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180 DEGREE STEERING SYSTEM ROBOTIC CAR

Technical Report · April 2016

DOI: 10.13140/RG.2.2.10576.38402/1

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180 DEGREE STEERING SYSTEM ROBOTIC CAR

Student Name Student ID

1) Takiur Rahman Nafees 130208002

2) Diprajit Biswas 130208006

3) Ashraf Ibn Rahman Dip 130208016

4) MD. Shawon Rana 130208050

B.Sc. in Mechanical Engineering

Department of Mechanical and Production Engineering

Ahsanullah University of Science and Technology

 INDEX

Contents Page

ACKNOWLEDGEMENT i

ABSTRACT ii

CHAPTER-1: Introduction

1.1. Steering System 1

1.2. Objective 1

1.3. Factors to be considered in this project 1

Chapter-2: Design, Parts and Fabrication

A. Mechanical Parts

2.1. Material Selected 2

2.2. Chassis 3

2.3. Connecting Rod 4

2.4. Chain Sprocket 5

2.5. Chain 6

2.6. Bearing 6

2.7. Wheel 7
Contents Page

B. Electrical Parts

2.8. Breadboard 7

2.9. Arduino 8

2.10. Motor Shield 11

2.11. Servo Motor 12

2.12. High Torque Gear Motor 13

2.13. Cable 14

2.14. Voltage Regulator 14

2.15. IR Sensor 15

2.16. Battery 15

2.17. Mechanical Switch 16

2.18. Remote 16

Chapter-3: Drawings

3.1. Drawing 1 17

3.2. Drawing 2 18

3.3. Drawing 3 19
Contents Page

Chapter-4: Cost Analysis 20

Chapter-5: Working Procedure and Application

5.1. Working Procedure 21

5.2 Application 22

Chapter-6: Advantages, Limitations and Difficulties Faced

6.1 Advantages 23

6.2. Limitations 23

6.3. Difficulties Faced and Solved During Project 23

Chapter-7: Future Recommendations 25

Chapter-8: Conclusion 26
 ACKNOWLEDGEMENT

The success and final outcome of this project required a lot of guidance and assistance from
many people, and we are extremely fortunate to have got this all along the completion of our
project. Whatever we have done this only due to such guidance and assistance and we would
not forgot to thank them. We respect and thank our teachers for giving us an opportunity to
do this project and providing us all supports and guidance which made us complete the
project on time.

This project can’t be completed without the effort and co-operating from our group members.
Finally, we would like to express our gratitude to all the people who supporting us
willingness to spend some time with us.

i
 ABSTRACT

The most conventional and general steering arrangement is to turn the front wheels using a
hand-operated steering wheel which is positioned in front of the Driver. The steering column,
which contain a universal joint which is part of the collapsible steering column which is
designed to allow it to deviate from a straight line according to the roadmap.

For this topic (180- degree steering system) we are specifically going to see some of the
design-oriented challenges that come in the way of designing a 4-wheel car/robot that uses a
chain steering for taking turns (left and right) or to make a complete 180- degree in place
(pivot) rotation (zero radius turning).

ii
 Chapter-1

INTRODUCTION

1.1 Steering System:

Steering is the term applied to the collection of components, linkages, which will allow for a
vessel or vehicle to follow the desired course. An exception is the case of rail transport by
which rail tracks combined with railroad switches provide the steering function.

The most conventional steering arrangement is to turn the front wheels using a hand –operated
steering wheel which is positioned in front of the driver, through the steering column, which
may contain universal joints to allow it to deviate somewhat from a straight line. Other
arrangements are sometimes found on different types of vehicles, for example, a tiller or
rear–wheel steering. Tracked vehicles such as tanks usually employ differential steering that
is, the tracks are made to move at different speeds or even in opposite directions to bring
about a change of course.

1.2 Objective:

In 180-degree steering system here a chain relates to 4 wheels which gave 180-degree
rotation at a time in 4 wheels by a High Torque Servo Motor. 180- degree rotation is
maintained by Arduino code which controls the servo motor. Total system is controlled by a
remote.

