Bachelor Thesis (B. Eng) : "Electronic Fencing System For Robot Work Area Using Infrared Sensors"

NTTF, ITEM
ELECTRONIC FENCING SYSTEM FOR ROBOT WORK

An institute of Steinbeis University. AREA USING INFRARED SENSORS.
“ELECTRONIC FENCING SYSTEM FOR ROBOT

WORK AREA USING INFRARED SENSORS”
Bachelor Thesis
(B. Eng)
Writer: GAGAN BATAKURKI

Guides: Prof. Manfred Lach
Mr. Hubert Reilard
Ms. Edla Blessy Phoebe
Duration: 01.01.2018 – 30.06.2018

NTTF, ITEM ELECTRONIC FENCING SYSTEM FOR ROBOT WORK
An institute of Steinbeis University. AREA USING INFRARED SENSORS
ABSTRACT
This proposal describes the electronic safety fencing system for robots using
infrared sensors. Industrial robots are operated with high power movements
and they are freely programmable with regards to routes and speed of
movement. It is not usually possible to predict the next movements of robot
hence accident hazards may arise with robots when humans enter into robot’s
workspace.
The current safety system for robots is often a mechanical visible fencing
system. Although mechanical fencing is implemented around robots for safety
still the accidents have been occurring due the human intervention inside the
workstation. So, in order to reduce the hazards with robots in current
mechanical fencing safety method, this proposal aims to increase the safety
level for workers by the addition implementation of electronic fence at level 2A
with the mechanical fencing system for robot work area so that the safety level
can be increased inside the work station. The proposed system can be build
using infrared fencing system that can be implemented in the vicinity of robot’s
reach or robot work envelope (The maximum volume of area up to which the
robot arm can move). The infrared fencing system can be done using infrared
sensors which has transmitter and receiver that can detect the interrupted IR
signals by an object.
An array of infrared transmitter and receiver can be place vertically at certain

height. IR LED as transmitter can be placed at one end and photodiode as
receiver at the other end. IR transmitter emits the IR radiation that will be received
by receiver. When any object interrupts the IR signal the receiver output pin goes
low. As soon as the output pin goes low, the robot’s emergency switch has to be
stopped using relay actuation and error triggering stop message should be
displayed as” IR signal is interrupted”. Relay will be interfaced with
Microcontroller, as soon as controller receives the signal from receiver it will
actuate the relay to switch off the emergency switch hence the robot movement
can be stopped. My thesis includes study of sensors and controllers hence it is
relevant to my domain.
BACHELOR THESIS 2018 GAGAN BATAKURKI

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Table of contents. III-IV
List of tables V
List of pictures V
List of abbreviation V
1.0 DESCRIPTION.............................................................................................. 01
1.1 Technical problem to be solved ............................................................... 01
1.2 Planned to do............................................................................................ 01
2.0 INTRODUCTION........................................................................................... 03
3.0 IMPORTANCE OF SAFETY ..........................................................................06
4.0 CHECK LIST DURING INSTALLATION OF SAFETY SYSTEM .................. 06
5.0 ROBOTS SAFETY METHODS ...................................................................... 07
6.0 OVERVIEW OF THE PROPOSAL… ............................................................. 08
7.0 DESIGN AND INSTALLATION OF INFRARED SENSORS.......................... 09
7.1 Calculation of safety distance .................................................................. 09
7.2 Parameters of sensor installation..............................................................10
7.3 Robots specifications ............................................................................... 10
7.4 Specifications of installed system ........................................................... 11
8.0 PHYSICAL VIEW OF FENCED SYSTEM ................................................... 12
8.1 FENCED SYSTEM FOR ROBOTS ........................................................ 13
9.0 BLOCK DIAGRAM .................................................................................... 14
10.0 EXPLANATION OF BLOCK DIAGRAM....................................................15
11.0 MECHANISM ............................................................................................16
12.0 INFRARED SENSOR ................................................................................ 18

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13.0 INFRARED LED ........................................................................................20
13.1 Description .................................................................................... 20
13.2 Specifications ................................................................................ 21
14.0 PHOTODIODE ...........................................................................................22
14.1 Description .................................................................................... 22
14.2 Working principle ................................................................................... 22
14.3 SPECIFICATION ................................................................................... 23
15.0 DESCRIPTION OF ASSOCIATED COMPONENTS .................................. 24
15.1 Comparator… ......................................................................................... 24
15.2 Microcontroller….................................................................................... 24
15.3 Relay...................................................................................................... 25
16.0 POWER SUPPLY UNIT… .......................................................................... 26
17.0 OVER ALL CIRCUIT DIAGRAM ................................................................ 26
18.0 FENCING SYSTEM WORKING ................................................................. 27
19.0 SYSTEM TESTING .....................................................................................28
20.0 BILL OF MATERILAS ............................................................................... 30
21.0 ADDITIONAL FEATURES OF THE SYSTEM… ........................................ 30
22.0 ADVANTAGE, DISADVANTAGE AND APPLICATION… ......................... 32
23.0 CONCLUSION ............................................................................................32
24.0 LIST OF REFERENCES ............................................................................. 33

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List of table:
Table no Particulars Page no

1 Bill of material 30
List of pictures
Figure no Particulars Page no

1.0 Conventional fencing 5
system
2.0 Fanuc robot 10
3.0 IR Fencing system 12
4.0 IR transmitter and receiver 13
5.0 Block diagram 14
6.0 Infrared sensor 19
7.0 Infrared LED 21
8.0 Photo diode 23
9.0 Relay 25
10.0 Circuit diagram 26
11.0 Test circuit 1 28
12.0 Test circuit 2 29
List of abbreviation
ANSI-American National standard institute

