JECT REPORT

on

PICK AND PLACE ROBOT

B.S. PATEL POLYTECHNIC, KHERVA

Project group:
Enrollment No :
(1) Pa
(126440319065)
(2) Chavda Parth Sureshbhai
(126440319076)
(3) Chauhan Jay Rakeshbhai
(126440319108)
(4) Patel Ravi Dineshbhai
(126440319117)
Internal / External guide: (1) Prof. K.P.Patel ( H.O.D.)

(2) Mr. A.M.Patel

2

Certificate

This is to certify that Mr. Patel Charmin Rajendrakumar having

Enrolment No :126440319065 has completed Part-I IDP Project
work having title PICK AND PLACE ROBOT. He has undergone
the process of shodh yatra, literature survey and problem
definition. He is supposed to carry out the residue IDP Part-II
work on same

problem during Semester-VI for the final fulfillment of the IDP

work which is prerequisite to complete Diploma Engineering.

Guide Mr. A.M.Patel H.O.D.-Prof. K.P.Patel

3

Certificate

This is to certify that Mr. Chavda Parth Sureshbhai having

Enrolment No :126440319076 has completed Part-I IDP Project
work having title PICK AND PLACE ROBOT. He has undergone
the process of shodh yatra, literature survey and problem
definition. He is supposed to carry out the residue IDP Part-II
work on same

problem during Semester-VI for the final fulfillment of the IDP

work which is prerequisite to complete Diploma Engineering.

Guide Mr. A.M.Patel H.O.D.-Prof. K.P.Patel

4

Certificate

This is to certify that Mr. Chauhan Jay Rakeshbhai having

Enrolment No :126440319108 has completed Part-I IDP Project
work having title PICK AND PLACE ROBOT. He has undergone
the process of shodh yatra, literature survey and problem
definition. He is supposed to carry out the residue IDP Part-II
work on same

problem during Semester-VI for the final fulfillment of the IDP

work which is prerequisite to complete Diploma Engineering.

Guide Mr. A.M.Patel H.O.D.-Prof. K.P.Patel

5

Certificate

This is to certify that Mr. Patel Ravi Dineshbhai having

Enrolment No :126440319117 has completed Part-I IDP Project
work having title PICK AND PLACE ROBOT. He has undergone
the process of shodh yatra, literature survey and problem
definition. He is supposed to carry out the residue IDP Part-II
work on same

problem during Semester-VI for the final fulfillment of the IDP

work which is prerequisite to complete Diploma Engineering.

Guide Mr. A.M.Patel H.O.D.-Prof. K.P.Patel

6

INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT

FORM

STUDENT PARTICULARS-1

FIRST NAME
Charmin

LAST NAME
Patel
MOBILE NO.
1
8401163001

EMAIL
Charmin1997@yahoo.com

ENROLLMENT NO. 126440319065

COLLEGE NAME
B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.
66/ Sanskar Bunglows,

ADDRESS

Nr.Raghav Gas Agency,

Vijapur.

BRANCH
MECHANICAL ENGINEERING
SEMESTER
5th SEM.
YEAR
2014-2015

TEAM NAME
14

SIGNATURE OF

STUDENT
STUDENT PARTICULARS-2

FIRST NAME
Parth
7

LAST NAME
Chavda

MOBILE NO.
1
9978326421

EMAIL
Parth.chavda.319@facebook.com

ENROLLMENT NO. 126440319076

COLLEGE NAME
B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

A/12 Dharendranagar society,

ADDRESS

Naroda,Ahamdabad

BRANCH
MECHANICAL ENGINEERING
SEMESTER
5th SEM.
YEAR

20142015

TEAM NAME
14

SIGNATURE OF

STUDENT
8

STUDENT PARTICULARS-3

FIRST NAME
Jay

LAST NAME
Chauhan

MOBILE NO.
1.
9586450846

2.

EMAIL
JAYRAKESH30@Gmail.com

ENROLLMENT NO.126440319108

COLLEGE NAME
B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

10,swapnabhumi society,
ADDRESS

Nr. Anandpura chokdi,

Vijapur

BRANCH
MECHANICAL ENGINEERING

SEMESTER
5th SEM.
YEAR

2014-2015

TEAM NAME
14

SIGNATURE OF

STUDENT
9

STUDENT PARTICULARS-4

FIRST NAME
Ravi

LAST NAME
Patel

MOBILE NO.
1.
8128282656

2.

