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Bachelor of Technology
In
Electrical Engineering
CERTIFICATE
This is to certify that the project under Skills and Hands-on Project
entitled “CEILING PICK AND PLACE INDUSTRIAL ROBOT”
submitted by our group of 10 members of Department of Electrical
Engineering fulfils the requirements of the regulation relating to the
nature and standard of work for the award of degree of B.Tech.
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Skills and Hands-On project College of Engineering And Technology
DECLARATION
I do hereby declare that our project under Skills and Hands-on Project
entitled “CEILING PICK AND PLACE ROBOT’ is being submitted
for bonafide work of research carried out by us under the guidance of
Mr Kamlesh Chandra Rout, Assistant Professor, Department of
Electrical Engineering and Er. B. Madhava, CTTC. The results of the
work have not been submitted by us for the award of any other
degree.
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Skills and Hands-On project College of Engineering And Technology
ACKNOWLEDGEMENT
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2 ABSTRACT
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Skills and Hands-On project College of Engineering And Technology
3 CONTENTS
CERTIFICATE -1-
DECLARATION -2-
1 ACKNOWLEDGEMENT -3-
2 ABSTRACT -4-
3 CONTENTS -5-
4 INTRODUCTION -6-
5 DESCRIPTION -7-
5.1 CEILING PICK & PLACE INDUSTRIAL ROBOTS -7-
5.2 ROBOTIC ARM -7-
5.3 END EFFECTOR -8-
5.4 DC MOTOR -8-
5.5 TERMINAL BLOCK -9-
5.6 SWITH MODE POWER SUPPLY -9-
5.7 LIMIT SWITCHES - 10 -
5.8 IR SENSOR - 10 -
5.9 JUMPER WIRES - 11 -
5.10 STRANDED WIRES - 11 -
5.11 RAINBOW CABLES - 12 -
5.12 ARDUINO MEGA 2560 - 12 -
5.13 MOTOR DRIVER L298N - 13 -
6 CONTINUITY - 13 -
7 WORKING - 14 -
8 ADVANTAGES - 17 -
9 DISADVANTAGES - 17 -
10 FUTURE SCOPE - 17 -
11 CONCLUSION - 17 -
12 REFERENCES - 18 -
13 APPENDIX - 18 -
13.1 PIN DIAGRAM OF ARDUINO MEGA 2560 - 18 -
13.2 PIN CONFIGURATION OF MOTOR DRIVER - 19 -
13.3 ARDUINO L298N DATA SHEET - 19 -
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Skills and Hands-On project College of Engineering And Technology
4 INTRODUCTION
The main objective of our project is to create a CEILING PICK & PLACE
INDUSTRIAL ROBOT by automation which will reduce human effort, saves
time and facilitates better utilization of space.
The major advantages of this type of pick and place robot is that it reduces
human effort, causes no damages to goods, saves time and facilitates better
utilization of space. It can replace human operation in tasks that involves in
convening system that takes the object from one place to its destination. It will
reduce operating time and working handling time significantly and enhances
better area management as the robot is attached to the ceiling.
It can perform tasks efficiently and with accuracy. It can have applications in
various industries, stockyards etc.
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Skills and Hands-On project College of Engineering And Technology
5 DESCRIPTION
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Skills and Hands-On project College of Engineering And Technology
5.4 DC MOTOR
A DC motor is any of a class of electrical machines that converts direct
current electrical power into mechanical power. The most common types rely
on the forces produced by magnetic fields.
Nearly all types of DC motors have some internal mechanism, either
electromechanical or electronic, to periodically change the direction of current
flow in part of the motor.
Most types produce rotary motion, a linear motor directly produces force and
motion in a straight line.
DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed
can be controlled over a wide range, using either a variable supply voltage or by
changing the strength of current in its field windings.
Small DC motors are used in tools, toys, and appliances. The universal motor
can operate on direct current but is a light weight motor used for portable power
tools and appliances.