1.3 Factors to Be Considered in This Project:

• Easily available equipment’s

• Cost effective
• Light weight
• Safety
• Comfort
• Durability

1
 Chapter-2

DESIGN, PARTS AND FABRICATION

A. MECHANICAL PARTS:
2.1 Material Selected:
Chassis: Mild Steel
Wheel: Rubber
Connecting Rod: Mild Steel
Pinion/Chain Sprocket: Mild Steel
Chain: Mild steel

Fig: 180- Degree Steering System Robotic Car (real picture)

2
2.2 Chassis:

Length: 2 Feet
Width: 2 Feet
Height: 0.75 Inch

Fig: Fabrication of Chassis Using Arc Welding.

We use 0.2mm thick GP sheet for base, where other Elements are built on it. We use flux
coated welding rod for arc welding.

3
2.3 Connecting Rod:

Diameter 1: 1 inch
Length 1:3 inch
Diameter 2: 0.75 inch
Length 2: 3 inch
Quantity: 4

Fig: Connecting rod with wheel

We use a connecting rod with two varies diameter. The side of diameter 1 is connected with
wheel carrier and other side connected with chain sprocket. It transform the rotational motion
from the servo motor to wheel and the wheel turns to 180- degree.

4
2.4 Sprocket:

Teeth: 14
Diameter: 60 mm
Thickness:5 mm
Pitch: 13.464 mm
Quantity: 5

Fig: Chain sprocket

Chain sprocket runs by the chain. It receives the rotational motion by chain from the servo
motor and passes it to the connecting rod and the wheels rotate to the required direction.

5
2.5 Chain:
Length: 9 feet
Type: Roller chain

Fig: Chain
Chain transfers the rotating motion from the servo motor to the connecting rods.

2.6 Bearing:
Inner diameter: 0.75 inch
Outer diameter: 2 inches
Type: Ball bearing
Quantity: 4

Fig: Ball Bearing

It fixed on the corner of the chassis, connecting rod pass through it and it reduce the friction
of the rod. Rod can rotate smoothly.

6
2.7 Wheel:
Diameter: 100 mm
Thickness: 25 mm
Quantity: 4

Fig: Wheel

It helps to move the car in the direction where we need to carry the loads.

B. ELECTRICAL PARTS:

2.8 Breadboard:

Fig: Breadboard

A breadboard is a construction base for prototyping of electronics. Originally it was literally a

bread board, a polished piece of wood used for slicing bread. We used it for making the
connection between electrical elements.

7
2.9 Arduino:

The Arduino Mega is a microcontroller board based on the ATmega1280 (datasheet). It has
54 digital input/output pins (of which 14 can be used as PWM outputs), 16 analog inputs,
4 UARTs (hardware serial ports), a 16 MHz crystal oscillator, a USB connection, a power
jack, an ICSP header, and a reset button. It contains everything needed to support the
microcontroller; simply connect it to a computer with a USB cable or power it with a AC-to-
DC adapter or battery to get started. The Mega is compatible with most shields designed for
the Arduino Duemilanove or Diecimila.

Fig: Arduino Mega

Summery:
Microcontroller ATmega1280

Operating Voltage 5V

Input Voltage (recommended) 7-12V

Input Voltage (limits) 6-20V

Digital I/O Pins 54 (of which 15 provide PWM output)

Analog Input Pins 16

DC Current per I/O Pin 40 mA

DC Current for 3.3V Pin 50 mA

Flash Memory 128 KB of which 4 KB used by bootloader

SRAM 8 KB

8
EEPROM 4 KB

Clock Speed 16 MHz

We use arduino IDE software for coding and programming was c programming
The code was attached in next page.