OSHA-Occupational Safety and Health Administration
IR-Infrared
LED-Light Emitting Diode

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1.0 DESCRIPTION
This thesis proposal describes the electronic safety system for the robot
work area using infrared sensors. The objectives of this topic are to increase
the safety level for workers around robots and also to improve the technology
behind the robot’s safety system by implementing the sensors.
There are four levels of safety zones inside robot’s workstation:
1) Level 1 – workstation penetration

2) Level 2A- Area inside the workstation but outside the reach of robots
3) Level 2B- Area inside the workstation but inside the reach of robots
4) Level 3- A small volume surrounding the robot arm which moves with the
robot arm.
The importance of this proposal is that as per present method of safety fencing
system the Level 1 of safety zone can be achieved by inserting the physical
barrier (mechanical fence) to prohibit the human movements inside the
workstation while robot working but since the people might open the doors of
mechanical fencing system to enter inside the workstation and they might cross
the Level 2A of safety zone which can result in occurrence of accidents with
robots that can cause severe injury and regarding this the past accidents
records are available.
In order provide the safety when people cross the level 2B of safety zone this
proposal can be a solution to ensure the safety for the workers. This system
can be built in less expensive using electronic devices like sensors,
microcontroller and safety relay but it is necessary to have preventive
maintenance to ensure the all the devices are working up to the mark.
1.1 TECHNICAL PROBLEM TO BE SOLVED:
The focused problem which is to be solved is that to avoid the chance of

accidents in robot workstation and to increase the safety level inside the robot’s
workstation for workers. Ensuring the safety for workers is most essential factor
that has to be considered before installing the robots. As the robots are playing
major role in most of the manufacturing process in industry, at other side the
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safety issues with robots have got huge demands in present generation of
robots.
If work force trapped with robots the huge hazards could happen and the
person may even die in some cases. Hence it must that every worker should be
protected by robot’s work area using effective safety system.
1.2 PLANNED TO DO:
The idea is to build the invisible electronic fence in the vicinity of robot’s reach
or work envelope using infrared sensor. Whenever anything interrupts this
sensor rays the robot movement has to be stopped in order to ensure the
safety for workers. It consists infrared led as transmitter that emits the infrared
rays and photodiode as receiver that receives the emitted rays from the
transmitter. The height of the fence depends on the size of the robot
To build the electronic fence at certain height with respect to the size of the
robot the number of infrared sensor are connected in series in direct incident
method. In direct incident method the infrared led and photodiode are placed
exactly opposite to each other hence whatever rays emitted by led directly falls
on the photodiode to produce the quick output voltage. This output is directly
proportional to the intensity of the emitted rays. The power supply will be
designed according the power rating of components used in this system.
As soon as power is supplied to the infrared sensor it will starts to emit the
infrared rays which invisible in nature, when anything interrupts the rays
whatever emitted rays will not fall on the photodiode, the resistance across the
photodiode changes hence output voltage changes according number of rays
falling on it.
The output from the photodiode is Analog signal. Since microcontroller needs
digital input hence this Analog signal can be converted into digital using
comparator. As soon as rays are interrupted the sensor will produce the output
signal. This signal will be given to controller that will actuates the relay to cut
the power to the robot, hence robot movement can be stopped temporarily.

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2.0 INTRODUCTION
An Industrial robot is machine system used in manufacturing to achieve the

more efficiency to increase the productivity hence the robots are adopted in
every manufacturing plant. The industrial robots are made automated and
capable of moving on three or more axes. Robots can be programmed to
operate for continuous production. Since the robot’s equipment are highly
flexible and can be used to perform complex operation.
Industrial robots are in grater use today hence manufacturing is increased to

stay competitive all around the world. Robots can replace number people
working for one task in industry and performs alone the same tasks on its own
more faster and accurately. If one robot does the tasks of what group of people
does, the labor cost can be reduced. Since humans cannot perform reputative
task hence robot is being installed to perform the reputative task accurately.
Robots can perform different tasks assigned to it through program like welding,
`painting, loading and unloading, cutting etc. Robots are used mainly in
assembly line where robots will be performing the given tasks with high power
movements in all directions rapidly. This leads to high productivity hence
everyone prefers the robots in industry.
As robot’s growth has been increasing faster, In the other side the safety issues
also are occurring with robots. Safety is one the most important thing which has
to be considered in industry. It needs to think not only how workers will be able
to perform their function integrally around robot but also about how safety has
to be ensured for worker with robots in the manufacturing plat. When robot is
placed in the industry it is important to know how to operate the robot and how
to operate it around safely.
Industrial robots operate with high forces and speed to injure severely or kill the
persons if they enter into robot’s workspace at operating time. These robots are
freely programmable with regards to routes and speed of movement and It is
not usually possible to predict the next movements of robot hence accident

