PORTABLE ROBOT ARM

Bachelor of Technology In Mechanical Engineering

M NAGA RANGAIAH M GOUTHAM T KARTHIK S M KRISHANAN KATTA M RAJESH

04P71A0312 05P71A0312 05P71A0314 05P71A0315 05P71A0326

Department Of Mechanical Engineering Swami Vivekananda Institute of Technology (Affiliated to JNTU, Approved by AICTE) Mahbub College Campus, Secunderabad-500003 2005-2009

PORTABLE ROBOT ARM A thesis submitted in Partial Fulfillment of the Requirements for the Award of Degree of Bachelor of Technology In Mechanical Engineering By M NAGA RANGAIAH M GOUTHAM T KARTHIK S M KRISHANAN KATTA M RAJESH 04P71A0312 05P71A0312 05P71A0314 05P71A0315 05P71A0326

Under the guidance of Dr. V. NARASIMHA RAO Principal Swami Vivekananda Institute of Technology, Secunderabad

Department Of Mechanical Engineering Swami Vivekananda Institute of Technology (Affiliated to JNTU, Approved by AICTE) Mahbub College Campus, Secunderabad-500003 2005-2009

Department Of Mechanical Engineering Swami Vivekananda Institute of Technology (Affiliated to JNTU, Approved by AICTE) Mahbub College Campus, Secunderabad-500003

CERTIFICATE This is to certify that the Project Report entitled PORTABLE ROBOT ARM, being submitted by M Naga Rangaiah, M Goutham, T Karthik, S M Krishnan Katta and M Rajesh, bearing the Roll Numbers 04P71A0312, 05P71A0312, 05P71A0314, 05P71A0315 and 05P71A0326 respectively, in partial the fulfillment of the requirements for the Award of the Degree of Bachelor of Technology in Mechanical Engineering, is a record of bonafide work carried out by them.

INTERNAL GUIDE (Dr V Narasimha Rao) Principal

EXTERNAL EXAMINER

(Prof. M.Basaveswara Rao) Associate professor and Head

Department Of Mechanical Engineering

DECLARATION

We hereby declare that the Project Report entitled PORTABLE ROBOT ARM, under the guidance of P CHANDRA SHEKAR, Technical Director, Techniq Design Group, Hyderabad, is submitted in the partial fulfillment of the requirements for the award of the Degree of Bachelor of Technology in Mechanical Engineering. This is a record of bonafide work carried out by us and the results embodied in this Project Report have not been reproduced/copied from any source. The results embodied in this project have not been submitted to any other University or Institute for the Award of any other Degree or Diploma.

(M Naga Rangaiah)

(M Goutham)

(T Karthik)

(S M Krishanan Katta)

(M Rajesh)

ACKNOWLEDGEMENT

We take great pleasure in acknowledging the roles of our Principal and internal guide Dr. V.NARASIMHA RAO and our Head of Department, Prof. M. BASAVESWARA RAO in helping us complete this project successfully. We thank Sri P Chandra Shekar Technical Director, Techniq Design Group, Hyderabad for his inspirational guidance and support throughout the project. We are also indebted to Prof. N LAXMI NARAYANA, associate Professor, for helping us throughout our course of B Tech by giving valuable inputs in academics. We also wish to thank our parents for giving us constant moral support during times of difficulty through the course of this project.

SYNOPSIS

The implementation of technology in industry is a common aspect to reduce human errors and increase efficiency. By implementing automation and robotics in industry the idle time of the machine is reduced. The project is development of a robot which is used for pick and place objects.

The project is prototype model of a portable robot arm, which is used in flexible manufacturing system for transferring of objects and materials from one machine to other. The robot is designed to do simple pick and place operations.

INDEX
Page Nos.

CHAPTER 1
INTRODUCTION AUTOMATION AND ROBOTICS TYPES OF AUTOMATION ROBOT FUNDEMENTALS OF ROBOTICS 2 2 3 5 7

CHAPTER 2
COMPOINENTS MECHANICAL COMPONENTS ELECTRONIC COMPONENTS ELECTRICAL COMPONENTS 14 17 30 52

CHAPTER 3
PARTS MAKING ASSEMBLY WORKING 59 64 66

CHAPTER 4
DESIGN & ANALYSIS RESULT & CONCLUSION 69 79

BIBLIOGRAPHY

80

Introduction
With the advent of technology the automation and robotics are the need of the hour. The state of art technology is used in various places to enhance the working conditions and to work effectively. The purpose of the project is to make a robot which is used for pick and place operations, by combining electronic and mechanical systems.

Automation and Robotics

In an industrial context, we can define automation as a technology that is concerned with the use of mechanical, electronic, and computer based systems in the operation and control of production. Examples of this technology are transfer lines, mechanized assembly machines, feedback control systems, numerically controlled machine tools, and robots. This means robotics is a form of industrial automation. An industrial robot is a reprogrammable, multifunctional

manipulator designed to move materials, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks. Various industrial operations are machine loading and unloading, spot welding, and spray painting.

Types of Automation
There are three types of automation Fixed automation Programmable automation and Flexible automation Fixed automation is used when the volume of production is very high and it is therefore appropriate to design specialized equipment to process the product very efficiently and at high production rates. Example of fixed automation can be found in automobile industry. The risk involved in fixed automation is high as initial investment cost is more. Another problem involved is that the equipment is designed to produce only one kind of material. Programmable automation is used when the volume of production is relatively low and there are a variety of products to be made. The equipment is designed to be adaptable to variations in product configuration. This adaptability feature is accomplished by operating equipment with a program of instructions, which has been prepared especially for the given product. It is not as economical for small production batches. The third category between fixed automation and programmable automation is flexible automation. It can also be called as flexible manufacturing systems, or computer-integrated manufacturing systems. It must be programmed for different product configurations, but the variety

of configurations is usually more limited than for programmable automation, which allows a certain amount of integration to occur in the system. Flexible automated systems typically consist of a series of workstations that are interconnected by a materials handling and storage system. A central computer system is used to control the various activities that occur in the system, routing various parts to the appropriate stations and controlling the programmed operations at the different stations. Of the three types of automation, robotics coincides with

programmable automation. An industrial robot is a general purpose, programmable machine that possesses certain anthropomorphic, or humanlike, characteristics. The most typical humanlike characteristic of present day robot is their movable arms. The robot can be programmed to move its arm through a sequence of motions in order to perform some useful work. It will repeat that motion pattern over and over until reprogrammed to perform some other task. Hence the programming feature allows robots to be used for a variety of different industrial operations many of which involve the robot working together with other pieces of automated or semi automated equipment.

Figure

Relation

b/w

fixed

automation,

programmable

automation and flexible automation

Robotics is an applied engineering science that has been referred to as a combination of machine tool technology and computer science. The integration of machine design, control theory, microelectronics, computer programming, artificial intelligence, human factors and production theory develops robotics. Advancement of technology in these fields will enlarge the scope of robotics.

