CHAPTER 1

INTRODUCTION
1.1 DEFINITION
There is only one definition of robot that is inter-nationally accepted. It was developed
by a group of industrial scientists from the Robotics Industries Association in 1979. They
design industrial robot “a re-programmable, multi-functional, manipulator design to move
materials parts tools or specialized devices through various programmed motions for the
performance of a variety of tasks”.

The term robots come from Czech and means forced labor. Czech writer KAREL
CAPEK invented the term in its present interpretation in 1921 as R.U.R (Rossum’s Universal
Robot). Capek’s robots look like human being.
Industrial robots do not look like human being but they do the work of humans.
G.C.DEVOL patented the concept of industrial robot in 1954. He describes how to construct
controlled mechanical arm, which can perform task in industry. The first industrial robot was
installed by UNIMATION
ROBO; The pick and place robot is used to pick the material from one place to another
place control through PC. It has along jib, or arm that extends several feet from a heavy base.
The and keeps the crane from tipping over. The end of the jib has a pulley. A rope or a cable,
with a lifting hook in the end runs from pull to a winch (crank) in the foundation. The operator
turns the winch to lift or lower the hook the arm is lowered. Thus a jib robot move a weight to
any point around the circumference of the circle its jib makes. The pillar jib has a pillar rising
from its base a cable attached to the top of the pillar rises and lowers the end of the jib so that
the jib can be moved up and down as well as from side to side. When the jib moves up it carries
the load toward the base of the robot lowered. It moves the load away form the base. Factories
and foundries often use. This type of robot moves back and forth on a bridge extending across
the width of a factory building. .

The pick and place arm is used to pick the material from one place to another place
control controlled by micro controller. It has along jib, or arm that extends several feet from a

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 heavy base. The end of the jib has electromagnet for lifting the material. The micro controller
control the arm up and down thus the electromagnet move a weight to any point around the
circumference of the circle its jib makes and place at the belt conveyer.

1.2 ADVANTAGE
1. It will move an where any place through remote control.
2. It will pick up to 200 gm weight.
3. It will move 360 degree clock wise and anticlock wise horizontal.
4. It will move vertical 90 degree.
5 .it is remote control operate

1.3 WORKING
The receiver IR LED (photo transistor) is placed in the base of transistor Q1.
The received IR signals is amplified at transistor Q1 and output is taken from collector and
given to the base of transistor Q2. The transistor Q2 is amplified input signal and fed to the
base of transistor Q3 through coupling capacitor Q4 and output is taken from collector and fed
to the base transistor Q4 through resister R8 and R9 and it is worked as a coupling, the output
from collector is given transistor Q5 through the diode D1.

The diode D1 is providing positive half cycle to the transistors. The diode D2 used as
a polarity diode. The negative voltage is extended from emitter to collector to the relay. When
there is no input signals the transistor 1-4 are not conducting so transistor Q5 all so will not
operate so negative voltage extended to the relay. One end of the relay coil is directly
connected to the positive terminal and the other end is connected to the collector of transistor
Q5 which is providing negative voltage to the relay for activation.
When there is no input signal the transistor Q1 to Q5 are in forward bias and the
transistor Q5 is produce negative voltage from emitter to collector the relay gets activated.
When the IR sensor receive the input signal from the transmitter is amplified by the
transistor Q1 to Q4 is amplified then fed to the base of transistor Q5 through a diode which de-
operating the transistor Q5 so there is no negative voltage from collector the relay gets no
negative and it is in ideal condition(de activated )

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 Through relay positive voltage is extended to .the LED and negative is applied
directly to the LED.

1.4 TRANSMITTE:
IC 555 is working as a stable multi vibrator used to generate a frequency in the
range of IR Frequency (40khzl) and is fed to the transistor BD 140.Pin no 1. The transistor
BD140 is amplify the IR signal and drive the signal through the IR Diode Registers are used to
provide DC biasing to the IC and transistor .Capacitor C1 used for triggering pulse to pin no 2
and capacitor C2 is working as filter and to generate a frequency in the range of IR level
(infrared radiation).

In this circuit it consist of the following section

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1. Micro controller

2. Stepper motor for movement of vertical, and horizontal

3. Electromagnet for pick and place

1.5 MICRO CONTROLLER :

We are using 89s52 microcontroller, which belongs to the family of ATMEL 8051/52
series, which is called as mother board from which interfacing of other components is done.
Main components like LCD display, MAX232, relays, sensors and power supplies are interfaced
with the microcontroller.

1.6 FEATURES:
• 8K Bytes of In-System Programmable (ISP) Flash Memory
• Endurance: 1000 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

1.7 DESCRIPTION:
The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with
8Kbytes of in-system programmable Flash memory. The device is manufactured using Atmel’s
high-density nonvolatile memory technology and is compatible with the industry-Standard

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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 contents but
freezes the oscillator, disabling all other chip functions until the next interrupt or hardware reset.
WHY 89S52?
1. Meeting the computing needs of the task efficiently and cost effectively
Speed, the amount of ROM and RAM, the number of I/O ports and timers, size,
packaging, power consumption. Easy to upgrade.
2. Availability of software development tools Assemblers, debuggers, C compilers,
emulator, simulator, technical support.
3. Wide availability and reliable sources of the microcontrollers.