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hazards may arise with robots when anything enters into robot’s workspace.
So, we must ensure the safety for robot workspace.
It is predicted based on the study analysis that 32 accidents were caused with
robots. it is showed that the robots accidents which are caused with robot’s
operators is 72%, Maintenance workers and programmers are 19% and 9%
respectively. Source: [1]
These accidents were results in various injuries like pinch injuries that occurs
when robot traps a worker between itself and an object and impact injuries that
occurs when robot and worker collide each other. The accidents might cause
due to unexpected behavior of robot, human errors and unexpected software
problem.
There are several reasons for which the humans enter into the robot’s work
area to set up the job, to reprogram the robot, for routine maintenance and to
inspect the robot operational system. They may not aware when to enter into
robot’s work area, at this time instantly they will enter into work area and get
harmed by robot.
In order to avoid these accidents, the conventional mechanical fencing system

has been implemented as safety system for robots. The robot’s workspace will
be fenced for all four sides of robots with single path with doors to transport the
parts into the robot’s workspace. The accidents are still uncontrolled with
mechanical fence hence the integration of mechanical and electronic fence can
increase the level of safety for the work force.
To achieve this proposal the invisible electronic fencing system can provide to
robot’s work area using infrared sensor that consist infrared led as transmitter
and photodiode as receiver. As soon as work force enters into the robot reach
by cutting the infrared rays, the robot machine will get stopped. This system will
give quick attention to the human as he will notice the machine stops working.
To cover robot work area up to certain height, series of infrared led and series
of photodiode can be place in direct incidence. In case of direct incidence, the
transmitter and receiver are kept opposite to each other. When anything

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interrupts the IR rays emitted by infrared led, the resistance of photodiode

decreases hence the voltage drop also decreases across the photodiode.
Using the variable resister connected with photodiode the output voltage can be
adjusted as our requirement either high or low.
When this output signal is given to microcontroller it will actuate the relay to
stop the robot machine. This infrared fencing system is easy to implement and
it costs less compare to mechanical fencing system.
Source: [2] Fig 1.0 CONVENTIONAL FENSING SYSTEM

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3.0 IMPORTANCE OF SAFETY

Accidents are unpredictable and unexpected in nature. The accidents are
caused by ourselves due to several reasons like lack of concentration, interest
and knowledge about the work which is being done. The result of these
accidents may lead to the severe injury or sometimes the person may die.
Hence in each and every work area the safety must be ensured for the worker
to prevent the causes of accidents particularly in robot work area. There is huge
risk out of these robot accidents because the speed of the robot motion is
unpredictable in every instant of time. If workers get tapped with robots, the
person may not survive. there will be safe work environment in the work, if the
safety is ensured hence workers can work effectively to give the best out of
them.
4.0 CHECK LIST DURING THE INSTALLATION OF SAFETY SYSTEM

1) Correct safety distance.
2) Ensuring there is no space to stand which is undetected by the sensor.
3) There should not be reach over, reach under or reach behind.
4) No large gaps left open. (not more than the 15mm)
5) The system should be always active. (By performing the preventive
maintenance that helps to ensure the proper working of each
components before it gets fail to perform its function)
6) It should be used only at protecting area not everywhere. Source: [3]

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5.0 ROBOT’S SAFETY METHODS
As robot’s growth is occurring rapidly in modern days for achieving the

quick and more accuracy job in every industry. However, the safety system
should be installed wherever the robots are placed to protect the workers from
the hazards that occur with robots in workplace. There are various safety
methods that are installed around the robots.
The following are the safety methods for robots:
1) Fixed barriers.
2) movable guards
3) sensitive protective equipment.
a) Pressure sensitive protective equipment.
b) Electro sensitive protective equipment.
1) Fixed barrier: The fixed barrier computes the mechanical fence, barriers
and covers which are removable by using the tools. These are the traditional
safety methods of robots where the wire grid will be welded into particular
frame size with minimum distance that prevents the entering of hand from one
wire to another wire.
2) Movable guards: Movable guards include the doors, gates and covers
which are manually or power operated. Sliding doors will be fixed which can be
opened and closed easily either by manually or using the power.
3) Sensitive protective equipment: sensitive protective equipment includes

pressure sensitive protective equipment and electro sensitive protective
equipment. the pressure sensitive equipment like mats and floors, edges and
bumpers are used as protection for the robots. In addition to it the photo voltaic
devices like light curtains, laser scanners safety cameras which will detects the
motion of objects due the interruption of rays emitted by these devices.

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6.0 OVERVIEW OF PROPOSAL
The proposal deals with the installing of electronic fence to achieve the
level 2 safety for the worker inside the robot work cell. The level 1 safety is
achieved by the mechanical fence that covers the robot work area. To increase
the safety level, the electronic fence is being installed at the level 2 of the safety
zone.
The industrial automated robots perform the tasks independently with high
power movements which are programmed to do specific tasks; hence it is
difficult to analyze its movement. These unpredictable movements may cause a
serious injury when the person is standing in the robot work area. To protect
the work force when they are in robot’s work envelope, the electronic fence can
be installed using infrared sensors.
The infrared sensors is a photo voltaic devices that emits the rays
continuously from one end to other end with specific frequency. It has a
transmitter and receiver to emit the rays as well as to receive the rays emitted
by the transmitter.
This transmitter and receiver is placed in the vicinity of the robot reach with
minimum safety distance (according to the standards ANSI, OSHA) to stop
work force before he/she enters into robot’s work envelope. The height of the
fence depends on the size of the robot. Transmitter emits the infrared rays up
to distance around 19m towards receiver end where the rays falls.
When these beams are interrupted, the receiver generates the electrical
signal which is connected to the microcontroller. When the signal is generated,
this says that somebody is trying to enter inside the robot work area. As soon
as microcontroller receives the signal it will actuate the relay to cut the robots
power along with inducing the break to stop the robots until person comes out
from work area.
As per the safety standards, all the accessories like power supply and control
system should kept outside the work envelope. The installation should be done
using the safety standards made by different organization to meet the global
requirement.