Robot
Robot is a mechanical device, which can be programmed to perform some task of manipulation or locomotion under automatic control. Encyclopedia Britannica gives the following definition for a robot: A robot device is an instrumented mechanism used in science or industry to take the place of a human being. It may or may not physically resemble a human or perform its tasks in a human way, and the line separating robot devices from merely automated machinery is not always easy to define. In general, the more sophisticated and individualized the machine, the more likely it is to be classed as a robot device. Industrial robot: A programmable, multi-function manipulator designed to move material, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks. Pick and place robot: A simple robot, often with only two or three degrees of freedom, which transfers items from place to place by means of point-to-point moves. Little or no trajectory control is available.

Manipulator: A mechanism, usually consisting of a series of segments, jointed or sliding relative to one another, for the purpose of grasping and moving objects usually in several degrees of freedom. It may be remotely controlled by a computer or by a human. Intelligent robot: A robot that can be programmed to make performance choices contingent on sensory inputs. Fixed-stop robot: A robot with stop point control but no trajectory control. That is, each of its axes has a fixed limit at each end of its stroke and cannot stop except at one or the other of these limits. Such a robot with AT degrees of freedom can therefore stop at no more than 2N locations (where location includes position and orientation). Some controllers do offer the capability of program selection of one of several mechanical stops to be used. Often very good repeatability can be obtained with a fixed-stop robot. Sensory-controlled robot: A robot whose program sequence can be modified as a function of information sensed from its environment. Robot can be servoed or non-servoed. Open-loop robot: A robot that incorporates no feedback, i.e., no means of comparing actual output to command input of position or rate. Mobile robot: A robot mounted on a movable platform.

Limited-degree-of-freedom robot: A robot able to position and orient its end effector in fewer than six degrees of freedom. Android: A robot that resembles a human in physical appearance.

Fundamentals of Robotics
The technical fields are highly interdependent in the manner, which they are used in robotics. To describe the technology of robot we must define a variety of technical features about the way the robot is constructed and the way it operates. Robots work with sensors, tools, and grippers.

Robot Anatomy
Robot anatomy is concerned with the physical construction of the body, arm, and wrist of the machine. Most robots used in plants are mounted on a 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 variety of positions. Relative movements between the various components of the body, arm, and wrist are provided by a series of joints. These joint movements usually involve either rotating or sliding motions. The body, arm, and wrist are called as manipulator. Attached to the robots wrist is a hand. The technical name for the hand is end effector. The end effector is not considered as the part of robots anatomy. The arm and body joints of the manipulator are used to

position the end effector, and the wrist joints of the manipulator are used to orient the end effector.

Robot Configurations
Industrial robots are available in wide variety of sizes, shapes, and physical configurations. The vast majority of todays commercially available robots possess one of the four basic configurations: 1. Polar configuration 2. Cylindrical configuration 3. Cartesian coordinate configuration 4. Jointed arm configuration Polar configuration uses a telescopic arm that can be raised or lowered about a horizontal pivot. The pivot is mounted on a rotating base. These various joints provide the robot with the capability to move its arm within a spherical space, and hence the name Spherical Coordinate robot is sometimes applied to this type. The commercial models in the market of this type are Unimate 2000 Series and MAKER 110. The cylindrical coordinate robot uses a vertical column and a slide that can be moved up or down along the column. The robot arm is attached to slide so that it can be moved radially with respect to column. By rotating the column, the robot is capable of achieving a workspace that approximates a cylinder. Example of cylindrical model is GMF Model M1A.

The Cartesian coordinate uses three perpendicular slides to construct the x, y, and z-axes. By moving the three slides relative to one another, the robot is capable of operating within a rectangular work envelope. An example of this configuration is the IBM RS-1 robot.

Robot Motions
Industrial robots are designed to perform productive work. The work is accomplished by enabling the robot to move its body, arm, and wrist through a series of motions and positions. Attached to the wrist is the end effector, which is used by the robot to perform a specific work task. The robots movements can be divided into two general categories: Arm and body motions, and Wrist motions The individual joint motions associated with these two categories are sometimes referred as degrees of freedom and a typical industrial robot is equipped with 4 to 6 degrees of freedom. The robots motions are accomplished by means of powered joints. Three joints are normally associated with the action of the arm and body, and two or three joints are generally used to actuate the wrist. Connecting the various manipulator joints together are rigid members that are rigid members that are called links. In any link joint link chain the link closest to the base in the chain is called the input link.

The joints used in the design of industrial robots typically involve a relative motion of the adjoining links that is either linear or rotational. Linear joints involve in sliding or translational motion of the connecting links. A programmable mechanical manipulator, capable of moving along several directions, equipped at its end with a work device called the end effector (or tool) and capable of performing factory work ordinarily done by human beings. The term robot is used for a manipulator that has a built-in control system and is capable of stand-alone operation. The arm and body joints are designed to enable the robot to move its end effector to a desired position within the limits of robots size and joint movements. For robots of polar, cylindrical or jointed arm configurations the three degrees of freedom associated with the arm and body motions are: Vertical traverse this is capability to move the wrist up or down to provide the desired vertical attitude. Radial traverse this involves the extension or retraction of the arm from the vertical center of robot. Rotational traverse this is the rotation of arm about the vertical axis.

Work Volume Work volume is the term that refers to the space within which the robot can manipulate its wrist end. The convention 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 robots wrist. The end effector is an addition to the basic robot and should not be counted as the part of robots working space. The end effector attached to the wrist might not be capable of reaching certain points within the robots normal work volume because of the particular combination of joint limits of the arm. The work volume is determined by the following physical characteristics of the robot: The robots physical configuration The sizes of the body, arm and wrist components The limits of the robots joint movements A polar coordinate has a work volume that is a partial sphere, a cylindrical coordinate robot has a cylindrical work envelop, and a Cartesian coordinate has rectangular shaped work volume.

The project is made on the basis of the fundamentals of mechanics, electronics and robotics. The main aspects on the emphasis is given while making the robot are > To reduce weight of the arms > To increase efficiency of the robot > To reduce load bearing capacity on wheels > To create balance while lifting loads The powerhouse of robot is a 12V battery, which is used to drive all the motors in the robot. Also a 6V battery is used to run all the electronic components in the robot. The robot is operated with 434 MHz Radio Frequency Transmitter module. The remote control of the robot has a transmitter and the robot has a receiver placed in the chassis. The important feature of the robot is that it has an obstacle sensor which senses the obstacles in the path of the robot and alerts the user with a buzzer sound and stops the robot to avoid accidents. The solar panel fixed at the end of the robot is another feature. It is fixed to give support to the battery of robot, when the robot is in idle condition the internal resistances consume power of the battery, to balance this loss of power a solar panel is placed. The robot does a simple pick and place operation. It can be exclusively used in Flexible Manufacturing System (FMS) and can be used to handle nuclear fuel rods and hot materials.

Components
The main components of the robot are divided into two categories, electronic components and mechanical components. These components are fixed on the chassis and connected to electronic circuits which are operated by a remote control. The mechanical components constitutes of gears, wheels, grippers, and motors. These are the main components that play vital role in the motion of robot. The motor is connected to gears for accomplishing the motion of arms in two different ways. Even wheels are connected to motors; four motors are used to drive the wheels. The wheels in the opposite direction constitute for circular motion which makes the robot turn on the place itself. The mechanical components are driven by battery, which is an electrical component, the main power source of the robot. The electronic components are connected to the motor the circuits are operated by remote control. Mechanical components are the main drivers of any robot mechanism. These mechanical components are operated by electronic components which have circuits that play major role in operation of devices. The electronic components use microcontroller which is connected to each relative circuit of the robot. The electronic devices act as control to mechanical systems where each motion is obtained by each control given to the device.