EMAIL
Ravipatel0302@gail.com

ENROLLMENT NO.126440319117

COLLEGE NAME
B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

C-2 Anand Coloni,

ADDRESS

Nr.exp.highway,C.T.M.,

Ahamdabad

BRANCH
MECHANICAL ENGINEERING

SEMESTER
5th SEM.
YEAR

2014-2015

TEAM NAME
14

SIGNATURE OF

STUDENT
10

ABSTRACT

Mankind has always strived to give life like qualities to its artifacts in an attempt to find
substitutes for himself to carry out his orders and also to work in a hostile environment. The
popular concept of a robot is of a machine that looks and works like a human being.

The industry is moving from current state of automation to Robotization, to increase

productivity and to deliver uniform quality. The industrial robots of today may not look the
least bit like a human being although all the research is directed to provide more and more
anthropomorphic and humanlike features and super-human capabilities in these.

One type of robot commonly used in industry is a robotic manipulator or simply a robotic
arm. It is an open or closed kinematic chain of rigid links interconnected by movable joints.
In some configurations, links can be considered to correspond to human anatomy as waist,
upper arm and forearm with joint at shoulder and elbow. At end of arm a wrist joint connects
an end effector which may be a tool and its fixture or a gripper or any other device to work.

Here how a pick and place robot can be designed for a workstation where loading and
packing of lead batteries is been presented. All the various problems and obstructions for the
loading process has been deeply analyzed and been taken into consideration while designing
the pick and place robot.
11

INDEX

SR.
TOPICS NAME
PAGE NO.
NO.

1.
Introduction Of Project
13 to 17

2.
Classification of Robot
18 to 19

3.
Selection of Task
20 to 22

4.
Design Procedure
23 to 28

5.
Steps of Designing
29 to 30

6.
Works to be Done
31 to 32

7.
Advantages
33 to 33

8.
Disadvantages
34 to 34

9.
Application
35 to 35

10.
References
35 to 35

11.
Estimation
36 to 36
12

LIST OF FIGURES & TABLES

FIGURES

KEY COMPONENTS OF ROBOTS.

ACTUATORS.

SENSORS.

INDUSTRIAL ROBOT.

AGRICULTURAL ROBOT.

TELE-ROBOT.

PICK & PLACE ROBOT.

FLEXIBLE PACKAGING.

CARTOONIG PROCESS.

ROTARY CARTOONING.

PALLETIZING & DEPALLETIZING.

PICK AND PLACE ROBOT.

SEALING ROBOTS.

BAG OPENING ROBOTS.

4.1 GRAPHICAL INTERFACE OF MATLAB WORKSPACE.

WORK SPACE LAYOUT.

DEGREE OF FREEDOM.

6.1 INTERFACING OF ROBOT WITH COMPUTER,

TABLES
1.1 HISTORY OF ROBOTS.
13

CHAPTER 1

INTRODUCTION

Robotics is the branch of engineering science & Technology related to robots, and their
design, manufacture, application, and structural disposition. Robotics is related to
electronics, mechanics, and software. Robotics research today is focused on developing
systems that exhibit modularity, flexibility, redundancy, fault-tolerance, a general and
extensible software environment and seamless connectivity to other machines, some
researchers focus on completely automating a manufacturing process or a task, by providing
sensor based intelligence to the robot arm, while others try to solidify the analytical
foundations on which many of the basic concepts in robotics are built.

In this highly developing society time and man power are critical constrains for completion of
task in large scales. The automation is playing important role to save human efforts in most of
the regular and frequently carried works. One of the major and most commonly performed
works is picking and placing of jobs from source to destination.

Present day industry is increasingly turning towards computer-based automation mainly due
to the need for increased productivity and delivery of end products with uniform quality. The
inflexibility and generally high cost of hard-automation systems, which have been used for
automated manufacturing tasks in the past, have led to a broad based interest in the use of
robots capable of performing a variety of manufacturing functions in a flexible environment
and at lower costs. The use of Industrial Robots characterizes some of contemporary trends in
automation of the manufacturing process. However, present day industrial robots also exhibit
a monolithic mechanical structure and closed-system software architecture. They are
concentrated on simple repetitive tasks, which tend not to require high precision.

The pick and place robot is a microcontroller based mechatronic system that detects the
object, picks that object from source location and places at desired location. For detection of
object, infrared sensors are used which detect presence of object as the transmitter to receiver
path for infrared sensor is interrupted by placed object.

