication of the
automatic guided vehicle has broadened during the late .@th century and they are no longer restricted
to industrial environments.
The lower cost versions of $9: are often called as automated guided carts, which are available in
variety of models and can be used to move products on assembly line, transport goods throughout
plants as what our project demands.
$n $9: to be used here will be using path select mode which chooses a path it uses the
measurements taken from the sensors and to the value given to them by programmer when an $9:
approaches a decision point then it only has to decide whether to follow path among 1,.,< etc .This
43
decision is rather simple since it already knows its path from its programming .This method can
increase the cost of an $9: because it re8uires to have team of programmers to program the $9:
with correct paths and change the path as when necessary . This method whereas is easy to change
and setup.
In its simplest form it follows the concept of line follower mechanism , thus sensing and
maneuvering the robot to stay on course while constantly correcting wrongs moves by using
feedbacks mechanism forms a simple yet effective closed loop system .
It may be that the path be irregular which implies for inefficient line following, thus making the use
of microcontroller one can actuate a motor to run at certain rpm and the other to move at another
.This can generate any radius of curvature and give the most effective line follower.
It may be possible that the photodiodes so used behave differently .thus we need to calibrate the
sensors so that the logical part of the code deals with the same range of sensors.
(A)&bstacle sensing
It consist of IR transmitter T*O/ receiver sensor while moving the on track its emits infra red light
in forward direction in case some obstacle is present on the way of moving the reflection of infrared
light is receive by T*O/ receiver sensor which amplified the weak signal and give the output in
<Bkh' fre8uency which are connected on the interrupt pin of the controller which enable immediate
stopping all the operation and vehicle stop while interrupt disable when object is not present on in
front of vehicle no repletion will come and vehicle performing its programmed functions.
orking of obstacle sensing de-ice
44
(B) Component study
3i4 "echanical part
3ii4 /rogrammable part
3iii4 Operating system
3iv4 sensors
%he details of these areas under :
4!
(i) mechanical parts
3a4 ,aster wheel
3b4 !, motor
Block diagram of an line follo.er robot
)or moving an $9: 3line following robot4 we have two dc motors attached to the wheels and gear
4"
system and two caster wheel.
3a4 Caster .heel %
It has
Omani
directional motion of freedom it has metal sphere in the casting of metal cup its move
according to force of motion on e(ert on it.

(b) DC motors
hy dc motors/
The dc motors are most easy to control .One dc motor will re8uire 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 . &e can vary speed by varying the voltage across the motor by making use of
gears.
The dc motor does not have enough tor8ue to derive a robot directly by connecting wheels to it,
gears increases the tor8ue at the e(pense of the speed.
"athematical interpretation
Rotational power3p4C Tor8ue3t4DRotational speed3w4
T C /5w
/ is constant for dc motor with constant electrical power.
Thus the tor8ue is inversely proportional to the speed
T a 15w
#y using two motors we can move robot in any direction, the steering mechanism of robot is
4#
called as differential drive.
$sage of motor dri-er:
)rom microcontroller we cannot connect a motor directly because microcontroller cannot give
sufficient current to the drive the dc motor + the motor drive connected across it is a current
enhancing device which act as a switch ,thus we insert a motor derive between motor and
microcontroller.
-sing our 2.;E F#ridge based product, one can easily drive relays, solenoids, !, and stepmotors.
It has G control lines which allow you to drive forward, backward and stop two !, motors.
here we are using 2.;E! and 2.;<! motor drivers
)eatures
D Fosts a 2.;<! F#ridge
D G input 5 G output 3ma(. Ga4
D @?: TT2 level microcontroller interface
D Integrated diodes
D *ingle power source 3B <B:4
D *mall si'e 3?(G 4cm


/icture of 2.;E F#ridge motor driver
4$
+- Bridge Motor Control
Clock.ise rotation :
Anticlock.ise rotation :
49
(a) )0 sensors
IR !istance sensors are a lowcost, easy to use analog distance sensor. IR *ensors produce a
constantly updated analog output signal depending upon the intensity of the reflected IR, which in
turn can be used to calculate appro(imate range. These sensors are perfect for obstacle avoidance,
line following, and even map buildingH #rowse a large selection of IR *ensors with different distance
ranges, applications, and output types. IR /hoto reflectors are generally used in line following or
encoder application, at short distances to detect white or black colors. These sensors are easy to use
and low in cost, making them the perfect addition to our ne(t autonomous robot project.
!0
(ii) !rogrammable parts