Figure 3: DC MOTOR
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Skills and Hands-On project College of Engineering And Technology
supply due to the smaller transformer size and weight. Switching regulators are
used as replacements for linear regulators when higher efficiency, smaller size
or light weights are required. They are, however more complicated, their
switching currents can cause electrical noise problems if not carefully
suppressed, and simple designs may have a poor power factor.
5.8 IR SENSOR
An infrared (IR) sensor is used to detect obstacles in front of the robot or to
differentiate between colours depending on the configuration of the sensor.
An IR sensor consists of an emitter, detector and associated circuitry. The
circuit required to make an IR sensor consists of two parts: the emitter circuit
and the receiver circuit.
The picture shown is a very simple black box model of the IR senor. The senor
emits IR light and gives a signal when it detects the reflected light.
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constant flow. The longer the pulses the faster the wheel will turn, the shorter
the pulses, the slower the water wheel will turn. Motors will last much longer
and be more reliable if controlled through PWM.
6 CONTINUITY
We have used the method of continuity at various points . In this method , two
metal plates are used . One plate is given with 5v and other plate is grounded .
When both the plates come in contact with each other i.e. it gets shorted, current
flows from high potential to ground i.e. from 5v to gnd . This current is too
large and can damage the circuit. So to prevent that we have used resistors as a
kind of load across it. We are using 2.2k ohms as per our convenience. When
current flows to ground , we have taken a wire shouldered before the resistor as
feedback to the Arduino. At places like arm and claw , we have implemented
this technique. This is similar to that happens in the limit switches. To restrict
the downward motion of the arm up to a certain limit and to restrict the motor
for opening claw, we have used this method.
Figure 13:CONTINUITY
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Skills and Hands-On project College of Engineering And Technology
7 WORKING
The switch mode power supply is used as a power source. The motors used in
the robotic arm are 5v motors. The SMPS gives us an output voltage of 12v. So,
we have used 7805 ICs to bring that voltage down to 5v.The output rating of
SMPS is 12v,5amp. But the output of individual 7805 is 5v,600 milli ampere .
We have used 4 such voltage regulators to control individual motor .
The motors used are high torque motors (30rpm).In the arm we have 3 motors
for base , arm , claw actions. For forward and backward movement of the arm
we have a 12v ,200rpm motor coupled with the lead screw via pulley
arrangement. In conveyor we also have a 12v ,50 rpm motor used. In order to
control all these motors we have used three motor drivers .Every motor driver of
l298n type can give a current of 1amp each at its output port. The motor driver
has a 5v , 12v and GND pin in order to enable it. So, for 5v motors we give 5
volts supply to both 5v pin and 12v pin .For 12v motors , we give 5v to 5v pin
and 12 v to the 12v pin. For that purpose we use individual voltage regulator for
every motor driver.
There are many feedbacks used in order to control the movement of the robotic
arm. We have used limit switches for the claw closing and for the base motion
towards extreme right and extreme left. To restrict the position of the arm in the
downward direction and for the full opening of the claw we have applied the
method of continuity .The conveyor to detect the object right below the arm we
have used IR sensors. To control the motion of the lead screw , we have also
taken the help of the IR sensors at various points – start , end , across object
position 1.The arm should recognise the positions that are filled and empty. For
that purpose separate IR sensors are also implemented at the object base ,that
gives the necessary feedback to the arm via the controller .
Every function , operation and execution is being programmed under the
necessary feedbacks . The feedbacks taken at the various points are the impulses
to the robotic arm that describes its motion . The robotic arm can travel in x,y,z
co-ordinates according to the set of instructions and necessary feedbacks. As
long as the object places are empty the robotic arm continues to work. When all
the positions will be filled up the arm stops to work.
The robotic arm is provided with an initial position method. This method is so
declared as to give the robotic arm a posture and a reference from which the rest
of the instructions can be implemented and executed without any error.