1.1 HISTORY OF ROBOTS

Robot is a word that is both a coinage by an individual person and a borrowing. It has been in
English since 1923 when the Czech writer Karel Capek's play R.U.R. was translated into
English and presented in London and New York. R.U.R., published in 1921, is an
abbreviation of Rossum's Universal Robots, robot itself comes from Czech robota, "servitude,
forced labor," from rab, "slave." The Slavic root behind robota is orb-, from the Indo-
European root orbh, referring to separation from one's group or passing out of one sphere of
ownership into another. Czech robota is also similar to another German derivative of this root,
namely Arbeit, "work. Arbeit may be descended from a word that meant "slave labor," and
later generalized to just "labor."
14

The various developments in the field of Robotics with the progress in scientific technology
have been revealed as follows:
Robot Name moving peacocks
Date Significance
Inventor
First Descriptions of more than 100 machines
century and automata, including a fire engine, a Ctesibius, Philo of
A.D. and wind organ, a coin-operated machine, and a Byzantium, Heron
earlier steam-powered engine, in Pneumatica and of Alexandria, and
Automata by Heron of Alexandria others
Robot band,
hand-washing
Created early humanoid automata, automaton
1206 programmable automaton band
, automated Al-Jazari

1495 Designs for a humanoid robot

1738 Mechanical duck that was able to eat, flap

its wings, and excrete
1898 Teleautomation
Nikola Tesla demonstrates first radio- Nikola Tesla
1921 controlled vessel.

First fictional automatons called "robots"

1930s appear in the play R.U.R.

Humanoid robot exhibited at the 1939 and

1940 World's Fairs
Rossum's
Mechanical Karel Capek
Leonardo da Vinci
Universal Robots
knight

Westinghouse

Elektra
Digesting Duck Electric
Jacques de

Corporation
Vaucanson

1948 1956 Simple robots

exhi viors William Grey
bitin Elsie and Elmer
g First commercial robot, from the Walter
biolo Unimation company founded by George
gical Devol and Joseph Engelberger, based on Unimate
beha Devol's patents George Devol
l robot. First palletizing robot
196
1 First industrial robot with six Famulus
electromechanically driven axes KUKA Robot
196
3 Programmable universal manipulation
arm, a Unimation product Group
197
3
Unimate
197 George Devol
5

Firs
t PUMA
insta Palletizer Victor Scheinman
lled Fuji Yusoki Kogyo
indu
stria

TABLE 1.1 HISTORY OF ROBOTS

15

1.2 LAW OF ROBOTICS

Isaac Asimov conceived the robots as humanoids, devoid of feelings, and used them in a
number of stories. His robots were well-designed, fail-safe machines, whose brains were
programmed by human beings. Anticipating the dangers and havoc such a device could
cause, he postulated rules for their ethical conduct. Robots were required to perform
according to three principles known as Three laws of Robotics which are as valid for real
robots as they were for Asimovs robots and they are:

A robot should not injure a human being or, through inaction, allow a human to be harmed.

A robot must obey orders given by humans except when that conflicts with the First Law.

A robot must protect its own existence unless that conflicts with the First or Second law.

These are very general laws and apply even to other machines and appliances. They are
always taken care of in any robot design.

1.3 WHAT IS AND WHAT IS NOT A ROBOT?

Automation as a technology is concerned with the use of mechanical, electrical, electronic

and computer-based control systems to replace human beings with machines, not only for
physical work but also for the intelligent information processing. Industrial automation,
which started in the eighteenth century as fixed automation has transformed into flexible and
programmable automation in the last 15 or 20 years. Computer numerically controlled
machine tools, transfer and assembly lines are some examples in this category.
FIG 1.1 KEY COMPONENTS OF A ROBOT.
16

Common people are easily influenced by science fiction and thus imagine a robot as a
humanoid that can walk, see, hear, speak, and do the desired work. But the scientific
interpretation of science fiction scenario propounds a robot as an automatic machine that is
able to interact with and modify the environment in which it operates. Therefore, it is
essential to define what constitutes a robot. Different definitions from diverse sources are
available for a robot.

COMPONENTS OF ROBOT:-1. STRUCTURE

The structure of a robot is usually mostly mechanical and can be called a kinematic chain.
The chain is formed of links, actuators, and joints which can allow one or more degrees of
freedom. Most contemporary robots use open serial chains in which each link connects the
one before to the one after it. These robots are called serial robots and often resemble the
human arm. Robots used as manipulators have an end effector mounted on the last link. This
end effector can be anything from a welding device to a mechanical hand used to manipulate
the environment.