1.8 POWER SUPPLY CIRCUIT:

1.9 WORKING OF THE BRIDGE RECTIFIER CIRCUIT:

The bridge wave rectifier is used in power supply circuit. AC220V of input
signal is given to the bridge wave rectifier circuit. During positive half cycle of the circuit
diodes D1 and D3 will conduct, which produces the rectified output at the load. During the
negative half cycle diodes D2 and D4 will conduct to produce the rectified output at the load.
The load contains bypass capacitors, which bypasses the AC components and produces only DC
components to the next circuit. Here we use IC7805, which acts as a voltage regulator to
produce +5V of power supply required for LCD and the MICROCONTROLLER and IC7812
which produces +12V of power supply required for other devices.

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1.10 BASIC PRINCIPLE OF OPERATION OF A D.C. GENERATOR:
Let us consider a single-turn rectangular copper conductor loop ABCD rotating
in a clockwise direction about its own XX’ in a uniform magnetic field provided by either
permanent magnets or electromagnets, as shown in Fig. 5.1(a). The two ends of the coil are
joined to two slip of rings ‘a’ and ‘b’, which are insulated from each other and from the central
shaft. Two collecting brushes Br2 and Br1 made of carbon or copper, press against the slip
rings. Their function is to collect the current induced in the coil and to convey it to the external
load resistance R. The rotating coil may be termed as ‘armature’ and the magnets as ‘field
magnets’.
As the coil is rotated in the magnetic field by some mechanical means, the flux
linking with the loop changes continuously and hence an e.m.f. is induced in it. The linking
flux at that instant and its direction is given by Fleming’s Right Hand Rule. The working of this
Generator may be described stage wise, as follows:
a) When the rotation is Zero:
When the loop ABCD assumes the position at a particular instant during its
rotation, i.e., when the loop ABCD is just parallel to the faces of field magnets N and S, the flux
linking with the loop is maximum, but the rate of change of linking flux is zero, as at this instant
no flux is cut by the coil sides AB and CD, which are just moving parallel to them. Hence
induced e.m.f. is zero, when the loop is called the neutral position and it is taken as the starting
position and the angle of rotation is measured from this position.
b) When rotation is from 0-90:
As the loop is turned in the clockwise direction at a constant speed, the coil sides begin
to cut across the field, slowly at first but increasing gradually. So, the magnitude of the e.m.f.
induced gradually increases as shown in
During this period the loop rotates through 90 and the induced e.m.f. in the loop
increases in accordance with the sine law. The direction of e.m.f. induced in the coil, as given
by Fleming’s Right Hand Rule is from B to A and from D to C. In the position of the loop, the
coil sides are moving at right angles to the field and so are cutting across the field at maximum
rate. As a result, the e.m.f. induced at this instant is of maximum value.
c) When rotation is from 90- 180:

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 During this rotation, the rate at which the conductors cur across the magnetic field
gradualy decreases, causing the magnitude of induced e.m.f. to fall gradually with the angular
movement of the loop and becomes zero at the instant the loop becomes again parallel to the
faces of the field magnets, but with the sides AB and CD’s positions interchanged with respect
to the zero position
d) When rotation is from 180-270:
During this rotation, the rate at which the conductor cuts across the magnetic field
increases and consequently the induced e.m.f. also increases, and becomes maximum at the
instant the loop assumes the position depicted .However, the direction of the e.m.f. in the loop is
now from A to B and from C to D i.e., opposite to that in the first two quarters.
e) When rotation is from 270-360:
During this rotation of the loop, the induced e.m.f. decreases as the coil moves and
becomes zero when it completes 360from the starting position. At this instant the loop returns
to its original initial position and completes one cycle. The cycle then repeats for each armature
rotation. The e.m.f. generated in this manner in the loop is called alternating e.m.f.
The current induced in the coil is collected and conveyed to the external load circuit by
connecting the coil terminals continuously to two insulated rings, ‘a’ and ‘b’, called slip rings,
mounted on the generator shaft. Two stationary brushes press against the slip rings, one brush
on each ring, when the coil is rotated, the generated alternating e.m.f. causes a current to flow
first in one direction then in the other through the coil and external circuit. This kind of current
is called alternating current.
In order to make the flow of current unidirectional in the external circuit, we use split-
rings in place of slip-rings. These split-rings are made of conducting cylinder which is cut into
two halves or segments, insulated from each other by a thin sheet of mica. As in the earlier case,
the coil ends are joined to this segments on which rest the brushes. The current collecting
arrangement with split rings (also known as commutator). The segments S1 and S2 of the
commutator are attached to the ends of the sides AB and CD of the rotating coil. The brushes
B1 and B2 collect the current the current and deliver it to the external circuit.
In the first half-cycle, the current flows in the loop along ABCD and brush B2
remain in contact with segment ‘a’ and brush B1 with segment ‘b’. Therefore brush B2 is
positive and B1 is negative. The current delivered to the load R is from L to M.

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 The next half-cycle, the direction of induced current in coil sides AB and CD is
reversed. At the same time, segment ‘b’ comes in contact with brush B2 and segment ‘a’ is in
contact with brush B1. It is apparent that even now the segment ‘b’ delivers current to brush B2,
making it positive. The current delivered to the load is still in the same direction i.e., from L to
M.
The waveform of the current through the external circuit. Thus, current is
unidirectional but not continuous like pure direct current.
We should note that the position of the brushes is arranged in such a manner
that the changeover of segments ‘a’ and ‘b’ from one brush to the other takes place when the
plane of the rotating coil is at right angles to the plane of the lines of flux. This is so because,
in that position, the induced e.m.f. in the coil is zero.