&ith reference to the present $9: we use the $Tmega1B microcontroller.
(a) A%mega"1A microcontroller
The $Tmega1B$ is a lowpower ,"O* Ebit microcontroller based on the $:R enhanced RI*,
architecture. #y e(ecuting powerful instructions in a single clock cycle, the $Tmega1B$
achieves throughputs approaching 1 "I/* per "F' allowing the system designed to optimi'e
power consumption versus processing speed.
!in diagram of A%mega"1A microcontroller
!1
2eatures
I Fighperformance, 2owpower $:RJ Ebit "icrocontroller
I $dvanced RI*, $rchitecture
K 1<1 /owerful Instructions K "ost *ingleclock ,ycle 6(ecution
K <. ( E 9eneral /urpose &orking Registers
K )ully *tatic Operation
K -p to 1B "I/* Throughput at 1B "F'
K Onchip .cycle "ultiplier
I Figh 6ndurance Lonvolatile "emory segments
K 1BM #ytes of In*ystem *elfprogrammable )lash program memory
K ?1. #ytes 66/RO"
K 1M #yte Internal *R$"
K &rite56rase ,ycles% 1@,@@@ )lash51@@,@@@ 66/RO"
K !ata retention% .@ years at E?N,51@@ years at .?N,314
K Optional #oot ,ode *ection with Independent 2ock #its
I In*ystem /rogramming by Onchip #oot /rogram
I True Read&hile&rite Operation
!
K /rogramming 2ock for *oftware *ecurity
I OT$9 3I666 std. 11G;.1 ,ompliant4 Interface
K #oundaryscan ,apabilities $ccording to the OT$9 *tandard
K 6(tensive Onchip !ebug *upport
K /rogramming of )lash, 66/RO", )uses, and 2ock #its through the OT$9 Interface
I /eripheral )eatures
K Two Ebit Timer5,ounters with *eparate /resales and ,ompare "odes
K One 1Bbit Timer5,ounter with *eparate /resale, ,ompare "ode, and ,apture
"ode
K Real Time ,ounter with *eparate Oscillator
K )our /&" ,hannels
K Echannel, 1@bit $!,
I E *ingleended ,hannels
I P !ifferential ,hannels in TQ)/ /ackage Only
I . !ifferential ,hannels with /rogrammable 9ain at 1(, 1@(, or .@@(
K #yteoriented Twowire *erial Interface
K /rogrammable *erial -*$RT
K "aster5*lave */I *erial Interface
K /rogrammable &atchdog Timer with *eparate Onchip Oscillator
K Onchip $nalog ,omparator
I *pecial "icrocontroller )eatures
K /oweron Reset and /rogrammable #rownout !etection
K Internal ,alibrated R, Oscillator
K 6(ternal and Internal Interrupt *ources
K *i( *leep "odes% Idle, $!, Loise Reduction, /owersave, /owerdown, *tandby
and 6(tended *tandby
I I5O and /ackages
K <. /rogrammable I5O 2ines
K G@pin /!I/, GGlead TQ)/, and GGpad Q)L5"2)
I Operating :oltages
K ..P ?.?: for $Tmega1B$
I *peed 9rades
K @ 1B "F' for $Tmega1B$
I /ower ,onsumption R 1 "F', <:, and .?N, for $Tmega1B$
K $ctive% @.B m$
K Idle "ode% @.. m$
!in Descriptions
:,,
Digital supply -oltage#
9L!
!3
(round#
!ort A (!A3:!A44
/ort $ serves as the analog inputs to the $5! ,onverter.
/ort $ also serves as an Ebit bidirectional I5O port, if the $5! ,onverter is not used. /ort pins can
provide internal pullup resistors 3selected for each bit4. The /ort $ output buffers have symmetrical
drive characteristics with both high sink and source capability. &hen pins /$@ to /$P are used as
inputs and are e(ternally pulled low, they will source current if the internal pullup resistors are
activated. The /ort $ pins are tristated when a reset condition becomes active, even if the clock is
not running.
!ort B (!B3:!B4)
/ort # is an Ebit bidirectional I5O port with internal pullup resistors 3selected for each bit4. The
/ort # output buffers have symmetrical drive characteristics with both high sink and source
capability. $s inputs, /ort # pins that are e(ternally pulled low will source current if the pullup
resistors are activated. The /ort # pins are tristated when a reset condition becomes active, even if
the clock is not running.
/ort # also serves the functions of various special features of the $Tmega1B$ as listed on page
?P.
!ort C (!C3:!C4)
/ort , is an Ebit bidirectional I5O port with internal pullup resistors 3selected for each bit4. The
/ort , output buffers have symmetrical drive characteristics with both high sink and source
capability. $s inputs, /ort , pins that are e(ternally pulled low will source current if the pullup
resistors are activated. The /ort , pins are tristated when a reset condition becomes active, even if
the clock is not running. If the OT$9 interface is enabled, the pullup resistors on pins /,? 3T!I4,
/,< 3T"*4 and /,. 3T,M4 will be activated even if a reset occurs.
/ort , also serves the functions of the OT$9 interface and other special features of the $Tmega1B$
as listed on page B@.
!ort D (!D3:!D4)
/ort ! is an Ebit bidirectional I5O port with internal pullup resistors 3selected for each bit4. The
/ort ! output buffers have symmetrical drive characteristics with both high sink and source
capability. $s inputs, /ort ! pins that are e(ternally pulled low will source current if the pullup
resistors are activated. The /ort ! pins are tristated when a reset condition becomes active, even if
the clock is not running.
/ort ! also serves the functions of various special features of the $Tmega1B$ as listed on page
B..
!4
0'S'%
Reset Input. $ low level on this pin for longer than the minimum pulse length will generate a reset,
even if the clock is not running. . *horter pulses are not guaranteed to generate a reset.
5%A,"
Input to the inverting Oscillator amplifier and input to the internal clock operating circuit.
5%A,6
Output from the inverting Oscillator amplifier.
A*CC
$:,, is the supply voltage pin for /ort $ and the $5! ,onverter. It should be e(ternally connected
to :,,, even if the $!, is not used. If the $!, is used, it should be connected to :,, through a
lowpass filter.
A0'2
$R6) is the analog reference pin for the $5! ,onverter.
Crystal &scillator
ST$21 and ST$2. are input and output, respectively+ of an inverting amplifier which can be
configured
for use as an Onchip Oscillator, as shown in )igure 6ither a 8uart' crystal or a ceramic resonator
may be used.
!!
,1 and ,. should always be e8ual for both crystals and resonators. The optimal value of the
capacitors depends on the crystal or resonator in use, the amount of stray capacitance, and the
electromagnetic noise of the environment.