CODE

#include <Servo.h>
#include <IRremote.h>

Servo myservo,servo2;
//Servo servo2;
int pos,j;
IRrecv irrecv(6);
String button;
decode_results results;
char c;
void setup()
{
Serial.begin(9600);
irrecv.enableIRIn();
myservo.attach(9);
servo2.attach(10);
pos=1;
myservo.write(0); // set servo to mid-point
servo2.write(60);
}
void loop(){
if(irrecv.decode(&results)){
button=String(results.value,HEX);
Serial.println(button);
if(button=="f0771735" || button=="40bd08f7"){
Serial.println(button);
for(j=pos;j<=pos+10;j++){
myservo.write(j);
}
if(pos<=170){
pos+=10;
}

}
else if(button=="40bd8877" || button=="80eb69e1"){
Serial.println(button);
for(j=pos;j>=pos-10;j--){
9
 myservo.write(j);
}
if(pos>=10){
pos-=10;
}
}
else if(button=="40bdc837" || button=="f93dd945"){
clock();
Serial.println(button);
}
else if(button=="aa01a849" || button=="40bd48b7"){
counterClock();
Serial.println(button);
}
else if (button=="40bda857" || button=="40bda857"){
midServo();
}
irrecv.resume();
delay(500);
}
}

void counterClock(){
int i;

for(i=46;i<=125;i++){
servo2.write(i);
delay(10);
}
}

void midServo(){
int i;

for(i=46;i<=100;i++){
servo2.write(i);
delay(10);
}
}

void clock(){
int i;
for(i=125;i>45;i--){
servo2.write(i);
delay(10);
}
}

10
2.10 Motor Shield:

The Arduino Motor Shield is based on the L298 (datasheet), which is a dual full-bridge driver
designed to drive inductive loads such as relays, solenoids, DC and stepping motors. It lets
you drive two DC motors with your Arduino board, controlling the speed and direction of
each one independently. You can also measure the motor current absorption of each motor,
among other features. The shield is TinkerKit compatible, which means you can quickly
create projects by plugging TinkerKit modules to the board.

Fig: Motor shield

Summery:

Operating Voltage 5V to 12V

Motor controller L298P, Drives 2 DC motors or 1 stepper motor
Max current 2A per channel or 4A max (with external power supply)
Current sensing 1.65V/A

We use it to run and control the servo motor.

11
2.11 Servo Motor:

A servomotor is a rotary actuator or linear actuator that allows for precise control of angular
or linear position, velocity and acceleration.[1] It consists of a suitable motor coupled to a
sensor for position feedback. It also requires a relatively sophisticated controller, often a
dedicated module designed specifically for use with servomotors.

Servomotors are not a specific class of motor although the term servomotor is often used to
refer to a motor suitable for use in a closed-loop control system.

Fig: Servo motor

We used 2 servo motor. One for 180- degree steering rotation and the other for controlling
the high torque DC motor.

12
2.12 High Torque Gear Motor:

Type: DC Motor
Input Voltage: 24 V
Current Ratting: 9 A
Output speed: 30 RPM
Capacity: 40 kg
Quantity: 2

Fig: High Torque Gear Motor

These are used to move the Robotic Car. The total weight of the Robotic Car and Loads are
bear by the two Motors

13
2.13 Cable:

We use cable to connection in circuit and connect the motor with battery.
We use two types cable.

Fig: Cables

2.14 Voltage Regulator:

We use 7805 IC for regulate the voltage into 5 volt for arduino.

Fig: Voltage Regulator

14
2.15 IR Sensor:
We use it to receive the signal which was send by remote. It’s a led sensor.

Fig: IR Sensor

2.16 Battery:
We use two batteries. One for arduino and the other one is for high torque gear motor.
Small one is 7.2 V 2000 mAh.
Big one is 12 V 9 A.

Fig: Battery

15
2.17 Mechanical Switch:

Fig: Mechanical Switch

This is used to supply power required to run the High Torque Gear Motors from the battery.

2.18 Remote :

Fig: Remote
Remote is used to run the Robotic Car by giving the signals to the aurdino.

16
 Chapter-3

DRAWINGS

3.1 Drawing 1:

This diagram shows the how electrical parts are connected.

Fig: Circuit diagram

17
3.2 Drawing 2:

This diagram show how the mechanical parts are connected.