1.11 FIELD SYSTEM:

The object of the field system is to create a uniform magnetic field, within which the
armature rotates. Electromagnets are generally preferred in comparison with permanent in a
Magnets because they are cheap, small in size, produce greater magnetic effect and the field
Strength can be easily varies by changing the magnetising current.

The field system consists of the following parts:

i) Yoke
ii) Pole cores
iii) Pole shoes
iv) Field coils

1.12 YOKE
1. A cylindrical yoke is normally used which services as a frame of the machine, and has a twin
function. Firstly, it provides mechanical support to poles and serves as a protective cover for
the generator. Secondly, it carries the magnetic flux produced by the poles.
2. For small machines, the yoke is made of cast iron. But for large machines, the yoke is made
of case steel or rolled steel because they have better magnetic properties than cast iron.

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 1.13 POLE CORES:
Usually pole cores are of circular section. They are made of cast steel or wrought iron
laminations and fixed o the yoke. They carry coils of insulated copper wire through which
magnetising current flows.

1.14 POLE SHOES:

The pole shoes are at the ends of the poles, and have the following two functions:
a) They support the field coils
b) They spread out the flux in the air gap.
c) They are of large cross-section, due to which the reluctance of the path is
reduced.

1.15 FIELD COLIS:

These are coils of copper wire wound round the poles, they are also called exciting
coils. The object of theses field coils or magnetising coils is to provide, under various conditions
of operation, the number of ampere – turns of excitation required to given the proper flux through
the armature, to induce the desired potential difference. All the field coils are connected in such a
way that, when current flows through them, the adjacent poles have opposite polarities.
There are different types of field construction, depending on the type of excitation.
In a shunt field, many turns of fine wire as used, whereas in a series field a few turns of large
cross – section are used; in a compound field, both shunt and series windings are used. Shunt
coils are usually wound with double cotton covered wires. The field coils after proper winding,
are dipped in an insulating varnish and baked in an oven, which results in stiffness, mechanical
strength and good insulating properties to the windings.
While designing a generator, the number of poles required by the field structure
depends on the speed of the armature, and the output for which the machine is designed. In a
two – pole machine there are two voltage maximums per revolution of the armature, while in a
four – pole machine there are four voltage maximums for one revolution. If the armature speed
is kept constant, the number of poles determine the rate at which the individual oils cut the

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magnetic flux. Thus, the output voltage increases with the increase in the number of poles for a
constant armature speed. A typical laminated pole core, pole shoe and exciting coil.
1.16 FIELD COLI:
These are coils of copper wire wound round the poles, they are also called exciting
coils. The object of theses field coils or magnetising coils is to provide, under various
conditions of operation, the number of ampere – turns of excitation required to given the proper
flux through the armature, to induce the desired potential difference. All the field coils are
connected in such a way that, when current flows through them, the adjacent poles have
opposite polarities.
There are different types of field construction, depending on the type of excitation. In
a shunt field, many turns of fine wire as used, whereas in a series field a few turns of large cross
– section are used; in a compound field, both shunt and series windings are used. Shunt coils
are usually wound with double cotton covered wires. The field coils after proper winding, are
dipped in an insulating varnish and baked in an oven, which results in stiffness, mechanical
strength and good insulating properties to the windings.
While designing a generator, the number of poles required by the field structure
depends on the speed of the armature, and the output for which the machine is designed. In a
two – pole machine there are two voltage maximums per revolution of the armature, while in a
four – pole machine there are four voltage maximums for one revolution. If the armature speed
is kept constant, the number of poles determine the rate at which the individual oils cut the
magnetic flux. Thus, the output voltage increases with the increase in the number of poles for a
constant armature speed. A typical laminated pole core, pole shoe and exciting coil are shown
in Fig.

1.17 ARMATURE CORE:

The purpose of the armature core is to house the armature conductors and to provide a
path of very low reluctance to the flux through the armature from a N-pole to a S-pole. The
armature is mounted on a shaft so that when it is rotated, the conductors housed in it cut the
magnetic flux and electric current is induced in it.
The armature core is made from high permeability silicon – steel stampings, each
stamping being separated from its neighbouring one by thin paper or varnish as insulation.

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 High – grade steel is used for two reasons: firstly, to keep Hysteresis loss low, which is
due to cyclic change of magnetisation caused by the rotation of the core in the magnetic field:
secondly, to reduce the eddy currents in the core which are induced by the rotation of the core in
the magnetic field. By using stampings or laminations the path of the eddy current is cut into
several units. The laminations should be in such a direction that they are perpendicular to the
paths of eddy currents and parallel to the flux.
Ventilating ducts are provided to dissipate the heat produced by Hysteresis, eddy
current losses etc. Air is drawn through these ducts by the fanning action of the armature.
A small air gap exists between the pole pieces and the armature, taking care to see that
there is no rubbing in the generator. This gap should be kept very small so as to keep the field
strength at a maximum.
In armatures of small diameters, holes are punched in the centre of the laminations for
the shaft. However, in the large machines, a spider is provided, so that the angular laminations
are rigidly fastened to the shaft. The latter construction permits air to flow freely between the
radial arms to keep the armature ventilated and cooled.