The importance of various auxiliary devices is that they help in smooth operation of the robot. Each motion has its own circuit that is connected to the motor. The connection given to motor then it is connected to the battery, the power house of the robot. The power form battery is in DC mode where the power is directly used to drive dc motors. The components are fixed in a chassis. Then each circuit is connected to a 6V battery and signals are transmitted by radio frequency transmitter module. The frequency range is 434 MHz. this range is used to avoid clashes with other frequency ranges.

The various components used in the robot are classified as given below

Mechanical Components Gears Chain Drive Wheels and Grippers Electronic Components RF Transmitter Module Micro Controller Encoders & Decoders Relays Electrical Components Battery Solar Plate Motors and All these components are arranged in a chassis schematically which completes the robot body.

Mechanical Components
Mechanical Components are like the soul of any robot. By the involvement of mechanical components the robot is accomplished. For any robot a mechanical component is must in any of the form. The various mechanical components used in the robot arm are described below.

Gears
Gears are used in the robot to reduce or increase speed according to requirement. The various types of gears are Spur Gears Helical Gears Bevel Gears etc., Spur Gear is cylindrical in shape, with teeth on the outer circumference that are straight and parallel to the axis (hole). There are a number of variations of the basic spur gear, including pinion wire, stem pinions, rack and internal gears. The various types of spur gears are Pinion Wire is a long wire or rod that has been drawn through a die so that gear teeth are cut into its surface. It can be made into small gears

with different face widths, hubs, and bores. Pinion wire is stocked in 4 ft. lengths. Stem Pinions are bore-less spur gears with small numbers of teeth cut on the end of a ground piece of shaft. They are especially suited as pinions when large reductions are desired Rack is also a spur gear. Racks have their teeth cut into the surface of a straight bar instead of on the surface of a cylindrical blank. Rack is sold in two, four and six foot lengths, depending on pitch. Internal Gears have their teeth cut parallel to their shafts like spur gears, but they are cut on the inside of the gear blank. 1-8 GEAR LOGY

Helical Gears
A helical gear is similar to a spur gear except that the teeth of a helical gear are cut at an angle (known as the helix angle) to the axis (or hole). Helical gears are made in both right and left hand configurations. Opposite hand helical gears run on parallel shafts. Gears of the same hand operate with shafts at 90-degrees.

Bevel Gears
A bevel gear is shaped like a section of a cone and usually operates on shafts at 90-degrees. The teeth of a bevel gear may be straight or spiral. If they are spiral, the pinion and gear must be of opposite hand in order for

them to run together. Bevel gears, in contrast to miter gears, provide a ratio (reduce speed) so the pinion always has fewer teeth. Miter gears are identical to bevel gears except that in a miter gear set, both gears always have the same number of teeth. Their ratio, therefore, is always 1 to 1. As a result, miter gears are not used when an application calls for a change of speed.

Worms & Worm Gears

Worms are a type of gear with one or more cylindrical threads or starts (that resemble screw threads) and a face that is usually wider than its diameter. A worm gear has a centre hole (bore) for mounting the worm on a shaft.

Worm Gears
Worm gears like worms also are usually cylindrical and have a centre hole for mounting on a shaft. The diameter of a worm gear, however, is usually much greater than the width of its face. Worm gears differ from spur gears in that their teeth are somewhat different in shape, and they are always formed on an angle to the axis to enable them to mate with worms. Worms and worm gears work in sets, rotating on shafts at right angles to each other, in order to transmit motion and power at various speeds and speed ratios. In worm and worm gear sets, both the worm and worm gear are of the same hand. (Because right- hand gearing is considered standard, right-hand sets will always be furnished unless otherwise specified.

Conjugate gear-tooth action

Spur Gears
The most common type of gear is spur gear. Spur gears are the simplest and most common type of gears with teeth parallel to the shaft axes and transmitting motion between parallel shafts. The robot here uses a spur gear, which is made of plastic. The use of plastic gears reduces noise, wear and tear of the material. Nylon gears are used in the robot. The gear train used here is of compound type. The compound gear train is used to reduce the speed of the outer gear. The combined gear train in the robot has four gears connected to it. The first gear in the mechanism is bigger one with 62 teeth the gear this gear has a small gear connected to the big gear. The small gear has 12 teeth to it. This gear is connected to a gear which has 76 teeth to it. The speed at the first gear is reduced by five times this reduces the rpm of the arm connected to the gear. The rpm of the motor is reduced by five times by using a compound gear train. The torque of the arm is increased by the arrangement. By the increase in torque, the load lifting capacity of the arm increases. This enhances the load bearing capacity of the end effectors. By varying the arm height the load can be handled accordingly. The greater the height the lesser the weight can be lifted. The lower the height the more the load can be lifted. All this mechanism can be achieved by varying the power consumption and reducing the gear ratio.

Geometry and Nomenclature

The basic requirement of gear-tooth geometry is the ability to transmit motion in a constant angular velocity ratio at all times. For example, the angular velocity ratio between a 20-tooth and a 40-tooth gear must be precisely 2 in every position. The action of a pair of gear teeth satisfying this requirement is termed conjugate gear tooth action. The basic law of conjugate gear-tooth action is: As the gear rotate, the common normal to the surfaces at the point of contact must always intersect the line of centres at the same point P, called the pitch point. Various tooth shapes can satisfy the law of conjugate geartooth action, but the most important one is the involute of the circle. An involute of the circle is the curve generated by any point on a taut thread as it unwinds from a circle. The gears used in the robot are combined to form a gear train which reduces the motor speed. There are two gear trains used in the arm motion which gives two degrees of freedom to arm in two ways. The arm parallel to is driven by the gear train far from it, the other one is driven by gear train near to it. Eight gears are used to drive the arms. The gears are connected to the motors which are fixed in a frame. The gears rotate when the motor is turned on this gives the drive mechanism. The gear to arm in the form of linear motion transmits the power. The circular motion of gears is converted to linear motion of arm end effector.

Chain Mechanism
The chain mechanism is used to drive the arm in direction perpendicular to ground. The chain drive is used to drive the arm such that the arm can be handled with more torque, it has more grip on the arm which gives stability to arm when lifting weight. The chain becomes stiff and hard while tension is applied on to it, or else it will be tight when there is no load on it. Chain drives operate with a constant ratio. Due to the positive interaction between the chain and sprockets, there is no slipping. The pitch of a chain is the distance between adjacent roller centers. The driving sprocket and the driven sprocket each have a number of teeth designed to match the size and pitch of chain. The transmission of rotational speed and power between the sprockets follows relations similar to those developed for gears. Lubrication is an important factor in chain drive maintenance. A property-lubricated chain can last 100 times longer than an identical, improperly lubricated chain.