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DESIGN AND INSTALLATION OF INFRARED SENSORS
7.1 CALCULATING THE SAFETY DISTANCE:

The minimum distance should be ensured between the hazard and the
person who is operating or monitoring the system. This safety distance
helps to stop the machine before the persons enter into the hazard area.
The formula for calculating the safety distance:
S= K*(Ts+Tc+Tr) + Dpf.
S: Safety distance
K: Approach speed to the detection zone (the value recommended by the
OSHA standards is 1600mm/s)
Ts: machine’s stop time
Tr: response time of the device from ON to OFF
Tc: maximum response time of the controller
Tbm: additional time
Dpf: additional distance
According to the ANSI formula, Dpf is calculated as shown
below: Dpf: 3.4*(d-7.0) (where d is the detection capability)
Dpf: 3.4*(20-7.0)
Dpf: 44.2mm
K=1600mm/s
Ts+Tc =0.06s
Tr=0.01s
Dpf= 44.2mm
Hence,
S= 1600* (0.06+0.01) +44.2
S= 156mm.Source: OMRON F3SJ light curtain. Source: [4]

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7.2 PARAMETERS OF SENSOR INSTALLATION: For

finger detection- the minimum beam gap is 9mm. For
hand detection- the minimum beam gap is 15mm.
For hand, limb and body detection- the minimum beam gap is 25mm.
NOTE: With reference to the above mentioned minimum beam gap, the
preferred one is 15mm which is suitable for hand detection.
Source: [5]
7.3 ROBOT SPECIFICATIONS:

Manufacturer: FANUC robot
Robot series name: LR Mate 200Id 4s
Reach: 550mm
Height: 650mm
Source: [6] Fig 2.0 FANUC ROBOT
The above-mentioned robot has been included in the proposal to design the
electronic fence to understand the concept. The design of the fence is made
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with respect to the above mentioned robot specifications which is installed in

the NTTF robotics lab.s
The height of the robot is 650mm, the distance between the IR beams is 15mm
hence the number of beam are required to cover the robot height are 43.
NOTE: The robot reach is 550mm and the safety distance calculated using the
related parameters of the robot is 134mm hence the sensors have to be placed
at the distance of 684mm from the robot.
7.4 SPECIFICATIONS OF INSTALLED SYSTEM:

This safety system consists IR sensor which is placed in the direct
incidence method. During installation of this sensor as safety for the robot,
several parameters like safety distance, height of the protected area, distance
between the one beam of light to the other beam and effective indication signal
to make the people alert etc.
The following are the specifications of the installed safety system for robots:
1) Safety distance from the machine to the sensor’s beam = 156mm

2) Height of the area which is fence with IR sensor = 700mm
3) Distance between one beam to other beam of the infrared light = 15mm
4) Number of sensors placed on each of the robot work area = 43
5) Display system along with the alarm for alerting the people.

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8.0 PHYSICAL VIEW OF THE FENCED SYSTEM
TABLE
Fig 3.0 IR FENCING SYSTEM
(Reference: The above picture has been drawn in the fusion 360 software)
The above pictures represents robot protected electronic fence infrared rays
transmission from the transmitter to the receiver which are invisible to necked
eyes.. The safety fence is designed for the height of the 650mm for the robot of
700mm.The safety distance should be calculated in order to restrict the entry
before moving inside the robot reach which is calculated with respect to the
response time of the sensor and other parameters is 156mm. the selected
robot’s reach is 550mm, hence the sensors are been installed vertically at
distance of 606mm from the robot base. The beam gap is 15mm which is
suitable for hand detection hence 43 transmitters and receivers are connected
to cover the height of 700mm with the 15mm gap.

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NOTE: Above described specifications of the fenced system is only for one side
of the robot. The same specifications have to be designed for the other three
sides of the robot work area.
8.1 FENCED SYSTEM FOR ROBOTS:
Fig 4.0 IR TRANSMITTER AND RECEIVER
(Reference: The above picture has been drawn in the fusion 360 software)
The above picture represents the physical view of installed sensors at the
vicinity of the robot. The infrared transmitter and receiver placed opposite to
each other. The emitted rays are invisible to the necked eyes hence it is a
invisible electronic fence which is build using the infrared sensors for the robot
which is kept on the table.

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9.0 BLOCK DIGRAM OF SYSTEM
AC 230V,50Hz TRANSFORMER RECTIFIER FILTER REGULATOR
5V
P
SAFETY
I 0
RELAY
C
INFRARED 1
SENSOR
6
F
8
ROBOT
7
MACHINE
7
A
Fig 5.0 Block Diagram

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10.0 EXPLANATION OF OVERALL BLOCK DIAGRAM

The above fig 2.0 represents the overall block diagram of the system. it
consists six major blocks which are associated with each other to describe the
working of the system. the first block is power supply, the power supply is
required to supply the power for all components for their operation. The power
required by the one component to other component will vary, hence it is
essential to design power supply with respect to desired power required to
components used in the system. So, every system should have power supply
unit to make components to work properly.
The key component is infrared sensor, this sensor plays an important role
as it is monitoring the interrupts in the vicinity of the robot work area. The
infrared sensor consists transmitter and receiver which will perform their job
respectively. The transmitter and receiver are placed in direct incidence
method. The sensor also consists some associated components with
photodiode like op-amp and variable pot (potentiometer). The op-amp is used
as comparator to produce output voltage and variable pot is used to adjust the
output voltage.
The third block is microcontroller unit, it is acting as a controlling element of

the system that controllers the various elements which are interfaced with it.
This is able to perform the task according to the instruction fed in the program.
It is receiving the signal from the receiver end, then actuating the relay to stop
the robot machine.
The fourth block is safety relay, safety relay checks and monitor a safety
system and either enables the machine to start or executes the given
commands to stop the machine. These safety relays are flexible, cost-effective
and easy to use. This safety relay is interfaced with controller to stop the robot
machine when IR rays are interrupted.