1.18 ARMATURE WINDINGS:

The function of a commentator is to collect current from the armature conductors. As
has been shown in Section 5.2., it converts the alternating current induced in the armature
conductors into unidirectional current in the external load circuit. It is of cylindrical
construction and is made up of wedge – shaped segments of high – conductivity, hard – drawn
copper. These segments are insulated from each other by thin layers of mica. The number of
segments is equal to the number of armature coils. Each commutator segment is connected to
the armature conductor by means of a copper lug or strip. These segments have V – grooves so
as to prevent them from flying out due to centrifugal forces. These grooves are insulated by
conical micanite rings.
The function of brushes is to collect current from the commutator. They are
normally made of carbon and are in the shape of a rectangular block. These brushes are housed
in brush – holders, which are usually of the box – type variety. The brush – holder is mounted
on a spindle and the brushes can slide in the rectangular box open at both the ends. The brushes
are made to press down on the commutator by means of a spring, whose tension can be adjusted

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 by operating a lever. A flexible copper pigtail, mounted at the top of the brush, carries the
current from the brushes to the holder. The number of brushes per spindle depends on the
magnitude of the current to be collected from the commutator.

CHAPTER 2

2.1 BEARINGS:
Ball – bearings are usually used as they are more reliable. However, for heavy
duty work, roller bearings are preferred. The ball and rollers are packed in hand oil for quieter
operation and for minimizing wear of the bearings.
The following two basics types of armature winding are most commonly used for drum
type armature:
1. Lap Winding
2. Wave Winding

2.2 ARMATURE REACTION:

The effect of the magnetic field up by the armature current on the distribution of flux
under the main poles of the generator (or motor) is known as Armature Reaction.
When the armature field is absent, the main field flux divides itself equally and
symmetrically about the axis of the pole. This is the situation under no-load condition. When
the generator supplies a load, the armature field also comes up, hence both the fields having
different directions exist simultaneously. Consequently there is a reaction between the two
fields.

2.3 THE MAJOR EFFECTS OF ARMATURE RECATION:

i) It demagnetises (or weakens) the main pole flux, and
ii) It has a cross – magnetising effect distortion of the main flux.
Because of the memagnetising effect, the average flux per pole is slightly reduced. As
the induced e.m.f. , E too is slightly reduced. Thus, for the same speed and field current, the
induced e.m.f. on load is less than the induced e.m.f. under no – load conditions.

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2.4 CLASSIFICATION OF ROBOT:

 According to the path -

a. Continuous path.
b. Point-to –point robotic systems.
c. Trajectory planning.

 According to structure,
a. Cartesian : three linear axes.
b. Cylindrical : two linear axes & one rotary axis.
c. Spherical : one linear axis & two rotary axes.
d. Article or jointed : three rotary axes.

2.5 CARTESIAN COORDINATE SYSTEM:

A robot, which is constructed around this configuration, consists of three orthogonal
slides. The three slides are parallel to the x, y and z axes of Cartesian coordinate system.
By appropriate movement of these slides, the robot is capable of moving its arm to any
point within its three dimensional rectangular spaced workspace.

2.6 CYLINDRICAL CORDINATES CONFIGURATION:

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 In this configuration, the robot body is a vertical column that swivels about a vertical
axis. The arm consists of several orthogonal sides, which allow the arm to be moved up and
down and in and out with respect to the body.

2.7 POLAR COORDINATES CONFIGURATION:

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 This configuration also goes by the name “spherical coordinate”, because the workspace
within which it moves its arm is a partial sphere.The robots have a rotary base and a pivot that
can be used to raise and lower a telescopic arm.

2.8 THE JOINTED ARM CONFIGURATION :

The jointed arm configuration is similar in appearance to the human arm. The arm
consists of several straight members connected by joints which are analogous to the human

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 shoulder, elbow and wrist. The robot arm is mounted to a base, which can be rotated to provide
the robot with the capacity to work within a quasi-spherical space. This is as shown in figure
below.

2.9 SIX DEGREE OF FREEDOM:

There are six basic motions or degree of freedom, which provide the robot with the
capability to move the end effects through the sequence of motions. These six degrees of
freedom are intended to emulate the versatility of movement possessed by the human hand. Not
all robots are equipped with the ability to move in all six degrees. The six basic motions as
described below,

 Vertical traverse: up and down motion of the arm caused by pivoting the entire arm about a
horizontal axis moving the arm on a vertical slide.

 Radial traverse : extension and retraction of the arm

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  Rotational traverse: rotation about the vertical axis(right and left swiveling)
 Wrist motion: rotation of the wrist.
 Wrist bend: up and down movement of the wrist, this also involves the rotational
movement.
 Wrist law: right of left swivel of the wrist.

Programming concept
The programming is done to control various operations of the robot. The robot
controller to execute set of motion sequences interprets these programs. The overall process in
the conversion of the program into mechanical motion shown as the figure

Co-ordinate
transformation

Robot
Comparator Drive arm
Controller D.A.C
unit joint

ENCODER
Counter

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 The programming software used for the proof-of-concept was written for Microsoft
Windows using Visual Basic. It allows instructions to be input in an intuitive form by the user,
simulating them graphically for verification and then sending them via serial link to the control
circuit. Simple instruction interpreter and serial transfer program were created in C to be
compatible with sequence files saved by the Windows software, which was compiled for
GNU/Linux and FreeBSD
The different methods of robot programming are:-
 Manual teaching method
Here the robot movements along the particular axis are controlled by setting
Mechanical stops, Cams, Switches or Relays. It is ideal for pick and place applications.
 Walk through method
This is used in point to point application. Each axis of the robot manually till
the desired point is reached. Then the co-ordinates are stored in memory by pressing the
push buttons in a control box. The speed control is done separately. It is ideal for spray
painting and welding applications.
 Lead through method
A teach pendant is used to guide the manipulate arm through the specified
motion sequence. The pendant consists of feather touch keys and dials to regulate the
movement of arms. All the motion sequences are recorded in the memory for the later
playback.
 Off-line programming
Here the program is prepared at a programming station. This program is
downloaded in the memory of the robot controller during operation. The robot can be
interfaced with the manufacturing data based of a CAD/CAM system. The robot motion
program can be generated based on the CAD information available about the desired
product handling; such integration increases productivity of Robots, as times spent on
programming is minimized.