POWER SOURCE

At present mostly (lead-acid) batteries are used, but potential power sources could be:

Pneumatic (compressed gases)

Hydraulics (compressed liquids)

Flywheel energy storage

Organic garbage (through anaerobic digestion)

Still untested energy sources (e.g. Nuclear Fusion reactors)

ACTUATION

Actuators are like the "muscles" of a robot, the parts which

convert stored energy into movement. By far the most popular FIG 1.2
actuators are electric motors that spin a wheel or gear, and ACTUATORS
linear actuators that control industrial robots in factors. But
there are some recent advances in alternative types of
actuators, powered by electricity, chemicals, or compressed
air.

4. TOUCH

Current robotic and prosthetic hands receive far less tactile

information than the human hand. Recent research

FIG 1.3 SENSORS

17

has developed a tactile sensor array that mimics the mechanical properties and touch
receptors of human fingertips. The sensor array is constructed as a rigid core surrounded by
conductive fluid contained by an elastomeric skin. Electrodes are mounted on the surface of
the rigid core and are connected to an impedance-measuring device within the core. When the
artificial skin touches an object the fluid path around the electrodes is deformed, producing
impedance changes that map the forces received from the object.

5. VISION

Computer vision is the science and technology of machines that see. As a scientific
discipline, computer vision is concerned with the theory behind artificial systems that extract
information from images. The image data can take many forms, such as video sequences and
views from cameras.

In most practical computer vision applications, the computers are pre-programmed to solve a
particular task, but methods based on learning are now becoming increasingly common.

Computer vision systems rely on image sensors which detect electromagnetic radiation which
is typically in the form of either visible light or infra-red light. The sensors are designed
using solid-state physics. The process by which light propagates and reflects off surfaces is
explained using optics. Sophisticated image sensors even require quantum mechanics to
provide a complete understanding of the image formation process.

MANIPULATION

Robots which must work in the real world require some way to manipulate objects; pick up,
modify, destroy, or otherwise have an effect. Thus the 'hands' of a robot are often referred to
as end effectors, while the arm is referred to as a manipulator. Most robot arms have
replaceable effectors, each allowing them to perform some small range of tasks. Some have a
fixed manipulator which cannot be replaced, while a few have one very general purpose
manipulator, for example a humanoid hand.

Mechanical Grippers: One of the most common effectors is the gripper. In its simplest
manifestation it consists of just two fingers which can open and close to pick up and let go of
a range of small objects. Fingers can for example be made of a chain with a metal wire run
trough it.

Vacuum Grippers: Pick and place robots for electronic components and for large objects like
car windscreens, will often use very simple vacuum grippers. These are very simple astrictive
devices, but can hold very large loads provided the pretension surface is smooth enough to
ensure suction.
18

CHAPTER 2

CLASSIFICATION OF ROBOTS

Industrial robots are found in a variety of locations including the automobile and
manufacturing industries. Robots cut and shape fabricated parts, assemble machinery and
inspect manufactured parts. Some types of jobs robots do: load bricks, die cast, drill, fasten,
forge, make glass, grind, heat treat, load/unload machines, machine parts, handle parts,
measure, monitor radiation, run nuts, sort parts, clean parts, profile objects, perform quality
control, rivet, sand blast, change tools and weld.

Outside the manufacturing world robots perform other important jobs. They can be found in
hazardous duty service, CAD/CAM design and prototyping, maintenance jobs, fighting fires,
medical applications, military warfare and on the farm.

2.1 TYPES OF ROBOTS AS PER APPLICATIONS

Nowadays, robots do a lot of different tasks in many fields. And

this number of jobs entrusted to robots is growing steadily.
That's why one of the best ways how to divide robots into types
is a division by their application.

INDUSTRIAL ROBOTS: Robots today are being utilized in a

wide variety of industrial applications. Any job that involves
repetitiveness, accuracy, endurance, speed, and reliability can be
done much better by robots, which is why many industrial jobs
that used to be done by humans are increasingly being done by
robots.