Grippers
An end effector is a device that attaches to the wrist of the robot arm and enables the general-purpose robot to perform a specific task. There are wide assortments of end effectors required to perform the variety of different work functions. The various types can be divided into two major categories: 1. Grippers and 2. Tools In the robot a gripper is used which is used to hold devices. Grippers are end effectors used to grasp and hold objects. The objects are generally work-pieces that are to be moved by the robot. These part handling applications are machine loading and unloading, picking parts from a conveyor, and arranging parts onto a pallet. Even cartons, bottles, raw materials and tools can be handled by robot using grippers. Various types of grippers are: Mechanical Grippers Vacuum Cups Magnetic Grippers Adhesive Grippers Hooks, scoops and other miscellaneous devices

Mechanical Grippers
A mechanical gripper is an end effector that uses mechanical fingers actuated by a mechanism to grasp an object. The fingers are the appendages of the gripper that actually make contact with the object. The fingers are attached either to the mechanism or to an integral part of the mechanism. If the fingers are of attachable type, then they can be detached and replaced. The common type of gripper has two fingers to it. The function of gripper mechanism is to translate some form of power input into the grasping action of the fingers against the part. The power input is supplied from battery. The mechanism must be able to open and close the fingers and to exert sufficient force against the part when closed to hold it securely. There are two ways of constraining the part in the gripper. The first is by physical construction of the part within the fingers. The gripper fingers enclose the part to some extent, thereby constraining the motion of part. This is usually accomplished by designing the constraining the surfaces of the fingers to be in the approximate shape of the part geometry. The second way of holding the part is by friction between the fingers and work piece. With this approach, the fingers must apply a force that is sufficient for friction to arise during the holding portion of the work cycle.

Types of Gripper Mechanisms

The grippers can be classified on the basis of Finger Movement 1. Pivoting Movement 2. Linear or Translational Movement Kinematic Device used for actuation of Finger Movement 1. Linkage Actuation 2. Gear and Rack Actuation 3. Cam Actuation 4. Screw Actuation 5. Rope and Pulley Actuation, etc., The grippers in the robot are actuated by screw mechanism. A motor, usually accompanied by a speed reduction mechanism, turns the screw. When the screw is rotated in one direction, this causes a threaded block to be translated in one direction. When the screw is rotated in the opposite direction the threaded block moves in opposite direction. The threaded block is connected to the gripper fingers to cause the corresponding opening and closing action. The screw thread mechanism used in gripper is to give strength to fingers while holding the object. The thread wont slip when an object is lifted. The motor has a shaft fixed to it; to it a nut is welded in which a

threaded shaft rotates. When the motor is actuated the nut revolves in the thread by which the gripper opens.

Tools as End-effectors
In a limited number of applications, the end effector is a gripper that is designed to grasp and handle the tool. The reason for using a gripper in these applications is that there may be more than one tool to be used by rocket in work cycle. In most of the robot applications in which a tool is manipulated, the tool is attached directly to the robot wrist. In these cases the tool is the end effector. Some examples of tools used as end effectors are: 1. Spot-welding Tools 2. Arc-welding Torch 3. Spray-painting Nozzle 4. Rotating spindles for: 1. Drilling 2. Routing 3. Wire Brushing 4. Grinding 5. Liquid cement applications 6. Heating Torches 7. Water jet cutting Tool

Materials Used
The material used for making arm is aluminum and for chassis mild steel rods are used. The main purpose of using aluminum is to reduce weight on the body of the robot and also to reduce the load acting on the motors. As aluminum weight is lesser than the mild steel rods, so it is used to make arms and holes are drilled into the aluminum rods to further reduce the weight of the arm. The aluminum rods are non corrosive, and durable this makes it as the most appropriate metal for making arm. The mild steel rods are used to make chassis. As aluminum rods are not suitable to bear heavy loads (up to 20kgs of the robot) and cannot be welded, mild steel is used. The chassis is emulated from pyramids structure by removing top and bottom parts. Then chassis is painted with black color. The chassis is covered by aluminum sheets. Drilling is done on the chassis and parts where required and taping is done to the holes to fix bolts and join the parts. It is also done on the shaft of the motor to fix bolt to it.

Electronic Components
The electronic components used in the robot enable us to communicate with the robot and its inner parts. The components consist of mainly: 1. RF Transmitter Module 2. Micro Controllers 3. Encoders & Decoders 4. Relays The electronic components are connected on a circuit board, to which a power supply is given. The power required to run the components is taken from the battery. The other important component is remote in which a separate circuit is taken. The remote is medium of transmitting signal to robot.

RF Transmitter Module
Radio frequency (RF) transmitters are widely used in radio frequency communications systems. With the increasing availability of efficient, low cost electronic modules, mobile communication systems are becoming more and more widespread. Wireless communications systems, including cellular phones, paging devices, personal communication services (PCS) systems, and wireless data networks, have become ubiquitous in society.

mobile

terminal

apparatus

used

in

the

cellular

radio

communications system receives a radio frequency signal transmitted from a base station, by an antenna, inputs the signal to a receiving radiofrequency unit via an antenna duplexer, high frequency amplifies the signal, removes unnecessary waves outside the receiving band from the signal, converts the signal to an intermediate frequency signal, demodulates the intermediate frequency signal by a demodulator, and converts the signal into a base band signal. Generally, a radio transmitter and receiver is used for performing a radio transmission and receiving operation, whereby a high frequency signal outputted from a modulator is transmitted to an antenna of the radio transmitter and is transmitted there from to a remote radio transmitter and receiver, or the thusly transmitted signal is received through another antenna. The transmitting base band signal is subjected to a predetermined signal process, input to a modulator, which modulates a carrier wave signal. The modulated carrier wave signal is converted into a radio frequency by a transmitting radio-frequency circuit and amplified to a predetermined transmitting power, and transmitted to the base station from the antenna via the duplexer. Communication systems are known to support wireless and wire lined communications between wireless and/or wire lined communication devices. Such communication systems range from national and/or international cellular telephone systems to the Internet to point-to-point in-home wireless networks. Depending on the type of wireless communication system, a wireless communication device, such as a cellular

telephone, two-way radio, personal digital assistant (PDA), personal computer (PC), laptop computer, home entertainment equipment, etc., communicates directly or indirectly with other wireless communication devices. For direct communications, the participating wireless communication devices tune their receivers and transmitters to the same channel or channels. For indirect wireless communications, each wireless communication device communicates directly with an associated base station and/or an associated access point via an assigned channel. Compact radio frequency (RF) transmitters are widely employed to transmit radiating signals for use in connection with remote signal communication systems. RF transmitters are widely used in repeater-based communications systems, such as cellular and satellite mobile phone communications systems. A wide variety of compact transmitters are commonly used with automotive vehicle remote keyless entry systems for remotely controlling access to a vehicle in addition to controlling other vehicular functions such as alarm system features, trunk release, etc. Similarly, compact transmitters are also widely used for remotely controlling the operations provided with automatic garage door systems, electronic sound systems, televisions and VCRs. In cellular systems, a plurality of base stations is distributed across the service area. Each base station services wireless communications within a respective cell. Both base stations and subscriber units include radio

frequency transmitters and RF receivers, together they're called "RF transceivers." RF transceivers service the wireless links between the base stations and subscriber units. Transceivers are used in wireless communications to transmit and receive electromagnetic waves in free space. RF receivers generally either convert an input RF signal to an intermediate frequency, or directly mix an input signal to a direct current (DC) signal. The transmitter includes a data modulation stage, one or more intermediate frequency stages, and a power amplifier. The RF transmitter receives a base band signal from a base band processor, converts the base band signal to an RF signal, and couples the RF signal to an antenna for transmission. In most RF transmitters, the base band signal is first converted to an intermediate frequency (IF) signal and then the IF signal is converted to the RF signal. The data modulation stage converts raw data into base band signals in accordance with the particular wireless communication standard. The one or more intermediate frequency stages mix the base band signals with one or more local oscillations to produce RF signals. The power amplifier amplifies the RF signals prior to transmission via an antenna. The function of the receiver is to detect signals in the presence of noise and interference, and provide amplification, down conversion and demodulation of the detected the signal such that it can be displayed or used in a data processor.