(b) Componen
t
assembling
&e need to build
the sensor array
for the line
detection by the $9:. Fere Illustrated for IR sensors. &e are using ? channel grid following line
sensor module.
9eneral !escription
The T,RT2)*"K!igital sensor is used as a as a line sensor, but it can be used as a generalpurpose
pro(imity or reflectance sensor.
The module consist of ? IR emitter and receiver 3phototransistor4 pairs 6ach
/hototransistor. Theses high performance T,RT sensors IR 26!s emits IR
2ight and phototransistor receive that IR light after reflections.
T,RT gives out different analogue voltage for different color and distance.

!"
/in Lo. connection /in no. connection
1 9L! B *6L*OR ?
. :,, P *6L*OR <
< *6L*OR 1 E L,
G *6L*OR G ; :,,
? *6L*OR . 1@ 9L!
This $nalog voltage is given to comparator which compare analogue output
&ith reference voltage set by user. Then comparator will give digital output
that is either 2ogic TFighT :cc or 2ogic U2owT 9L!. ? sensors mounted in
*uch a way that it can be directly used for line following and grid navigation.
On board 26! indicator helps user to check status of each sensor with open
6yes without using any additional hardware.
T,RT provides day light blocking filter so erratic behavior is avoided.
The module is very compact and it gives directly digital output. The power
,onsumption is low for this module.
!in Configuration
If you hold the sensor in your hand with notch of connector facing
!#
upward as shown in figure then your pins will be

Application )deas
I 2ine sensing robots
I ma'e solving robot
I /osition sensor for shaft encoder
I !etection of reflective material such as paper, I#" cards,
"agnetic tapes etc.
I 9eneral purpose wherever the space is limited

&-er-ie. of 7 channel line follo.ing module
!$
Overview of
*chematic
There is ? T,RT
sensors and ?
comparators.
Output of
6ach sensor is applied to inverting terminal of com praetor. The other input to comparator is
reference voltage set by user which user can modify by varying
/OT. The output of T,RT sensor is compared with the ref voltage generated by the pot. The output
is dependent on the difference voltage. &hen we use black surface we
9et high output and for white surface the output depends upon the distance between T,RT module
and the surface.
!9
&orking %he line sensing mechanism