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CHAPTER 3

3.1 WORK VOLUME

Work volume is the super term that refers to the space within which the robot can
manipulate its wrist end. The points that can be reached by the maximum and minimum
movements of each axis or a combination of axis define is selecting the robot with appropriate
work volume is of great importance, as all interactions with peripheral devices and processes
must take place within this generated volume. Besides having the capacity to reach the
equipment within the operating volume, the robot must avoid collision with work pieces and
other robots working in the immediate vicinity
The work volume is determined by the following physical characteristics of the robot:
 The robot physical configuration
 The size of the body, arm and wrist components
 The limits of the robot joint movements

3.2 DRIVE SYSTEM

The three types of drive systems are:

1. Hydraulic drive
2. Pneumatic drive.
3. Electrical drive.

1. HYDRAULIC DRIVE:
This is associated with large and powerful robots. Usually an electric motor is used to
operate the hydraulic pump. The servo valves are also electrically initiated. But the motive power
is derived entirely from the oil forcing pistons or vanes to change a linear or angular position.
These in turn are linked to the link or joint of the robot and provide the force necessary for that
particular motion. The usual advantage of the hydraulic drive systems is that it provides the robot
with mechanical simplicity, greater speed and strength. The disadvantage is that it typically adds
to the floor space required by robot.

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 2. PNEUMATIC DRIVE:
This is generally reserved for smaller robots that possess fewer degrees of
freedoms. These robots are often limited to simple”Pick and Place” operation of piston devices
to provide translation movements of sliding joints. It can be used to operate rotary actuators
for rotational joints.

3. ELECTRICAL DRIVE:
Electrically powered robots are the most prevalent in industry. Either AC or DC electrical
power is used to supply energy to electromechanical motor-driven actuating mechanisms and
their respective control systems. Motion control is much better, and in an emergency an
electrically powered robot can be stopped or powered down more safely and faster than those
with either pneumatic or hydraulic power.

3.3 ADVANTAGES.
 Robot can work seven days in a week without rest.
 Capable of performing tasks more efficiently.
 They can make decisions by comparisons using sensors.
 Using computers they can be used to work, where accuracy is needed.
 Quality work can be achieved using robots in operations like spray painting,
welding, assembly etc.
 Productivity can be increased.
For automation of factory operations in large scale and for repeated activities robots
are the best devices.
 If the design of the project is subjected to quick changes, it is best to choose robots
to do work.
 Robots are flexible and can be reprogrammed to do something else.
 Time is money in manufacturing.
 The quicker time, retooling and production betters the return investments, this is
possible by means of Robots.

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3.4 APPLICATIONS OF INDUSTRIAL ROBOT.
 Material transfer.
 Machine loading.
 Processing operations.
 Assembly.

3.5 INTRODUCTION TO PICK AND PLACE ROBOT.

The Pick ‘n’ Place Robots are automated machines, which perform functions like
material handling, etc. There are various machines, which performs the user defined tasks, as
mentioned above. Our robot consists of two rotary axes; hence these types of robots are also
called as RR system. Here the movements are defined in terms of degrees of freedom, which are
supported. The degree of freedom refers to the possibility of the motions along a particular axis.
This model consists of two degree of freedom. These are grouped into the motions of
the arms and body assembly. Corresponding to arms and body, our model has rotational
traverses i.e., rotation of arms about the vertical axes.

3.6 Features of Robot.

 A robot can perform its work cycle with consistency and repeatability that cannot
be attained by humans.
 Robots can be substituted for human in hazardous or uncomfortable work
environment.
 Robots can be controlled by computers and therefore be connected to other
computer systems to achieve computer integrated manufacturing.
 A robot can be reprogrammed and equipped with necessary tooling to perform an
altogether different task.
 The Arm can rotate in clockwise and anticlockwise rotation
 This is moving around 360 degree.
 It can pick up the items in any place and drop in any place in working space.
 We can monitor the activities from the remote.

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 3.7 BLOCK DIAGRAM OF PICK AND PLACE ROBOT USING REMOTE

END-
EFFECTOR

REMOTE

STEPPER
MOTOR 2 ARM

IR SENSOR

COLUMN

MICRO-
CONTROLLER RELAYS STEPPER
MOTOR 1

BLOCK DIAGRAM OF PICK AND PLACE ROBOT USING REMOTE

3.8 END EFFECTORS

End effectors are device that attaches to the wrist of the robot arm and enables to perform a
specific task.
The two types of end effectors are
1. Grippers

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 2. Tools

 GRIPPERS
Grippers are end effectors used to grasp and hold objects.
The grippers are classified according to
1. GRIPPING MODALITIES
 Mechanical Grippers
 Vacuum Grippers
 Magnetic Grippers
 Adhesive Grippers
2. WAY TO GRASP
 External Grippers
 Internal Grippers
3. NUMBER OF FINGERS
 Two Fingered Gripper
 Three Fingered Gripper
 Four Fingered Gripper
 Five Fingered Gripper
4. NUMBER OF GRIPPING SYSTEMS
 Single Gripper System
 Multi Gripper System
Gripper need to be lighter as possible in order to minimize the static and dynamic load
imposed by the handling systems.
 As small as possible in order to minimize the space required for the gripper in the work
area.
 Sufficiently rigid for the work piece to be held accurately in position.
 Able to act on the work piece in sufficient gripping force, without damaging it.
 Reliable and flexible.
 Able to be designed and manufactured easily and should be in-expensive.
 Economic in maintenance expenses.