The RF receiver receives an RF signal, converts the RF signal to an IF signal, and then converts the IF signal to a base band signal, which it then provides to the base band processor. As is also known, RF transceivers typically include sensitive components susceptible to noise and interference with one another and with external sources. The RF receiver is coupled to the antenna and includes a low noise amplifier, one or more intermediate frequency stages, a filtering stage, and a data recovery stage. The low noise amplifier receives an inbound RF signal via the antenna and amplifies it. The one or more intermediate frequency stages mix the amplified RF signal with one or more local oscillations to convert the amplified RF signal into a base band signal or an intermediate frequency (IF) signal. Typical transmit circuitry includes a feedback loop (often a phaselocked loop, or PLL) that has a voltage-controlled oscillator (VCO) and a loop filter circuitry. Phase locked loops (PLLs) are becoming increasingly popular in integrated wireless transceivers as components for frequency generation and modulation. PLLs are typically used for one of a variety of functions, including frequency translation to up-convert a base band (BB) signal to an intermediate frequency (IF) or to up-convert a base band or IF signal to RF prior to amplification by a power amplifier and transmission. Inductive/capacitive (LC) oscillators are important elements of RF transmitters, where the LC oscillators are used as master oscillators or as receivers where the LC oscillators are used as local oscillators. In general, the function of a radio frequency (RF) transmitter is to modulate, up convert, and amplify signals for transmission into free space. An RF transmitter generally includes a modulator that modulates an input

signal and a radio frequency power amplifier that is coupled to the modulator to amplify the modulated input signal. The radio frequency power amplifier is coupled to an antenna that transmits the amplified modulated input signal. Power amplifiers are required in radio telecommunication systems to amplify signals before transmitting, because a radio signal attenuates on the radio path. For efficiency, the amplifier is often a non-linear amplifier operated near its peak capacity. To avoid distortion of the transmitted signals due to the non-linearity, the signals are pre-distorted by a predistorter before they are transmitted. The pre-distortion is required to prevent transmitter from

transmitting signals on channel bands other than the band assigned to the transmitter. Digital predistortion may be performed by multiplying the modulated signals prepared for transmission by a set of predistortion values. The predistortion values are chosen such that the product values entering the power amplifier will be distorted by the power amplifier to return to a substantially linear amplification of the modulated signals. A direct conversion transmitter system to produce a transmission signal is generally comprised of a low oscillator (LO), a phase locked loop (PLL), a quadrature generator, a modulator, a power amplifier (PA), and one or more filters. The low oscillator, coupled to the PLL, produces a signal with a frequency that is substantially equal to the frequency of a desired RF transmission signal. The quadrature generator is coupled to the low oscillator and the modulator. The PA is coupled to the quadrature

generator, and receives the transmission signal and amplifies it. The amplified signal may go through a filter to reduce noise or spurious outputs outside of the transmission band. High quality RF transmitters typically include band pass filters, such as surface acoustic wave (SAW) filters provide excellent performance. A typical cell phone may employ a band pass filter following the power amplifier to reduce undesired noise present at the antenna in different portion of RF spectrum to meet various standards' regulations and specifications. The optimal functioning of a transmitter in a telecommunications system depends upon the suitability of the bandwidth of the transmitted signal to its data rate and modulation type. Cellular phones are designed to operate within the environment of one of several mobile communications networks. Transmitters and receivers for communication systems generally are designed such that they are tuned to transmit and receive one of a multiplicity of signals having widely varying bandwidths and which may fall within a particular frequency range.

Microcontroller
There are two microcontrollers used in this robot. They are

1. AT89S52 and 2. ATmega8 AT89S52 Microcontroller

Features Compatible with MCS-51 Products 8K Bytes of In-System Programmable (ISP) Flash Memory Endurance: 10,000 Write/Erase Cycles 4.0V to 5.5V Operating Range Fully Static Operation: 0 Hz to 33 MHz Three-level Program Memory Lock 256 x 8-bit Internal RAM 32 Programmable I/O Lines Three 16-bit Timer/Counters Eight Interrupt Sources Full Duplex UART Serial Channel Low-power Idle and Power-down Modes Interrupt Recovery from Power-down Mode Watchdog Timer Dual Data Pointer

 Power-off Flag Fast Programming Time Flexible ISP Programming (Byte and Page Mode)

The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8K bytes of in-system programmable Flash memory. The device is manufactured using Atmels high-density nonvolatile memory technology and is compatible with the industry-standard 80C51 instruction set and pin-out. The on-chip Flash allows the program memory to be reprogrammed in-system or by a conventional nonvolatile memory programmer. By combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip, the Atmel AT89S52 is a powerful microcontroller which provides a highly-flexible and cost-effective solution to many embedded control applications.

The AT89S52 provides the following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the AT89S52 is designed with static logic for operation down to zero frequency and supports two software selectable power saving modes. The Idle Mode stops the CPU while allowing the RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power-down mode saves the RAM con-tents but freezes the oscillator, disabling all other chip functions until the next interrupt or hardware reset.

Pin Description VCC = Supply voltage. GND = Ground

Port 0
Port 0 is an 8-bit open drain bidirectional I/O port. As an output port, each pin can sink eight TTL inputs. When 1s are written to port 0 pins, the pins can be used as high-impedance inputs. Port 0 can also be configured to be the multiplexed low-order address/data bus during accesses to external program and data memory. In this mode, P0 has internal pull-ups. Port 0 also receives the code bytes during Flash programming and outputs the code bytes during program verification. External pull-ups are required during program verification.

Port 1
Port 1 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 1 output buffers can sink/source four TTL inputs. When 1s are written to Port 1 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 1 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. In addition, P1.0 and P1.1 can be configured to be the timer/counter 2 external count input (P1.0/T2) and the timer/counter 2 trigger input (P1.1/T2EX), respectively, as shown in the following table. Port 1 also receives the low-order address bytes during Flash programming and verification.