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11.0 MECHANISM
The working mechanism of the infrared fencing system is simple and easy
to understand. The electronic fencing is integrated with the conventional
fencing system to instruct the people quickly to not enter into robot’s reach.The
mechanism deals with stopping the movement of robot machine temporarily as
humans enters into the robot’s work area. This mechanism includes several
components required to set up this system around robots as safety system.
It includes the infrared sensor as a key component along with microcontroller

as control unit and safety relay to stop the machine. The operation of this
mechanism can be analyzed sequentially as the flow of operation is transmitted
from one component to other. The infrared sensors consist photodiode as
receiver along with operation amplifier as comparator to compare the output
voltage produced by the photodiode and produces the output voltage as either
high or low.
Since infrared sensor consist two major components infrared led and
photodiode. Infrared led is called as transmitter and photodiode is called as
receiver. These transmitter and receiver can be place in two methods
1) Direct incidence
2) Indirect incidence
In direct incidence the transmitter and receiver will be placed opposite to each
other. Transmitter will be placed at one end, whereas the receiver will be
placed another end. The rays emitted by the transmitter will directly falls on the
receiver.
In indirect incidence the transmitter and receiver will be placed at one side.
when any object comes in the path of infrared rays, the rays will hit to the object
and reflects back on the receiver hence the photodiode produces the output.
The both methods arrangement can be used depending upon the application.
As Infrared sensor gets required supply, the transmitter starts to emit the
infrared rays. These rays will travel certain distance and will hit to the receiver.

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As these rays starts falling on the photodiode which is connected in reverse

bias the resistance of the photodiode decreases rapidly and hence the voltage
drop across photodiode will decreases.
Since this photodiode output will be connected to the op-amp that will compare
the voltage and produces the output as high or low. This high and low condition
occurs with respect to the IR ray interruption which will be monitored by the
controller to stop the robot machine.

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12.0 INFRARED SENSOR
The infrared sensor is an electronic instrument used to detect the

characteristics of its surroundings. As it consists IR led as transmitter and
photodiode as receiver to emit the rays as well as receiving the rays that are
emitted. As it is placed in the direct incident, so it consists two different sections
they are
1) Transmitter section
2) Receiver section.
Both IR led and photodiode are active components. In order to provide the
required power rating to the IR led and photodiode it is necessary to design the
circuit to get the required power that ensure the proper working of components.
The power supply will be designed for the highest set voltage required for the
system hence the flow of voltage and current has to restricted as per the
component need.
12.1 WORKING PRINCIPLE:
The IR sensor consist IR led as emitter and IR photodiode as detector. The IR

photodiode is sensitive to the IR light emitted by the IR LED. The photodiode’s
resistance and output voltage changes in proportional to the amount of light
received by it.
The IR sensor can be placed in two types of incident 1) direct incident 2)

indirect incident. In direct incidence, the IR LED is placed opposite to the
photodiode, whatever the light emitted by the IR LED directly falls on the
photodiode. In indirect incidence, both IR LED and photodiode are placed one
side, if any object comes in the range of emitted rays, the rays will hit to the
object and reflects back which in turn falls on the photodiode.

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Source: [7] Fig 6.0 INFRARED SENSOR
An infrared sensor includes.
1) Infrared LED as Transmitter

2) Photodiode as Receiver
3) Comparator
4) Variable resister
5) Digital output and analog output

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13.0 INFRARED LED (TRANSMMITTER)
13.1 DESCRIPTION:
Infrared red led is a special purpose led that emits the infrared rays in infrared
range which is 700nm to 1mm wavelength. Different IR led may produce IR
rays which are differs in wavelength. IR led usually made up with gallium
arsenide or aluminum gallium arsenide. These are used as sensors in
complementary with IR receivers.
The appearance IR led is same as common led. Since the infrared rays which
are emitted are invisible to human eyes hence it is not possible to predict the
working of IR led by humans just by observing. These rays can be visualized by
using the mobile camera. It is mainly used as a transmitter that emits the
infrared rays in particular wavelength along with receiver to receive the emitted
rays by it hence it is commonly called as transmitter. Source: [8]
DESIGN:
voltage required by the infrared led is 1.4v.
current consumed by the infrared led is 100mA.
Therefore, the value of resistor to be used is
according to the ohm's law:
V=IR
we need to find the value of resister hence the formula can be written as
R=V/I
R= (Vs-V)/I
Vs= supply voltage
V= voltage across led
(Vs-V)- Difference between the Vs and V.
I- current required

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Therefore,
R= (5-1.4)/100*1O^-3
R= 360 ohm.
The above derived value of resistor will supply the voltage of 1.8v and current
of 100mA.
13.2 SPECIFICATION OF INFRARED LED:
Series name: IR333-A.
Forward voltage: 1,8v
Forward current: 100Ma
Peak wavelength: 940mm.