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CHAPTER 4

4.1 MECHANICAL PARTS:

The different parts in existing model can be listed as:
 Base.
 Stepper motor.
 Column.
 Arm.
 End effecter.

 Base:
The base is that part of model on which the vertical column was mounted. On the base,
the electrical component like P.C.B’s & stepper motor is mounted. Here we have used cast iron
as the base plate material. Area: 280 X 175 mm2

 Stepper motor:
In this project we are using the stepper motor as per the specification mentioned below.
The stepper motor is a 4 pole where in this poles are connected to the relay and is controlled by
the relay driver IC ULN 2003. At any given
Instant of time only 1 relay is activated such that depending upon the particular relay
activated that particular pole in stepper motor is energized and accordingly the stepper motor
moves to that particular pole due to excitation. Depending on the type of relay to be activated
and the particular order. Stepper motor accordingly moves in either clock wise or anti -
clockwise direction.

 Column:
A column is the vertical member of the robot, which support the arm & wrist part of
the robot with the necessary driving mechanism. The column was made rigid, so that it takes
entire torque. The column is mounted on stepper motor, which meshes with on rotator provided

24
 in stepper motor, from which it rotate high degree of accuracy. Here in our model we have used
PVC pipe of Length : 80 mm & Diameter : 20mm

 Arms:
An arm, which is also called as main frame typically, consist of mechanical link
connected through another stepper motor to give oscillating motion. Here we have used an arm
made up of aluminum material having Length: 150 mm

 End effecters:
End effecters used to grasp & hold object. The objects are generally work parts that are
to be moved by the robot. These part handling applications include, picking part from conveyor
& placing parts on a pallet. Here we have used an electro-magnet as an end effecter consists of a
metal piece wounded by copper wire.

4.2 ELECTRIACL AMD ELCTRONICS COMPONENTS:

The different electrical components used.
 Single sided board.
 Diodes.
 Capacitors.
 Resistors.
 Transistors.
 Relays.
 Remote
 Micro-controller.

 Single sided board:

The term single sided means the insulating substances contains circuit pattern on only
one side, which is called as solder side & the other side is component side these kinds of P.C.B
are used in professional & nonprofessional grades & are manufactured by print & etch method
In this method, single sided board is manufactured with limited copper on the surface.
It is used in professional & non- professional grade of P.C.B’s the precision of the circuit boards

25
depends on the image transfer on the substrate. This process is used for low cost commercial
mass production. The entire multi-layer, inner layers are prepared in this method. The
mechanical machining operations involved in P.C.B manufacturing are shearing, sawing,
punching, blanking, routing and darling, welding…etc

 Diodes:
The diodes re junctions, which allows the current to flow in one direction only. Its
main function is to avoid back e.m.f although the reverse break down occurs at very high
voltage, beyond which he current increase steeply for every increase in applied voltage. Here
we have used 12 numbers of in 4007 rectified diodes.

 Capacitors:
The capacitor is a device, which stores electrical charges, it consist of two conductors
separated by dialectical medium. The dielectric medium is a substance of high resistance (mica,
paper, ceramic, air, etc) for the flow of electric current. Here we have used ceramic capacitors.

 Transistors:
The transistor can be considered as two semiconductor diodes connected back-to-back
in a semiconductor crystal, it consist of three regions known as emitter, base & collector.

 Relays:
A relay is the simplest form can be defined as an electrically operated switch. This
description implies that the Relay consist of mechanism (electromagnet or thermal or electronic
relay) to make or break connection in electric circuit here we have used 12v, 279Ω relay.

26
 RL 8
STEPPER RL 4
MOTOR 1 END
CLK EFFECTER
MICRO MOVEMENT
RL 7 CONROLLER
STEPPER 16F505
MOTOR 1 RL 3
ACLK
RL 6
STEPPER
RL 2
MOTOR 2
CLK
RL 5
STEPPER RL 1
MOTOR 2 SENSOR
ACLK

 Resistors:
Resistor is a component which offers a specific amount of resistance to the flow of
current. These are made up of film of carbon or a coil of nichrome wire.

 Remote:
This is a device to control the robot in according to the convince. This consists IR
transmitter, which send signal through IR waves. Here we have used general T V remote to
operate. The Remote used here controls the two stepper motor for two degree of freedom.

4.3 MICRO-CONTROLLER:

27
 Microcontroller is an electronic device which is generally used to perform single
operation when compared with the microprocessor. Microcontrollers perform arithmetic and
logic operations at blazing speeds so as to perform complex operations within split seconds.
One single chip in the system is capable of controlling using the underlying software a huge
number of resources in real time.