MOBILE ROBOTS: Also known as Automated Guided

Vehicles, or AGVs, these are used for transporting material over
large sized places like hospitals, container ports, and FIG 2.1 INDUSTRIAL
warehouses, using wires or markers placed in the floor, or lasers, ROBOT
or vision, to sense the environment they operate in. An advanced
form of the AGV is the SGV, or the Self Guided Vehicle, like
PatrolBot Gofer, Tug, and Speci-Minder, which can be taught to
autonomously navigate within a space.
AGRICULTURE ROBOTS: Although the idea of robots
planting seeds, ploughing fields, and gathering the harvest may
seem straight out of a futuristic science fiction book,
nevertheless there are several robots in the experimental stages
of being used for agricultural purposes, such as robots that can
pick apples.
FIG 2.2 AGRICULTURAL
ROBOT

FIG 2.3 TELE ROBOT

19

TELEROBOTS: These robots are used in places that are hazardous to humans, or are
inaccessible or far away. A human operator located at a distance from a telerobot controls its
action, which was accomplished with the arm of the space shuttle. Telerobots are also useful
in nuclear power plants where they, instead of humans, can handle hazardous material or
undertake operations potentially harmful for humans.

SERVICE ROBOTS: The Japanese are in the forefront in these types of robots. Essentially,
this category comprises of any robot that is used outside an industrial facility, although they
can be sub-divided into two main types of robots: one, robots used for professional jobs, and
the second, robots used for personal use. Amongst the former type are the above mentioned
robots used for military use, and then there are robots that are used for underwater jobs, or
robots used for cleaning hazardous waste, and the like.

2.2 TYPES OF ROBOTS BY LOCOMOTION & KINEMATICS

As you can understand, robot's application alone does not provide enough information when
talking about a specific robot. For example an industrial robot - usually, when talking about
industrial robots we think of stationary robots in a work cell that do a specific task.

Cartesian robot /Gantry robot: Used for pick and place work, application of sealant,
assembly operations, handling machine tools and arc welding. It's a robot whose arm has
three prismatic joints, whose axes are coincident with a Cartesian coordinator.

Cylindrical robot: Used for assembly operations, handling at machine tools, spot welding,
and handling at die-casting machines. It's a robot whose axes form a cylindrical coordinate
system.

Spherical/Polar robot: Used for handling at machine tools, spot welding, die-casting,
fettling machines, gas welding and arc welding. It's a robot whose axes form a polar
coordinate system.

SCARA robot: Used for pick and place work, application of sealant, assembly operations
and handling machine tools. It's a robot which has two parallel rotary joints to provide
compliance in a plane.

Articulated robot: Used for assembly operations, die-casting, fettling machines, gas
welding, arc welding and spray painting. It's a robot whose arm has at least three rotary joints.

Parallel robot: One use is a mobile platform handling cockpit flight simulators. It's a robot
whose arms have concurrent prismatic or rotary joints.
20

CHAPTER 3

SELECTION OF TASK
3.1 TASKS

The various tasks which a pick and place robot can perform are as follows:-

3.1.1 Robot pick-and-place

The use of robots for placing products in cartons and transfer

of cartons and products between different stations in the
packaging lines is very common in all industries. High speed
pick-and-place robots for placing small items like candy and
cookies in packages are often combined with a visual
observation system for identifying products. FIG 3.1 PICK & PLACE
ROBOT
3.1.2 Handling of flexible packages

Flexible packaging material is the generic term for soft

packages made of film, foil or paper sheeting. Popular forms
are stand-up pouches, bags, sachets and envelopes. These
packages are often formed, filled and sealed in a vertical or
horizontal form-fill-seal machine. The package is then finally
put into a case by top loading.

3.1.3 Cartooning machines

FIG 3.2 FLEXIBLE
Cartooning machines erect boxes from flat sheets of PACKAGING
corrugated material. The erected boxes are then filled with
products or individual cartons and are then prepared for the
palletizing process. As with most packaging machines,
vacuum cups, vacuum pumps and other pneumatic
components are an essential part of the cartooning.

3.1.4 Rotary cartoners

Rotary cartoner is one of the most popular types of cartooning

machines. These machines use a series of vacuum bars
FIG 3.3 CARTONING
equipped with suction cups that move in a continuous rotary
PROCESS
motion. Rotary cartoners utilize a "pick-and-carry" motion to
move cartons.
FIG 3.4 ROTARY
CARTONING
2
1

F F

D R
22

SELECTION OF TASK

From the various tasks which can be done using the pick and place robots we have
particularly meshed the two process of picking & placing along with pallezting process.

We have decided to pick an Automobile Battery (Dimensions 45x45x65mm. Weight 250

grams) from the conveyor.

Then placing it at the packing center, also picking a packed battery from the packing station
and moving towards the Box-packing center.

Placing of Battery at Box-packing center and again movement to the conveyor to pick an
unpacked battery.