Fig: Solid Works Design

18
3.3 Drawing 3:

This is the final diagram after assembly.

Fig: Final Assembly

19
 Chapter-4

COST ANALYSIS

Items Price (In Taka)

1. Chassis 2,000

2. Wheels 650

3. Bearings 280

4. Chain 200

5. Gear motors 2,000

6. Servo motors 3,000

7. Ardiono 650

8. Motor shield 450

9. Battery 2,000

10. Wire & accessories 500

11. Sprocket 150

12. Connecting rod 500

Total 12,380

20
 Chapter-5

Working Procedure and Application

5.1 WORKING PROCEDURE

• For forward motion, the P+ button on the remote need to press.

• For rotating the wheel at right, the VOL+ button is pressed and for rotating the wheel
at left, the VOL- button is pressed. At each press, the wheel will rotate 10 degrees. By
pressing again and again we can rotate the wheels up to 180 degrees. Then the P+
button will give motion on that direction.
• For backward motion of the Robotic Car P- button is pressed.
• To stop the Robotic Car, the yellow button in the middle should press.

21
5.2 APPLICATION:

The ‘180- Degree Steering System Robotic Car’ should be used to carry loads (goods,
products etc.) inside a factory or industry. It will be able to cross a sharp 180- degree rotating
path or any sharp angular path with the loads.

Fig: Angular Position of Wheels

22
 Chapter-6

ADVANTAGES LIMITATIONS AND DIFFICULTIES FACED

6.1 ADVANTAGES:

• The whole car is designed with equipment’s found in the local markets.
• Every wheel is freely movable, so there is no need to use any differential to rotate the
wheels.
• Our careful selection of chassis material helped to reduce the weight of the Robotic
car.
• Primarily the weight capacity is up to 40 kg which can be increase by increasing the
motor torque and strength of the used material.
• It is an electrically powered system. So there is no emission of CO2 or any harmful
gas or elements.

6.2 LIMITATIONS:

• There is not a self-starting system.

• Due to remote control, an operator is always needed to run the Robotic Car.
• Only at steel position the required rotating angle can be obtained.
• There is no braking system.

6.3 DIFFICULTIES FACED AND SOLVED DURING PROJECT:

• The chain was not placed properly. The position of the Servo Motor was changed to
make the chain straight so that we can get the required angle of rotation of the wheel
transferred from the Servo Motor.
• The wheels were displaced during turning. Because the connecting rod was not
properly meshed with the bearing attached with the chassis. So, we grind the

23
 connecting rods and then put these into the bearings. So that the joint is perfectly
meshed, and the problem been solved.
• The sprocket gear was also not messed properly. This problem is also solved by using
the grinding technique.
• A major problem was faced in the power supply from arduino to the High Torque
Gear Motor. The Arduino couldn’t supply the required power to run the High Torque
Gear Motors. So a mechanical switch by using servo motor is used so that the High
Torque Gear Motors could be operated with remote control and also got the required
power to run.

24
 Chapter-7

FUTURE RECOMMENDATIONS

• A monitor can be added to show the angle at which the wheels rotate.
• An obstacle sensor can be added so that if there is not an operator, the Robotic Car
may switch off instead of heating any wall or objects.
• Also, a braking system can be added for instant stopping.
• A mechanical arm should be attached for lifting and putting down the loads
automatically. For this purpose, a weight sensor may use so that the arm may differ
different types of loads and separate them by weights and to carry.
• The load carrying route inside the industry or factory can be added in the program to
reach the destination automatically.

25
 Chapter-8

CONCLUSION

After our hard work we have finished our project what we have chosen within the time. But
there are some features that we would like to modify. We wish to continue our work with this
project for the betterment of the Robotic Car. We want to add some advanced features that
may increase the effectiveness and the efficiency. We couldn’t do these right now due to
shortage of time and money also. But the project has shown us wide and different aspects of
engineering. We wish to produce a better Robotic Car which may be use in industrial purpose
in near future.

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