4.4 FEATURES OF THE MICRO-CONTROLLER USED:

 16F505 compatible processor.
 Eight devices of 12 volt 5A rating can be directly connected.
 Visual indication of channel status.
 Single supply operation.
 Fully embedded design.
 Unit operated thru a customized Remote Control
 transmitter.
 High Sensitive receiver of fast and reliable response.
 Max control distance is 20m.
 We can control the motor through IR transmitter

4.5 PARTS TO BE FABRICATED.

 Base
 Column
 Arms
 End effectors.
 P.C.B
 Remote
He following steps was followed during
fabrication:-

28
Step 1: Preparation of base plate.
A suitable size metallic base is taken & marking were done for
placing stepper motor & P.C.B.

Step 2: Rotary column alignment.

A column with hallow was mounted on the stepper motor wheel
rotator in turn placed on base plate.
Step 3: Primary arm alignment.
A primary arm was fixed to the stepper motor to give oscillating
motion & gripper movements.
Step 4: Gripper alignment.
End effectors were fixed to the primary arm which is of the form
magnetic.
Step 5: P.C.B manufacturing.
P.C.B as manufactured by etching process, using ferric chloride an
Agent. Etching process by drawing the circuit on the copper laminated thin plastic
sheet, then removing the copper by dissolving in an agent.
Step 6: Electric circuit.
All electrical components like diodes, capacitors, resistors,
transistors, relays & L.E.D’s.
Step 7: Remote.
By remote controlling the two stepper motor for two degree of
freedom.
Step 8: Assembly.
All electrical circuit, column, primary arm, end effecter P.C.B were
interconnected or assembled.

29
CHAPTER 5

5.1 WORKING OF ROBOT

Pick ‘N’ Robot is basically operated through program or remote. Here we are
concentrated to operate robot through program and remote is used as an auxiliary.
Programmable options are used for continues type of operations in industries, where as remote
operation is used at irregular criteria. The following procedure will give the brief description
about the way of operating the robot under different circumstances.
In the case of pick ‘n’ place robot, sensors could be used to detect the position of the
object before pick up. In continuous path case, they might be used to track the desired weld path
ahead of the welding torch.
The performance of the tasks will be measured by the accuracy of the placement of the
object and over all cycle time of the operation.

5.2 PROCEDURE TO OPERATE WITH REMOTE:

 Connect the model with the power supply and switch it on.
 Press the desired keys in the remote.

Description of the keys required for the operation are as follows-

4 - Activation of the electro-magnetic (end-effecter).
5 - up-ward movement of the robotic arm.
6 - down-ward movement of the robotic arm.
7 - Clock-wise movement vertical column.
8 - Anti-clock wise movement of vertical column.

5.3 DESRIPTION OF WORKING PRINCIPLE:

 The working volume of the robot needs to be sufficient so that all the parts of the
working area can be reached.

30
 The speed and acceleration of the robot must be large enough so that the task can be
accomplished with an acceptable time.

 Max speed is only a guideline particularly when small movements are being made.
In this case the acceleration will dominate the time to accomplish the movement.

 The repeatability of the robot is a measure of the tolerance within which the end
effectors can be returned to pre determined point. The resolution of the robot is the smallest step move
that can be made at a given position.

 Typically the worst case is quoted over the whole of the working volume.

 The accuracy of the robot is different from that of repeatability.

 In this case the robot may have been programmed off-line to move to a given
location 10mm above a reference point.

 In practice it will not get exactly to that point, not only because of frictional effects
and discrete data effects in sensors and computers, but of the calibration errors.

 The feedback may be improved by additional sensory feedback.

5.4 ADAPTED PROCEDURE OF PICK ‘N’ PLACE WORKING :

 IR signal received by IR sensor
 Signal is sent to micro-controller
 At any given instant of time only 1 relay is activated. Such that depending upon
the particular relay activated that particular pole in stepper motor is energized
and accordingly the stepper motor moves to that particular pole due to
excitation.

31
  Stepper motor accordingly moves in either clock wise or anti - clockwise
direction.

5.5 STEPPER MOTOR

The stepper motors are unique type of motors that produce rotational movements in the
form of finite angular steps. The intermittent electrical pulses make the stepper motor shaft to
rotate in steps.

SELECTION:
The selection of the electric drive is based on the torque rating and the current rating of
the motor. The torque rating of a electric motor is derived from the power rating of the motor.
If ‘p’ is the power rating the torque rating
T= (60p)/ (2*3.14*N) where, N= speed (rpm)

R
F

The turning moment of a force about an axis is called the torque. It is the product of the
force and the radius at which the force acts about the axis.

5.6 MOTOR PRINCIPLE:

The figure shows the schematic arrangement of the stepper motor principle. The stator
in this case is made up of four-electromagnetic poles. The rotor is a permanent magnet with
two poles N and S. when the excitation of pole 2 is

32
 Changed to p3 pole the magnetic north of the rotates by 90 degree clockwise. By
continuous change in excitation in the order of p2-p3-p4-p1-p2 the clockwise rotation is
produced in the shaft of the rotor, which results in continuous movement.

P1
P4

P2

P3

Stepper motor principle

Salient features of stepper motors are:

 They are useful for low-torque applications.
 Position feedback is not required.
 One step per pulse.
 Rotation of the shaft is by rotation of the magnetic field.
 Need microprocessor circuit to start.