Port 2
Port 2 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 2 output buffers can sink/source four TTL inputs. When 1s are written to Port 2 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 2 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Port 2 emits the highorder address byte during fetches from external program memory and during accesses to external data memory that uses 16-bit addresses (MOVX @ DPTR). In this application, Port 2 uses strong internal pull-ups when emitting 1s. During accesses to external data memory that uses 8-bit addresses (MOVX @ RI); Port 2 emits the contents of the P2 Special Function Register. Port 2 also receives the high-order address bits and some control signals during Flash programming and verification.

Port 3
Port 3 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 3 output buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 3 pins that are externally being pulled low will source current (IIL) because of the pull-ups. Port 3 receives some control

signals for Flash programming and verification. Port 3 also serves the functions of various special features of the AT89S52, as shown in the following table.

RST
Reset input. A high on this pin for two machine cycles while the oscillator is running resets the device. This pin drives high for 98 oscillator periods after the Watchdog times out. The DISRTO bit in SFR AUXR (address 8EH) can be used to disable this feature. In the default state of bit DISRTO, the RESET HIGH out feature is enabled.

ALE/PROG
Address Latch Enable (ALE) is an output pulse for latching the low byte of the address during accesses to external memory. This pin is also the program pulse input (PROG) during Flash programming. In normal operation, ALE is emitted at a constant rate of 1/6 the oscillator frequency and may be used for external timing or clocking purposes. Note, however, that one ALE pulse is skipped during each access to external data memory. If desired, ALE operation can be disabled by setting bit 0 of SFR location

8EH. With the bit set, ALE is active only during a MOVX or MOVC instruction. Otherwise, the pin is weakly pulled high. Setting the ALEdisable bit has no effect if the microcontroller is in external execution mode.

PSEN
Program Store Enable (PSEN) is the read strobe to external program memory. When the AT89S52 is executing code from external program memory, PSEN is activated twice each machine cycle, except that two PSEN activations are skipped during each access to external data memory.

EA/VPP
External Access Enable; EA must be strapped to GND in order to enable the device to fetch code from external program memory locations starting at 0000H up to FFFFH. Note, however, that if lock bit 1 is programmed, EA will be internally latched on reset. EA should be strapped to VCC for internal program executions. This pin also receives the 12-volt programming enable voltage (VPP) during Flash programming.

XTAL1
Input to the inverting oscillator amplifier and input to the internal clock operating circuit.

ATmega8 Microprocessor
Features High-performance, Low-power AVR 8-bit Microcontroller Advanced RISC Architecture 130 Powerful Instructions Most Single-clock Cycle Execution 32 x 8 General Purpose Working Registers Fully Static Operation Up to 16 MIPS Throughput at 16 MHz On-chip 2-cycle Multiplier High Endurance Non-volatile Memory segments 8K Bytes of In-System Self-programmable Flash program memory 512 Bytes EEPROM 1K Byte Internal SRAM Write/Erase Cycles: 10,000 Flash/100,000 EEPROM Data retention: 20 years at 85C/100 years at 25C Optional Boot Code Section with Independent Lock Bits In-System Programming by On-chip Boot Program True Read-While-Write Operation Programming Lock for Software Security Peripheral Features Two 8-bit Timer/Counters with Separate Pre-scaler, one Compare Mode One 16-bit Timer/Counter with Separate Pre-scaler, Compare Mode, and Capture

 Mode Real Time Counter with Separate Oscillator Three PWM Channels 8-channel ADC in TQFP and QFN/MLF package Eight Channels 10-bit Accuracy 6-channel ADC in PDIP package Six Channels 10-bit Accuracy Byte-oriented Two-wire Serial Interface Programmable Serial USART Master/Slave SPI Serial Interface Programmable Watchdog Timer with Separate On-chip Oscillator On-chip Analog Comparator Special Microcontroller Features Power-on Reset and Programmable Brown-out Detection Internal Calibrated RC Oscillator External and Internal Interrupt Sources Five Sleep Modes: Idle, ADC Noise Reduction, Power-save, Powerdown, and Standby I/O and Packages 23 Programmable I/O Lines 28-lead PDIP, 32-lead TQFP, and 32-pad QFN/MLF Operating Voltages 4.5 - 5.5V (ATmega8) Speed Grades 0 - 16 MHz (ATmega8)

Pin Descriptions
Vcc = Digital supply voltage GND = Ground Port B [(PB7...PB0) XTAL1/XTAL2/TOSC1/TOSC2] Port B is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port B output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port B pins that are externally pulled low will source current if the pull-up resistors are activated. The Port B pins are tri-stated when a reset condition becomes active, even if the clock is not running. Depending on the clock selection fuse settings, PB6 can be used as input to the inverting Oscillator amplifier and input to the internal clock operating circuit. Depending on the clock selection fuse settings, PB7 can be used as output from the inverting Oscillator amplifier. If the Internal Calibrated RC Oscillator is used as chip clock source, PB7...6 is used as TOSC2...1 input for the Asynchronous Timer/Counter2 if the AS2 bit in ASSR is set. Port C (PC5...PC0) Port C is a 7-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port C output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port C

pins that are externally pulled low will source current if the pull-up resistors are activated. The Port C pins are tri-stated when a reset condition becomes active, even if the clock is not running. PC6/RESET If the RSTDISBL Fuse is programmed, PC6 is used as an I/O pin. Note that the electrical characteristics of PC6 differ from those of the other pins of Port C. If the RSTDISBL Fuse is un-programmed, PC6 is used as a Reset input. A low level on this in for longer than the minimum pulse length will generate a Reset, even if the clock is not running.

Port D (PD7...PD0) Port D is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The Port D output buffers have symmetrical drive characteristics with both high sink and source capability. As inputs, Port D pins that are externally pulled low will source current if the pull-up

resistors are activated. The Port D pins are tri-stated when a reset condition becomes active, even if the clock is not running.

RESET Reset input: A low level on this pin for longer than the minimum pulse length will generate a reset, even if the clock is not running.

Relay
Relay is a device that protects the circuit from gaining more current and avoids fluctuations in voltage and other mishandling effects. The errors are reduced by using relays. They protect the electronic equipment from getting damaged. Relays find applications in 1. Industrial electronics 2. PLCs 3. Timers 4. Office automation 5. UPS 6. Home appliances 7. Robotics

Electrical Components
The electrical components used can be classified as Motors Solar Plate Battery The electrical components are the main drivers of the robot. The power is supplied to robot from battery. This power is utilized in many ways for various motor movements. The power source is a battery, which is chargeable. Solar plate used in the robot is used as back up if any problem occurs in the battery. The schematic explanation of various components is given below.

Motors
A set of eight motors are used in the robot. The motors are the main driving source of the body and arms. The motors are placed at each wheel to drive the wheels. A set of two motors are combined and placed in chassis. The motors placed at the center of the chassis acts like the centre of gravity of the whole robot. These motors are used to drive the robot arm. The arms are classified into two parts, the arm perpendicular to base and parallel to base. The motor is set such that the arm parallel to the base move in up and down to earth as reference. The arm perpendicular to base moves in to and fro motion this is also fixed to same motor combination.