So both the picking & placing along with the packing procedure can be accompanied using
this pick and place robot.

WHY PICK & PLACE ROBOTS

We have selected the pick and place robots for this particular process due to the following
reasons:-

Using of Human labour for the loading and unloading of the Batteries and also for packing
purpose will consume more time.

Even though Number of laborers is required more, the loading and unloading time should
include allowances if laborers are considered.

Moreover the work can be done easily using a single pick and place robot, which is used for
both loading and unloading and pallezting purpose.

3.4 DEFINING WORK STATION

The work station for this operation of pick & place and pallezting is been designed in such a
way that:-

The unpacked battery coming from the belt conveyor is been sensed by a sensor and the
moment of the conveyor is been controlled by the sensor.

As one by one the battery comes, the Robot picks one battery and moves towards the packing
station, keeps the battery on the conveyor there.

Then picks the Packed Battery from there and moves towards the Box-packing center and
places the Battery for Box-packaging.

Further Robot movement continuous towards the return journey takes a Battery from
conveyor and again the above procedure is been carried out.
23

CHAPTER 4

DESIGN PROCEDURE

4.1 FACTORS TO BE CONSIDERED

The various factors to be considered while designing of pick and place robots are been discussed
as follows. The factors are all important while designing procedure of the robot.

4.1.1 CONTROLS

The mechanical structure of a robot must be controlled to perform tasks. The control of a
robot involves three distinct phases - perception, processing, and action. Sensors give
information about the environment or the robot itself (e.g. the position of its joints or its end
effector). This information is then processed to calculate the appropriate signals to the
actuators (motors) which move the mechanical.

The processing phase can range in complexity. At a reactive level, it may translate raw sensor
information directly into actuator commands. Sensor fusion may first be used to estimate
parameters of interest (e.g. the position of the robot's gripper) from noisy sensor data. An
immediate task (such as moving the gripper in a certain direction) is inferred from these
estimates. Techniques from control theory convert the task into commands that drive the
actuators.

At longer time scales or with more sophisticated tasks, the robot may need to build and
reason with a "cognitive" model. Cognitive models try to represent the robot, the world, and
how they interact. Pattern recognition and computer vision can be used to track objects.
Mapping techniques can be used to build maps of the world. Finally, motion planning and
other artificial intelligence techniques may be used to figure out how to act. For example, a
planner may figure out how to achieve a task without hitting obstacles, falling over, etc.

4.1.2 AUTONOMY LEVELS

Control systems may also have varying levels of autonomy.

Direct interaction is used for hap tic or tale-operated devices, and the human has nearly
complete control over the robot's motion.

Operator-assist modes have the operator commanding medium-to-high-level tasks, with the
robot automatically figuring out how to achieve them.

An autonomous robot may go for extended periods of time without human interaction. Higher
levels of autonomy do not necessarily require more complex cognitive capabilities. For
example, robots in assembly plants are completely autonomous, but operate in a fixed pattern.
24

Another classification takes into account the interaction between human control and the
machine motions.

Teleportation: - A human controls each movement; each machine actuator change is

specified by the operator.

Supervisory: - A human specifies general moves or position changes and the machine
decides specific movements of its actuators.

Task-level autonomy: - The operator specifies only the task and the robot manages itself to
complete it.

Full autonomy: - The machine will create and complete all its tasks without human
interaction.

BASIC METHODS OF PROGRAMMING ROBOTS

There are three basic methods for programming Industrial robots but currently over 90% are
programmed using the teach method.

4.1.3A Teach Method

The logic for the program can be generated either using a menu based system or simply using
a text editor but the main characteristic of this method is the means by which the Robot is
taught the positional data. A teach pendant with Controls to drive the robot in a number of
different co-ordinate systems is used to manually drive the robot to the desired locations.
These locations are then stored with names that can be used within the robot program. The
co-ordinate systems available on a standard jointed arm robot are:-

Joint Co-ordinates

The robot joints are driven independently in either direction.