Everytime the supply is provided , the arm first comes to its initial position and
taking it as the reference it performs other operations that are declared after it.
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Skills and Hands-On project College of Engineering And Technology
Figure 14: CONNECTION OF MOTORS ,MOTOR DRIVERS,VOLATGE REGULATORS,SMPS AND ARDUINO MEGA
Step by step working of the robotic arm for the first object is described below :-
Power supply is switched on. The robotic arm comes to its reference or pre –
defined position .The conveyor starts with object on it .The conveyor IR sensor
detects the object and gives feedback to the controller . The conveyor stops and
the arm goes down till the continuity is made. As the plates touch each other,
the claw closes with object in between. Thus , the limit switch of the claw is
pressed and a feedback is given to the controller.
The arm is moved up with the object in the claw and hence it loses its
continuity. It then checks for the next instruction. The leadscrew starts rotating
and the arm moves in the forward direction as soon as the IR sensor for
position- 1 detects . This IR sensor is detected only if both the object bases or
any one of the object base is empty.
For position- 1, the arm turns left till the rightmost limit switch is pressed. It
then bends down till the continuity holds true. As the downward continuity
feedback is fed to the controller , the claw is opened for 0.2 seconds of delay.
The objects slips out of the claw and is placed on the object base with no errors
in positioning . Thus object placing can be performed without any human effort
through automation of the robotic arm. As the object is on the base , the IR
sensor placed across the base detects the object. The red light glows showing
that the position -1 is filled with the object.
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Now the robotic arm comes to its referenced or pre – defined position and is
ready to hold the next object coming on the conveyor.
Similar approach is followed for the next objects. Accordingly the object bases -
2,3,4 are filled with the object. As all the places are occupied with objects , so
the robotic arm stops to function further.
The arm is so programmed that every time the first placed gets empty , it fills it
first. It first takes the feedback coming from the various IR sensors at the
different object bases and checks for the nearest postion . If the nearest place is
void of object it fills it first before going to the farther placed object bases.
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Skills and Hands-On project College of Engineering And Technology
8 ADVANTAGES
Ceiling robot is on rise in technical sector due to the innumerable advantages it
comes with. This robot is excellently value for money making this an affordable
robot. Its design provides high flexibility making it functional under highly
varied sectors. Its payload is ideal for light duty handling and process
applications. And its high repeatability delivers accurate process which reduces
chances of error. Compact body design with internally routed services makes it
highly desirable by allowing it to do small installation footprint.
9 DISADVANTAGES
With advantages there comes a few drawbacks too. For example, for installation
of the system the ceiling needs to be very strong and old ceilings have to be
reinforced with steel properly before fitting of the carrier track.
10 FUTURE SCOPE
This project has a multi usage scope in the industrial sector in near future. It can
possibly be used in place of cranes. High load and risky operation can be easily
carried out with this making it usable in heavy machinery industry. This
technology has been suggested for running buses and other mass transport
system and may end up as a part of autonomous cars navigating the freeway.
Smarter versions of line followers can be used to deliver mails within office
building and deliver medications in a hospital.
11 CONCLUSION
In this project we have studied and implemented a ceiling robot using
ARDUINO. The programming and Implementation of an ARDUINO have been
learnt. The functioning of various components like sensors, relays and other
electrical components used has been mastered.
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12 REFERENCES
1. http://www.instructables.com/id/Arduino-Modules-L298N-Dual-H-Bridge-Motor-Controll/
2. http://www.robotshop.com/en/robotic-arms.html
3. https://en.wikipedia.org/wiki/Jump_wire
4. https://arduino-info.wikispaces.com/MotorDrivers
5. http://www.connectwell.com/global/products/terminal-blocks-
connectors.aspx?lang=en®=IN
6. https://www.bastiansolutions.com/blog/index.php/2014/02/13/choosing-the-right-
conveyors-for-your-system/
13 APPENDIX
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