0
Operating temperature: -40 to +85 C. Source: [9]
Source: [10] Fig 7.0 INFRARED LED

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14.0 PHOTODIODE (RECEIVER)
14.1 DESCRIPTION:
Photodiode is a semiconductor device that converts light energy into electrical

energy (electrical current). The current is generated when the light energy
strikes on the surface of the photodiode which is absorbed by the photons. It
consists optical filters, built in lenses and may have large or small surface area.
The photodiode response time is directly proportional to its surface area. Larger
the
surface area, slower the response time and smaller the surface area, faster the
response time. it is a passive device which requires the energy to turn on it.
The amount of electricity produced is directly proportional to the amount of light
falling on it. The resistance of the photodiode will decrease as the light falls on
it. Based on the resistance variation across it, the output voltage will be
produced.
Source: [11]
14.2 WORKING PRINCIPLE:
Photodiode is p-n junction device. When the photon of sufficient amount of

energy falls on it, the electron hole pair forms. This mechanism is also known
as inner photoelectric effect. As soon as absorption of light took place at the
junction of the depletion region, the diffusion of charge carriers occurs. These
carriers are will move away from the junction due to the magnetic field at the
junction of the depletion region, due to which the holes are moved towards the
anode and the electrons towards the negative hence the photocurrent is
produced. The total current flowing photodiode is the sum of the dark current
and the photocurrent. Dark current is a current produced by the photodiode in
the absence of the light. This dark current should be minimized by increasing
the sensitivity of the device. Source: [12]

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14.3 SPECIFICATION:
Series name: PD333-3C.
Reverse voltage: 32v.

0
Operating temperature: -25 to +85 C.
Diameter of the surface: 5mm Source: [13]
Source: [14] Fig 8.0 PHOTODIODE

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15.0 DESCRIPTION OF ASSOCIATED COMPONENTS
15.1 COMPARATOR (LM358):
Receiver section consists photodiode as it has characteristics of producing the

voltage using light source. The output of the photodiode depends on amount of
light falling on it. The resistance of the across the photodiode is high when
there is no any light falling on it. As the light starts to fall on it, the resistance
decreases hence the voltage drop across the photodiode decreases. This
variation of voltage is connected to the operational amplifier that act as a
comparator. This comparator compares the two given inputs and produces the
output.
It has two input pins 1) inverting input 2) non-inverting input. The reference
voltage will be set at either inverting or non-inverting pin and the output the
photodiode will be connected to anyone of these two pins. When the voltage at
the inverting pin is greater than the set voltage then output will be high and vice
versa. The below drawn circuit represents the receiver section of the infrared
sensor.
15.2 MICROCONTROLLER:
Microcontroller is acting as a controlling element in this system. There are

various types of controllers available. The preferred controller is PIC
microcontroller because it has two communication ports where as other
controller has only one communication port. It has a RISC architecture where
only 35 instructions and hence programming is easy. The program is fed into
this controller to control the movements of robots when sensor detects anything
in the restricted area.
The instructions are fed in such a way that when sensor detects anything the
controller should actuate the relay to cut the power to it. In addition, once the
relay is actuated a certain delay has to be given and in return controller should
jump to the “if” condition where it can detect the sensor output level. If the

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output level is high or low the command which is fed into “if” loop will execute
those commands to achieve the required output.
15.3 RELAY:
Relay is an electromechanical device which act as a switch to actuate the

output device. It has two conditions like NO (normally open) and NC (normally
close) used based on the application. The role of the relay is to control the
robot motion by controlling the power source to the robot by its operation
condition (NO or NC). As soon as controller receives electrical signal (high or
low), it will actuate the relay from NC to NO to stop the robot as quick as
possible.
Source: [15] Fig 9.0 RELAY

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16.0 POWER SUPPLY UNIT
The power supply is designed for 5v for this system in order to provide the
sufficient power to the components being used. Since infrared led, photodiode
and LM358 are active components that requires the initial power source to turn
on itself. The 5v is fed to the infrared led, photodiode and LM358 that helps for
proper working of the components. The microcontroller as well as relay also
require the same 5v for their operation. The current which is supplied by power
supply unit is 1A. This value of current is designed with respect to the current
consumption of the components used.
17.0 OVER ALL CIRCUIT DIAGRAM
Fig 10.0 Circuit Diagram

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18.0 FENCING CIRCUIT WORKING
The circuit consists infrared sensor (transmitter and receiver) which is

connected with controller as input and relay which is connected as output with
controller. The led emits the infrared rays at a frequency of infrared range which
will falls on the photodiode. When any object interrupts the rays, the rays will
reflect to the object and it will not reach to the photodiode.
When the emitted rays do not reach the photodiode, resistance across the
photodiode decreases. As the resistance decreases the voltage drop across
the photodiode also decreases hence the output will be high. The output of the
photodiode will be connected at non-inverting pin of the operational amplifier
that converts the Analog signal into digital signal by comparting with reference
voltage set at the other pin.
As rays falls on the photodiode, it will produce the output voltage. If the output
voltage of goes beyond the set voltage, the operational amplifier will produce
output as high (1) or if the output voltage remains below the set voltage, the
operational amplifier will produce output as low (0).
The output of the operational amplifier is connected to the microcontroller as

input. If object interrupts the IR rays the operational amplifier output goes low,
as soon as the controller pin goes low where the output of the op-amp is
connected, the controller actuates the relay from NC to NO. Once the relay is
actuated some delay will be given in order to protect the robot. By the time
delay ends the controller checks status of the sensor.
The program instructions are written in such way that unless the sensor output
goes high the relay should not actuate to its original condition. Once the op-
amp goes high, the relay should actuate back to its original condition thereby
the robot’s movement can be stopped.