Global Co-ordinates

The tool centre point of the robot can be driven along the X, Y or Z axes of the Robots global
axis system. Rotations of the tool around these axes can also be performed

Tool Co-ordinates

Similar to the global co-ordinate system but the axes of this one are attached to the tool centre
point of the robot and therefore move with it. This system is especially useful when the tool is
near to the work piece.
Work piece Co-ordinates

With many robots it is possible to set up a co-ordinate system at any point within the working
area. These can be especially useful where small adjustments to the program are required as it
is easier to make them along a major axis of the co-ordinate system than along a general line.
The effect of this is similar to moving the position and orientation of the global co-ordinate
system.
25

4.1.3B LEAD THROUGH

This system of programming was initially popular but has now almost disappeared. It is still
however used by many paint spraying robots. The robot is programmed by being physically
moved through the task by an operator. This is exceedingly difficult where large robots are
being used and sometimes a smaller version of the robot is used for this purpose. Any
hesitations or inaccuracies that are introduced into the program cannot be edited out easily
without reprogramming the whole task. The robot controller simply records the joint
positions at a fixed time interval and then plays this back.

4.1.3C OFF-LINE PROGRAMMING

Similar to the way in which CAD systems are being used to generate NC programs for
milling machines it is also possible to program robots from CAD data. The CAD models of
the components are used along with models of the robots being used and the fixturing
required. The program structure is built up in much the same way as for teach programming
but intelligent tools are available which allow the CAD data to be used to generate sequences
of location and process information. At present there are only a few companies using this
Technology as it is still in its infancy but its use is increasing each year. The benefits of this
form of programming are:-

Reduced down time for programming.

Programming tools make programming easier.

Enables concurrent engineering and reduces product lead time.

4.1.4 PROGRAMMING LANGUAGES

4.1.4A KAREL

Karel is an educational programming language, created by Richard E. Pattis in his book

Karel the Robot: A Gentle Introduction to the Art of Programming. This language was first
used in courses at Stanford University. The language is named after Karel Capek,

Principles

A program in Karel is used to control a simple robot that lives in an environment

consisting of a grid of streets and avenues. Karel understands five basic instructions:

1.

2. move (Karel moves by one square in the direction he is facing), 3. turn left (Karel turns 90 left),

4. put beeper (Karel puts a beeper on the square he is standing at), 5. pick beeper (Karel lifts a
beeper off the square he is standing at),

Turnoff (Karel switches himself off, the program ends).

26

4.1.4B VISUAL LANGUAGE

The software system for the Lego Mindstorms NXT robots is worthy of mention. It is based
on and written by Labview. The approach is to start with the program rather than the data.
The program is constructed by dragging icons into the program area and adding or inserting
into the sequence. For each icon you then specify the parameters (data). For example for the
motor drive icon you specify which motors and by how much they move. When the program
is written it is downloaded into the Lego NXT 'brick' (microcontroller) for test.

4.1.4C SCRIPTING LANGUAGE

A scripting language is a high-level programming language that is used to control the

software application, and is interpreted in real-time, or "translated on the fly", instead of
being compiled in advance. A scripting language may be a general-purpose programming
language or it may be limited to specific functions used to augment the running of an
application or system program. Some scripting languages, such as RoboLogix, have data
objects residing in registers, and the program flow represents the list of instructions, or
instruction set, that is used to program the robot.

Programming
languages
are
generally
designed
for
building data
structures and algorithms from scratch, while
scripting
languages
are intended more for

connecting, or gluing, components and instructions together. Consequently, the scripting

language instruction set is usually a streamlined list of program commands that are used to
simplify the programming process and provide rapid application development.

4.1.4. D PARALLEL LANGUAGE

Another interesting approach is worthy of mention. All robotic applications need parallelism
and event-based programming. Parallelism is where the robot does two or more things at the
same time. This requires appropriate hardware and software. Most programming languages
rely on threads or complex abstraction classes to handle parallelism and the complexity that
comes with it, like concurrent access to shared resources. URBI provides a higher level of
abstraction by integrating parallelism and events in the core of the language semantics.

4.1.4. E MATLABS

The name MATLAB stands for MATrix LABoratory. MATLAB was written originally to
provide easy access to matrix software developed by the LINPACK (linear system package)
and EISPACK (Eigen system package) projects.
MATLAB is a high-performance language for technical computing. It integrates
computation, visualization, and programming environment. Furthermore, MATLAB is a
modern programming language environment: it has sophisticated data structures, contains
built-in editing and debugging tools, and supports object-oriented programming. These
factors make MATLAB an excellent tool for teaching and research.
27

FIG 4.1 GRAPHICAL INTERFACE TO MATLAB WORKSPACE.

MATLAB has many advantages compared to conventional computer languages (e.g.

C, FORTRAN) for solving technical problems. MATLAB is an interactive system whose

basic data element is an array that does not require dimensioning.