"0
Architecture of line follo.er
Oust looking at this drawing really gets brings up a host of ideas and 8uestions. Fardware, software,
logic,
"otor control and many other thoughts come rushing in. I need to slow down and compartmentali'e.
*ince this project is the basis of beginner7s rob optics projects or contests in just about every robotics
club on
The planet, the drawing provides an out class to teach the different aspects of robotics. The robot7s
program will re8uire the four main ingredients of every computer, microprocessor, microcontroller
and the
/rograms that run in them. Fere are the four and how they relate to line following project%
Input% Read the white5black on the floor and condition the input signal3s4for transmission into the
0brain0 or computer5"/ -5,/- in a way that 8uestions ,an be asked and decisions made. /rocess%
#ased on the inputs received, decide what change 3if any4 needs to be made to the robots speed and
direction. ,onvert
*omething that can be sent to motor speed control and5or steering. Output%
*end the old or the newly adjusted control signals to speed and5or steering devices. The steering
mechanism
"1
Block diagram of line follo.er

"
2lo. chart of .orking procedure chart :
"3
"4
364 !urpose of A(*
The robot must be capable of following a line.
It should be capable of taking various degrees of turns
It must be prepared of a situation that it runs into a territory which has no line to follow. 3#arren
land syndrome4
The robot must also be capable of following a line even if it has breaks.
The robot must be insensitive to environmental factors such as lighting and noise.
It must allow calibration of the line7s darkness threshold.
*calability must be a primary concern in the design.
The color of the line must not be a factor as long as it is darker than the surroundings.
(D) Scope

Industrial automated e8uipment carriers automated cars.
Tour guides in museums and other similar applications.
*econd wave robotic reconnaissance operations.



"!
CHAPTER 4
SYSTEM WORKING
C+A!%'0 8
""
S9S%'M &0:);(
The replacement of the manual labor being rendered by the man as against the work done by any
mechanical, electromechanical or an electronic system has always been viewed in collation with each
other.
#ut always a midway has served the best solution for it+ indeed the fact is their effort rather put on
either side of the line is less than what they can achieve working complementarily.
*o our system lays an emphasis on the same , what we have designed is best illustrated keeping the
scene of any conventional industrial frame of working ,especially the assembling section or any
packaging unit and here the former case is taken as an e(ample.

,omprising of mainly three components
1. *erver computer
.. Robotic arm
<. $utomated guided vehicle3$9:4
These all when put together forms a system ,what we call it as

U )ndustrial storekeeping by Autonomous guided system<
)or its working as soon as the operator in the machine shop finds the re8uirement of any auto part
3let4 , then it needs to put on that re8uirement in form of coded re8uest on the computer 3server
computer4 + this computer upon accessing the re8uest from the operator by the means of the R)
module that locally generates the signals which henceforth is transmitted by it and is directed
towards the two,
$9:
Robotic arm
The $9: which initially is in its base station called the charging unit, senses the re8uest signal, and
follows a path which directs it to take the position besides the robotic arm ,the robotic arm after
finding the $9: in the specified 3strictly defined4position after a delay of 1 minute, for which it is
already programmed to maintain after acknowledging the presence of $9: +then start performing
the operation of picking up and placing of the so re8uired auto part upon the $9: which after
getting the proper placement of the object then carries it to the machine shop where it is re8uired+ the
operator then picks up the object from the $9: thereby freeing the $9: from the so liable work
and then the $9: returns back to its initial position that is its charging unit.

Thus by the means of our, so designed system the tedious work of making the heavy auto parts
"#
carriage from one place to another within the department of the industry is hereby faithfully and
easily casted off by the system. This accomplishment has rendered the following
1.Time saving
.. 6limination of physical labor which otherwise is to be bored by human workers.
<. *ystematic operation.
G. "ore or less wireless operating mode of operation.
"$
Circuit diagram of 0obotic arm
"9
Circuit diagram of Automated guided -ehicle
#0
!CB of robotic arm and automated guided -ehicle
#1
#
CHAPTER 5
CONCLUSION
C+A!%'0 7
C&;C,$S)&;

314 Thus the aim for the atomi'ation in manufacturing units by the mean of employing process or
se8uence of programmed operation with little or no human labor using electromechanical techni8ues
is made.
3.4 The goal of less or no probability of error+ with real time management is achieved.
3<4 6asy operating format by use of computer is obtained.
3G4 6limination of the stressed watch by human operators on systematic working to achieve
desired production in the industry is made.
3?4 #y developing an autonomous nature of the system, the same is made a reliable one.
3B4 $ solution for the simultaneous accomplishment of assembling work done in the industries by
the means of single computes has not only provided ease in operation but also provides autocratic
nature for monitoring purposes is designed.
#3