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19.0 SYSTEM TESTING
The working of the proposed system is tested and the output is achieved
properly. The proposed parameters are working to meet the requirement of the
robot’s fence. The following pictures represents the test result of the system.
Fig11.0 Test circuit 1

The above picture consist transmitter as Infrared LED and receiver as
photodiode. The transmitter is emitting the infrared rays from one end which is
received by the receiver at another end. Since there are no interrupts between
the transmitter and receiver hence the LED are glowing that indicates the there
is no interruption of IR rays so that the robot can work in its work envelope.

1927-1621046
Fig 12.0 Test circuit 2

This picture shows that there is an interrupt between the transmitter and
receiver which indicates somebody is trying enter into the robot work area
which might cause hazard. Hence if there is an interrupt the LED will not glow
that states the IR rays are interrupted hence the robot has to stop immediately.

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20.0 BILL OF MATERIAL
Table 1
SL.NO COMPONENTS SPECIFICATION QTY
01 Infrared led 1.4v,5mm As required
02 Photodiode 32v,5mm As required
03 IC LM358 LM358 As required
04 Potentiometer 10K As required
05 Resistors 100E,10K As required
06 Microcontroller PIC16F877A 01
07 Relay 5V As required
21.0 ADDITIONAL FEATURES OF THE SYSTEM
1) The UPS (uninterrupted power supply) shall be installed to provide the

power supply to the system in case main power goes off. The system
should not fail to perform its job even the supply goes off.
2) The indicators are being installed to know the working condition of the
sensor. The green led light will be glowing that indicates all the sensors are
working properly.
3) The instructions will be displayed around the robot work area in order to
inform to the workers not to enter inside the robot work area.

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22.0 ADVANTAGE, DISADVANTAGE & APPLICATIONS
ADVANTAGE:
1) The safety level can be increased to the workers by protecting the level
2 safety zone of the robot work area.
2) Easy to transport the raw material inside the robot work area.
3) Less cost compares to the mechanical fencing system.
4) Design and installation is easy compare to mechanical fencing system.
DISADVANTAGE:
1) The system requires regular maintenance to ensure the proper working of

components.
APPLICATIONS:
1) This protecting system can be installed for robot’s safety.

2) This system might also use in press tool for protection of hands during
the press movement.
3) In addition to this, the system can be implemented to protect the danger
area in work place.

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23.0 CONCLUSION
Hence the integration of mechanical fence and electronic fence rises robot’s
safety level is increased for work force. Since the electronic fence cannot stand
alone as a safety system for robots hence it is integrated with mechanical fence
at next level of the work area to avoid the accidents occurs in the vicinity of the
robot reach. This electronic fence will give the quick signal to the work force as
soon as they are near to the robot reach, this may rescue the work force
against robot. The safety of the work force is important more than anything else
hence the proposal is described to increase the safety level.

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24.0 LIST OF REFERENCES
[1]: Chinniah Y. (January 30 2016). Robot Safety: Overview of Risk

Assessment and Reduction. Available at:
https://www.omicsonline.org/open-access/robot-safety-overview-of-risk-
assessment-and-reduction-2168-9695-1000139.php?aid=68463.
[2]: Axelent. Mesh panels. Available at:
https://www.google.co.in/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad
=rja&uact=8&ved=2ahUKEwjlq47i5ITcAhXJ6Y8KHVeBAZEQjRx6BAgBEAU&u
rl=http%3A%2F%2Fwww.axelentusa.com%2F&psig=AOvVaw3h1jeZsbQK_urH
Ni6foQhv&ust=1530771048176376.
[3]: Dick LaBelle & Barbara Donohue. (August 200). Are your light curtains
doing their job.? Available at:
http://www.production-resources.com/pdfs/Light-Curtain-Guidelines.pdf.
[4] OMRON. (march 2005). Safety Light Curtain F3SJ. Available at:
https://www.alliedelec.com/m/d/a55430fff46ba7cd8a340ede974d4083.pdf.
[5]: OMRON. (march 2005). Safety Light Curtain F3SJ. Available at:
https://www.alliedelec.com/m/d/a55430fff46ba7cd8a340ede974d4083.pdf.
[6]: Robotics lab- SUP centre. FANUC Robot LR Mate 200Id 4S.
[7]: Twerk lab Inc. (2016). Long range IR sensor. Available at:
=rja&uact=8&ved=2ahUKEwjJ3M7LzpPcAhXJPo8KHaOiC80QjRx6BAgBEAU&
url=http%3A%2F%2Ftweaklabsinc.com%2Fir-motion-sensor%2Flong-range-ir-
sensor.html&psig=AOvVaw2_f6qQypRnUXJB-
5nLmxI&ust=1531280473946411
[8]: electronics for you. (October 30 2017). Infrared LED. Available at:
https://electronicsforu.com/resources/learn-electronics/ir-led-infrared-
led-infrared-sensor