33
  Find less use in Industrial robots.
 Extensively used in robotic device.

STEEPER MOTOR

5.7 STEPPER MOTOR SPECIFICATION:

1. Step Angle 0.5%

2. Step angle accuracy 5%
3. Rate phase current 0.22A
4. Phase resistance 23 ohms
5. Holding torque 20 Ncm
6. Detent torque 2 Ncm
7. Rotor inertia 70 gram
8. Weight 0.2 kg
9. Voltage +12V, DC
10. Make Fuji Electronics

In this project we are using the stepper motor as per the specification mentioned above.
The stepper motor is a 4 pole where in this poles are connected to the relay and is controlled by
the relay driver IC ULN 2003. At any given instant of time only 1 relay is activated such that
depending upon the particular relay activated that particular pole in stepper motor is energized
and accordingly the stepper motor moves to that particular pole due to excitation. Depending
on the type of relay to be activated and the particular order. Stepper motor accordingly moves
in either clock wise or anti - clockwise direction.

34
5.8 PROGRAM TO RUN STEPPER MOTOR:

INPUT P3.0;
OUTPUT P1.7,1.6,1.5,1.4 FOR STEPPER MOTOR;
P1.4 TO P1.7 STEPPER MOTOR;
P1.3-OUTPOUT 5;
P1.2-OUTPOUT 6;
P1.1-OUTPOUT 7;
org 00h
sjmp main
main:
mov p1,#00h
mov p3,#0ffh
MAIN2:
JB P3.0,ONE
MOV P1,#02H
JMP MAIN2
ONE:
MOV P1,#00H
SETB P1.3
LCALL DELAY1
MOV P1,#00H
MOV R1,#7FH
ZERO:
djnz r1,CLOCK
ljmp ON6
CLOCK:
MOV P1,#040H
lcall DELAY2
MOV P1,#060H
lcall DELAY2
MOV P1,#020H
lcall DELAY2
MOV P1,#0A0H
lcall DELAY2
MOV P1,#080H
lcall DELAY2
MOV P1,#090H
lcall DELAY2
MOV P1,#010H
lcall DELAY2

35
 MOV P1,#050H
lcall DELAY2
ljmp Z

CHAPTER 6

6.1 SOFTWARE DESCRIPTION:

Some mean of interaction is necessary to interact with a robot so as to send signals of
operation on robot for which robot language must be used. However robot languages are
numerous but assembly languages are preferred so that the user can concentrate on the work to
be done rather than spending time doing the sequences, editing capabilities and so on. A high
level language can be used for controlling the robot.

6.2 SEQUENCES OF OPERATION CONTROLLED:

• The robot is made to move from the present position to the reference position.
• The robot is made to move from the source position to the destination position and
pace the object.
Various sub routines are written to perform each of these operations. Appropriate error
messages are also indicated.

6.3 ADVANTAGES:
• Greater flexibility, re-programmability.
• Greater response time to inputs than humans
• Improved product quality
• Maximize capital intensive equipment in multiple work shifts
• Accident reduction
• Reduction of hazardous exposure for human workers
• Automation less susceptible to work stoppage.

6.4 APPLICATION:
Current day robotics includes a very wide variety of applications in production
operations. Few of them are:

36
 Material transfer and machining loading/unloading.
1. Pick and place operations.
2. Palletizing and related operations.
3. Die casting.
4. Plastic molding.
5. Forging and related operations.

 Processing operations.

1. Spot welding.
2. Continuous arc welding.
3. Spray coating.
4. Other operations.

 Assembly & inspection operations.

1. Parts presentation.
2. Assembly tasks.
3. Assembly cell design

37
 CHAPTER 7

7.1 TESTING:
Observation

• Maximum weight that can be lifted including end effector = 50gm

• Accuracy of the model = +/- 5mm
• Maximum reachable distance from the centre of the column =150mm
• Total weight of
the model = 2 kg

Fig: Photo of Pick and Place

Robot

38
 Fig: Relay Circuit of Robot

CHAPTER 8

Conclusion

As intended by us, we as the project group were successful in devoting a product that can be
used in industries to be automated. Any newly developed device may not be perfect in all respects;
At the same time full efficiency can be acquired only by passing through a series of
experimental stages. We tried to translate the picture that arouse in our mind in to finished product &
further improvements can be carried over at various subsequent stages till al our needs are complicated
attained in an efficient manner. intension of making prototype of pick ‘n’ place for application in small
scale industries, for segregation purposes and for demo purposes.
Overall the performance is satisfactory with minimal drift and considerable accuracy, and very
much optimized for the money spent on it knowledge we take is equal to implement we make

SUGGESTIONS & IMPROVEMENTS

Future robots can change the robots have potential to change our economy, our health, our
standard of living & the world we live. New uses bring hopes & possibilities, but also dangers & risks.
The pick and place robot can be updated to do assemblies and other specific works with
special attachments. It can be made according to the specification of the user and their application. By
replacing the jaw with other accessories, robot can also be employed in different areas.
The uses of robots are not only limited for industrial use but, may also be implemented for
domestic purposes. Robots are now fast gaining important in space activities.
Science fiction often helps us explore new ways as to how new technology & science could
affect our future. Some of them are.
 Multi arm programming, Path planning and Obstacle avoidance.
 Future robotics will not only include manufacturing but also non manufacturing
applications.

39
REFERENCES

1. Mechatronics By Macgraw Hill.

2. Robotic Engineering By Richard D. Klafter.

Thomas A. Chmielewski.
Michael Negin.

3. Industrial Robotics By M.P Groover.

Mitchell Weiss.
Roger.N.Nagel.

4. Robotics For Engineers By Yoram Korean.

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