The arm perpendicular to base has a chain drive affixed; to it the other arm is connected with a pulley. The arm parallel to the base is driven by the pulley connected to it by a chain drive. Motors are combined to add mass to the chassis and give stability when the body moves on uneven surface. The battery and the motor are balanced in weight in the chassis. A motor is used to drive the grippers which are rotated by the screw that is fixed to its shaft, on revolution of screw in shaft the gripper opens and the fingers are opened in turn. The fingers have degrees of freedom to move in open and close directions. Another motor is used to drive the solar plate fixed at the end of the robot. The plate uses a screw thread mechanism to open and close. The shaft of the motor is connected to the screw in which a threaded shaft revolves; by this motion the solar plate moves at a fixed end resulting in open and close operation. The robot has a separate motor fixed to drive each wheel on the corners of the chassis. These motors play important role in robot motion and load bearing capacity of arm while moving. The motor on the right of wheels allow robot to steer right and at left makes robot to steer left. The steering motion is accomplished when the motors are coupled to each other so that when pressed right in remote make robot to move right on the spot. The mechanism is facilitated when the motor in right revolves in forward direction and left in reverse direction; resulting the robot to move in left direction. Similarly when to move right the right side motor will revolve in reverse direction.

All the motors are actuated by a radio frequency transmitter remote. A set of twelve switches are used to operate each motor in each specific direction, i.e. forward or reverse.

Solar Plate
A solar plate is fixed on the back of the chassis. The purpose of the solar plate is to give backup to the main battery when the battery gets discharges. The solar plate charges the battery when placed in light. The plate absorbs protons in the light rays and emits the power. This power is stored in the battery and used as backup. The solar plate is operated according to the suns direction by a motor placed in the chassis. The motor is operated by a remote.

Battery
Two batteries are used in the robot. A 6V battery is used specifically for electronic circuit operation. A 12V battery is used for running motors, to this battery a charging point and solar plate is fixed. An on-off toggle switch is used to start the robot. The battery and motors are joined by using electronic circuits to control the operation of robot. The purpose of using two batteries is to reduce load on the single battery and reduce power consumption and weight of robot. Instead of using a single battery with more power and weight, a separate battery is

used for each purpose as electronic circuits consumes less power than motors so a smaller power battery is given. Specifications Battery used for robot operation: Output Voltage : 12 V 7 Amp-Hr 84 kWHr

Output Current : Power :

Battery used for electronic circuits: Output Voltage Power : : 6V 7 Amp-Hr 42 kWHr

Output Current :

Obstacle Sensor An obstacle sensor is placed in front of the robot to sense the objects that come in the way of the robot. It is coupled to a flash bulb which actuates when an obstacle is sensed and buzzer is actuated. Features Photo detector and preamplifier in one package Inter filter for PCM frequency Improved shielding against electrical field TTL and CMOS compatibility Output active low Low power consumption High immunity against ambient light Continuous data transmission possible

A TSOP17 sensor is fixed on the front of the robot tray this senses the object that is placed before robot using Infra Red radiation.

Parts Making
The important aspect of construction of a robot is to make parts. In this chapter the various steps involved in making robot and joining them will be explained. As the parts are not readily available in market we have to make it in the requirements of the purpose. The parts that are made to build robot are 1. Chassis 2. Arms 3. Grippers

Grippers
In the process of design the first part made was gripper and fingers. The material used for making the arms and fingers is aluminum. The reason for selecting aluminum is to reduce weight of the parts. As aluminum has lower weight than mild steel or cast iron sheets. The metal is non-corrosive, malleable, and durable. First the required shape of the fingers is designed. The shape is the replicated on a mild steel plate for testing the shape. Now the required changes are made to the fingers design practically. Then the main model is made on the aluminum metal rods. The dimensions of the fingers are 10 cm in length and the width of the rods is .5 cm. The rods are bent to required shape by fixing metal to bench vice and hitting on the rod.

When the required shape is achieved the rods are joined by an aluminum metal sheet. The sheet is joined on the outer part of the rods by riveting on the corners of the sheet. The fingers are actuated by a screw thread mechanism. To operate using a screw thread mechanism the fingers are connected by an S shaped link on the non-working part of the fingers. The link is made on mild steel sheet as it can take wear and tear. To the ends of the sheet holes are drilled to join those to the fingers similarly on the fingers holes are drilled to join the links at required position. Two such links are made to join both the fingers to the threaded shaft. The links are joined to shaft by welding it to a rod and placing it perpendicular to the threaded shaft. Threaded shaft mechanism is used in the gripper to open and close the fingers. The reason to use this mechanism is to give strength to gripper while lifting load. As threaded shaft has thread on its surface, when the nut revolves around the thread the teeth are fixed in the groove so that there is no slip in drive mechanism. The rotational motion of the motor is converted to linear motion of the gripper. The motor revolves when current is supplied to it. This revolution is converted to forward and reverse motion of the threaded shaft. This is the first conversion of linear motion to rotational motion. Then the linear motion of the threaded shaft is converted to to and fro motion of S shaped link, this link is connected to gripper. The motion of S

link is converted to horizontal motion of fingers this motion is perpendicular to the arm. A rubber strip is pasted on the inner part of the fingers. This is pasted to avoid direct contact of aluminum rods with materials being handled. The strip acts as insulation for fingers. This gives grip to fingers from slipping of materials.

Arms
The main part of the robot is arms. The arms are made by cutting aluminum rods to required length. Aluminum is used to reduce load on motor and overall weight of robot. The arms are made to the function required. The functions that are served by arms are; first to give support to grippers and fingers, and other to give support to the arm holding fingers. The arms are operated by motors placed in the chassis of robot. The motors are coupled to each other. A shaft from each motor is taken out to run gears affixed on the shaft, which are connected to arms. The arms are named according to their functions. The arm perpendicular to base is middle arm. The arm parallel to base is gripper arm as it is joined to gripper. The gripper arm is supported by middle arm. The gripper arm is operated using a chain drive mechanism. The drive gives grip and torque to hold and lift the object. Slots are made into the arm to reduce its weight.

The middle arm is driven by gears connected at the end of the arm. The middle arm gives support to the gripper arm. The arm is supported by the weight of the motors placed besides it. The motors act as centre of gravity of the robot to which all the attachments are mounted and connected to balance the arm and body while in action. The gears are connected to reduce the speed of the motor. By reduction is speed more torque is obtained. This torque allows the arm to lift loads more than the critical limit. The more torque; the more the capability to lift loads and the more power consumption.

Chassis
The important point in making chassis is that the load bearing capacity of the arm is totally managed by the lower body of the arm, chassis. By considering the total weight of the robot we have designed chassis to bear load up to 50 times of the load lifted by the arm. The design of the chassis is primarily based on the structure of pyramid. But the top part of the pyramid is removed for accommodating arm. The design is based to support the arm at all positions when load is being lifted by grippers. The chassis is made by welding the mild steel rods according to the design requirements. The rods are welded to form a box like structure. The box is painted in black color. Holes are drilled where the aluminum sheets are to be joined.

To the front part of chassis two metal rods are welded to hold tray. The rods are drilled with holes to hold tray. The obstacle sensor is placed below the tray to sense obstacle and to stop the robot to avoid further accidents. To the back part of the chassis a hinge is welded for holding solar plate to it. The solar plate is attached to the hinge by using bolts. The solar plate is operated by motor placed in the chassis. All the motors are actuated by a remote which transmits signals from the remote to robot and actuates the motors.