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[9]: Jaine Tsai. (20.07.2005). Technical Data Sheet Infrared LED. Available at:
https://cdn-shop.adafruit.com/datasheets/IR333_A_datasheet.pdf
[10]: RadioShack. (2018). High output infrared LED. Available at:
=rja&uact=8&ved=2ahUKEwjbv_jM05PcAhWMuY8KHUC2CpcQjRx6BAgBEAU
&url=https%3A%2F%2Fwww.radioshack.com%2Fproducts%2Fhigh-output-
infraredled&psig=AOvVaw0_plpTZbaMbYWmKsiBPSJw&ust=1531281845100
496.
[11]: Wikipedia. (11 June 2018). Photodiode. Available at:
https://en.wikipedia.org/wiki/Photodiode
[12]: Wikipedia. (11 June 2018). Photodiode. Available at:
https://en.wikipedia.org/wiki/Photodiode
[13]: Everlight Electronics Co. Ltd. Datasheet photodiode. Available at:
http://www.everlight.com/file/ProductFile/PD333-3C-H0-L2.pdf
[14]: Mouser electronics. Photodiode. Available at:
=rja&uact=8&ved=2ahUKEwjiqrLNppTcAhXOXysKHf3PAcQQjRx6BAgBEAU&
url=https%3A%2F%2Fwww2.mouser.com%2FProductDetail%2FONSemicondu
ctorFairchild%2FQSD2030F%3Fqs%3DAuirqnPfump6SiKy0OWVjw%253D%2
53D&psig=AOvVaw3bic6j7CxIzquSnE-qTrDs&ust=1531304101553557
[15]: Maker electronics. SPDT Relay. Available at:
=rja&uact=8&ved=2ahUKEwiD6tffp5TcAhUN4o8KHbEiDsYQjRx6BAgBEAU&u
rl=https%3A%2F%2Fwww.makerlab-electronics.com%2Fproduct%2F5-pin-
mini-spdt-relay-12v-
10a250v%2F&psig=AOvVaw0j4eDXpQ9ElmEn8FQoCHXz&ust=15313044482
51960

1927-1621046

Bachelor Thesis (B. Eng) : "Electronic Fencing System For Robot Work Area Using Infrared Sensors"

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Bachelor Thesis (B. Eng) : "Electronic Fencing System For Robot Work Area Using Infrared Sensors"

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ELECTRONIC FENCING SYSTEM FOR ROBOT WORK

“ELECTRONIC FENCING SYSTEM FOR ROBOT

Writer: GAGAN BATAKURKI

Duration: 01.01.2018 – 30.06.2018

An array of infrared transmitter and receiver can be place vertically at certain

BACHELOR THESIS 2018 GAGAN BATAKURKI

Table of contents. III-IV

1.1 Technical problem to be solved ............................................................... 01

1.2 Planned to do............................................................................................ 01

3.0 IMPORTANCE OF SAFETY ..........................................................................06

4.0 CHECK LIST DURING INSTALLATION OF SAFETY SYSTEM .................. 06

5.0 ROBOTS SAFETY METHODS ...................................................................... 07

6.0 OVERVIEW OF THE PROPOSAL… ............................................................. 08

7.0 DESIGN AND INSTALLATION OF INFRARED SENSORS.......................... 09

7.1 Calculation of safety distance .................................................................. 09

7.2 Parameters of sensor installation..............................................................10

7.3 Robots specifications ............................................................................... 10

7.4 Specifications of installed system ........................................................... 11

8.0 PHYSICAL VIEW OF FENCED SYSTEM ................................................... 12

8.1 FENCED SYSTEM FOR ROBOTS ........................................................ 13

9.0 BLOCK DIAGRAM .................................................................................... 14

10.0 EXPLANATION OF BLOCK DIAGRAM....................................................15

11.0 MECHANISM ............................................................................................16

12.0 INFRARED SENSOR ................................................................................ 18

BACHELOR THESIS 2018 GAGAN BATAKURKI

13.0 INFRARED LED ........................................................................................20

13.1 Description .................................................................................... 20

13.2 Specifications ................................................................................ 21

14.0 PHOTODIODE ...........................................................................................22

14.1 Description .................................................................................... 22

14.2 Working principle ................................................................................... 22

14.3 SPECIFICATION ................................................................................... 23

15.0 DESCRIPTION OF ASSOCIATED COMPONENTS .................................. 24

15.1 Comparator… ......................................................................................... 24

16.0 POWER SUPPLY UNIT… .......................................................................... 26

17.0 OVER ALL CIRCUIT DIAGRAM ................................................................ 26

18.0 FENCING SYSTEM WORKING ................................................................. 27

19.0 SYSTEM TESTING .....................................................................................28

20.0 BILL OF MATERILAS ............................................................................... 30

21.0 ADDITIONAL FEATURES OF THE SYSTEM… ........................................ 30

22.0 ADVANTAGE, DISADVANTAGE AND APPLICATION… ......................... 32

23.0 CONCLUSION ............................................................................................32

24.0 LIST OF REFERENCES ............................................................................. 33

BACHELOR THESIS 2018 GAGAN BATAKURKI

Table no Particulars Page no

Figure no Particulars Page no

ANSI-American National standard institute

BACHELOR THESIS 2018 GAGAN BATAKURKI

There are four levels of safety zones inside robot’s workstation:

1) Level 1 – workstation penetration

1.1 TECHNICAL PROBLEM TO BE SOLVED:

The focused problem which is to be solved is that to avoid the chance of

Bachelor Thesis 2018 Page|1 GAGAN BATAKURKI

1.2 PLANNED TO DO:

Bachelor Thesis 2018 Page|2 GAGAN BATAKURKI

An Industrial robot is machine system used in manufacturing to achieve the

Industrial robots are in grater use today hence manufacturing is increased to

Bachelor Thesis 2018 Page|3 GAGAN BATAKURKI

In order to avoid these accidents, the conventional mechanical fencing system

Bachelor Thesis 2018 Page|4 GAGAN BATAKURKI

interrupts the IR rays emitted by infrared led, the resistance of photodiode

Source: [2] Fig 1.0 CONVENTIONAL FENSING SYSTEM