Assembly
In assembly all the parts are joined schematically to make a robot. The important point to be noted while making robot is to consider factors like slip, jerk, balance and load bearing capacity. These factors must be rectified on testing the robot practically. The robot assembly is main phase of the robot building. The sequence followed in assembly is reverse to the parts making. First the motors are fixed in the chassis, and then arms are fixed to the motors. At the same time motors to run the wheels are fixed. Then batteries are fixed. After fixing arms chain is fixed to the arm. At the end solar panel is fixed. After fixing of mechanical components, electronic components are fixed. Each motor is connected to the circuit accordingly. The motors are connected to the circuit by soldering the wires to the terminals. An obstacle sensor is placed below the tray and a flash led is connected to it, simultaneously a buzzer is connected to the sensor; the bulb and buzzer are actuated when an obstacle is sensed. All the electronic components are connected to a 6V battery. After fixing of aluminum sheets on the chassis, to cover all the inner parts, solar panel is fixed at the hinge. Solar panel is already connected to the battery for backup. Then a on off toggle switch is placed below the solar panel, this switch is used to turn on or off the robot. When the robot is

turned on the led in red is turned on as indication. When solar panel is charging the battery green color led is turned on. A charge point is given to the robot to charge the battery externally. This battery is charged using an adapter which converts AC current to DC current. At the end of assembly wheels are fixed to the chassis. The wheels are fixed directly on to the shafts of the motors. The wheels are joined to the motors by placing a bush in to each wheel. Drilling hole into shaft and bush a bolt is placed to join the wheels. A set of six wheels are used to drive the robot. The centre wheels are idle and are used to give support to the robot.

Testing
Before robot actually starts working it is tested to various working conditions. In testing the robot ability is assessed and alterations are made to the design. Testing involves checking the working of mechanical and electronic components. If any problem occurs when testing the robot the error is rectified. The robot is also analyzed using ANSYS software for thermal and structural analysis for further development of robot in real working conditions.

Working
After robot is tested for severe working conditions the robot is used for real time work environment. The robot finds its application in flexible manufacturing system where the robot moves in fixed area with constant work volume and similar work. The robot is used to handle work pieces from one machine to other. It picks the work piece at one machine and transfers to other machine. The robot can lift various objects of different shape and size. The various general shapes the robot can transfer are Cylindrical objects less than 4 inch diameter Square and rectangular object less than 4 inch length Spherical objects less than 4 inch diameter

The object is first grasped by fingers. To grasp an object the robot must go near to the object and pick it up. To pick the object the fingers are actuated using a remote. After the object is picked the transfer of object comes next. To move the robot the forward button in remote is pressed to move forward. To move backwards the back button is pressed. To turn right and left relative buttons are pressed. Then the robot is moved to required position and the object is placed. The steering mechanism used in the robot is a replica of steering mechanism used in military tanks. To move right the wheel at right of the

chassis runs in reverse direction and wheels at left run in forward direction. Similarly when robot has to turn left the wheels at left revolve in reverse direction and wheels in right runs in forward direction. This mechanism helps the robot to turn on the spot. The arms are moved using motors placed at the bottom of the middle arm. The motors make the arm move in their degrees of freedom limit. The middle arm moves in forward and backward direction corresponding to base. The gripper arm moves in longitudinal direction corresponding to base.

Design
The robot is designed in Pro-E. the design is done on the basis of dimensions of the robot. This is the application used to test the conditions of the robot by performing further analyses on the robot to various load conditions.

Pro-E
Pro-E is a CAD package used for designing the model in graphical user interface. The model generated in pro-e package is a simulated model of the real model. The design helps us to analyze the model further by transferring it any analyses software. By drawing the model in CAD software the model is replicated according to the user requirements. The procedure of drawing is simple in Pro-E. The figure is first constrained to the axis and the model is developed. The developed model is generated according to the dimensions of the robot. By fixing the constraints the model generation is easier and errors are removed. Pro-E is used to generate the model because this software enables us to transfer data from pro-e to ansys. The CAD software is a complete package which can be used for developing and simulating models.

The above figure shows the CAD model of the robot. This model is drawn in Pro-E the model represents the robot in real time. First the arms are drawn then the gripper is designed and assembled to the arm. Then chassis is drawn and the parts are assembled to each other.

ANSYS
The figure drawn in pro-e is transferred to ansys for further analyses on the robot. The analysis of robot is nothing but testing the robot artificially. The robot is tested for various load conditions. Then the results are tabulated in the image this gives the limits of working. The factor of safety is calculated from the picture obtained. Ansys is software used for analyzing various models of various thermal and structural analyses. The analyses done gives us the limiting working conditions of the model for which analysis is done. The robot has undergone load tests in sequence of 1kg, 2kg and 2.5kg. The values are saved and working conditions are determined.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in X direction. The values obtained are Deflection: 8.9 mm Shear Stress: 761.79 N/m2 Load: 1kg The color of figure is green this implies that the beam is safe when load is applied in X direction.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in Y direction. The values obtained are Deflection: 8.9 mm Shear Stress: 1041 N/m2 Load: 1kg The color of figure is greenish yellow this implies that the beam is safe but on further application of load causes deflection when load is applied in Y direction.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in Z direction. The values obtained are Deflection: 8.9 mm Shear Stress: 2588 N/m2 Load: 1kg The color of figure is green this implies that the beam is safe when load is applied in Z direction.

The above figure shows the model generated in wire frame. Which shows the deflection in arm when 2.5kg of load is applied. This means that at 2.5kgs of load the bending starts in arm. So the limiting load can be 2.5kg to 3kg maximum.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in X direction. The values obtained are Deflection: 18.855 mm Shear Stress: 1796 N/m2 Load: 2.5kg The color of figure is green this implies that the beam is safe when load is applied in X direction. But the gripper is deflected this shows the maximum limit bearable is approached.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in Y direction. The values obtained are Deflection: 18.855 mm Shear Stress: 5121 N/m2 Load: 2.5kg The color of figure is green this implies that the beam is safe when load is applied in Y direction. But the gripper is deflected this shows the maximum limit bearable is approached.

The figure shows the analyses done on the robot arm for 1kg of load. The values are noted in Z direction. The values obtained are Deflection: 18.855 mm Shear Stress: 6142 N/m2 Load: 2.5kg The color of figure is green this implies that the beam is safe when load is applied in Z direction. But the gripper is deflected this shows the maximum limit bearable is approached.

Conclusion
The robot is analyzed and the results are At 1kg load the gripper is within the safe range. At 2kg load the gripper is within the safe zone. At 2.5kg load the gripper is within the safe zone but the gripper starts deflecting. This deflection shows the maximum limit is approached.

Specifications
No of axes Maximum reach Payload Speed : : : : 4 1m 2kg .33m/sec or 1ft/sec

BIBLIOGRAPHY
Industrial Robotics by Groover M P Robotics by K S Fu CAD CAM CIM by Radhakrishnan Software used PRO-E for designing the robot ANSYS for the analysis of robot.