It has powerful built-in routines that enable a very wide variety of computations. It

also have easy to use graphics commands that make the visualization of results immediately
available. Specific applications are collected in packages referred to as toolbox. There are
toolboxes for signal processing, symbolic computation, control theory, simulation,
optimization, and several other fields of applied science and engineering.

4.1.4F C LANGUAGE

As a programming language, C is rather like Pascal or Fortran. Values are stored in variables.
Programs are structured by defining and calling functions. Program flow is controlled using
loops, if statements and function calls. Input and output can be directed to the terminal or to
files. Related data can be stored together in arrays or structures. Of the three languages, C
allows the most precise control of input and output. C is also rather more terse than Fortran or
Pascal. This can result in short efficient programs, where the programmer has made wise use
of C's range of powerful operators.
28

4.1.4G C++ LANGUAGE

C++ is also the language from which both Java and C# are derived. Simply stated, to be a
professional programmer implies competency in C++. It is the gateway to all of modern
programming. The purpose of this module is to introduce C++, including its history, its
design philosophy, and several of its most important features. By far, the hardest thing about
learning a programming language is the fact that no element exists in isolation. Instead, the
components of the language work together. This interrelatedness makes it difficult to discuss
one aspect of C++ without involving others. To help overcome this problem, this module
provides a brief overview of several C++ features, including the general form of a C++
program, some basic control statements, and operators. It does not go into too many details,
but rather concentrates on the general concepts common to any C++ program.

4.1.4H VISUAL BASIC .NET

Visual Basic 2008 is a development tool that you can use to build software applications that
perform useful work and look great within a variety of settings. Using Visual Basic 2008, you
can create applications for the Windows operating system, the Web, hand-held devices, and a
host of other environments and settings. The most important advantage of Visual Basic is that
it has been designed to increase productivity in your daily development work especially if
you need to use information in databases or create solutions for the Internet but an important
additional benefit t is that once you become comfortable with the development environment
in Microsoft Visual Studio 2008, you can use the same tools to write programs for Microsoft
Visual C++ 2008, Microsoft Visual C# 2008, Microsoft Visual Web Developer 2008, and
other third-party tools and compilers.

4.1.5 SAFETY REQUIREMENTS

The various safety requirements which were considered while designing the robot are decided
as follows:

The Robot should not be programmed such that it should damage the Battery while holding it
in its gripper.

Correct holding position should be set as if it not set then while movement of the Robot it
may drop the Lead Batteries which can arise a Hazardous situation in the industry.
The Robot should be interfaced properly with the sensors been placed near the Belt conveyor
so as to know when the belt conveyor is to be stopped or to be started to move the batteries
ahead.
Load carrying capacity should be maintained as it should be always more than the default
load which is to be shifted.
29

CHAPTER 5

STEPS OF DESIGN

5.1 SELECTION OF PRODUCT

From the number of products available we selected the Battery of automobiles for been used
in our project. We had number of options for the selection of product, as per our requirement
the Battery was matching the conditions. The other products which we considered were as
follows:-

BEARING:- Due to radial cross section of the bearing, it would be little bit difficult for the
Robot Gripper to hold the bearing in it and transport from one place to another holding it. So
we rejected this product.
BAGS OF IRON ORE: - The fines bagging system was pre-decided but due to the weight
limit we switched over the other products.

CELL PHONE PACKING: - As due to the light and sensitive parts of the Cell phones we
also skipped it as there are chances of causing damage to the Cell phones while holding in the
grippers of the Robots.

BOTTLE PACKING: - The radial shape of the bottles was not able to grip inside the
grippers of the robots. Though pick and place robots are used in bottle packing industries but
they are been designed very precisely and are costly so as the grippers are to be such that it
can hold the bottles and move towards the decided target.

DESIGNING OF WORKSPACE

The designing of work space have been done by keeping following points in mind:-

It should utilize Minimum time for doing the job.

No obstructions should be there in between the workspace envelope.
Idle time should be reduced as much as possible.
Efficient and safe transportation of the Batteries should be under gone.

The design of work space includes a Belt conveyor which brings the charged batteries from
the plant and it is been transferred to the Packing centre Using the Robotic arm. There is
moment of 90 degrees; the robot picks a packed Battery from the packed centre after placing
the unpacked Battery. Then the robots proceed towards the Box packing centre where it
unloads the Battery and further moves towards the Belt conveyor to repeat the same
procedure.
30

5.3 DEGREE OF FREEDOM

The number of DOF that a manipulator possesses

is the number of independent position variables
that would have to be specified in order to locate
all parts of the mechanism; it refers to the number
of different ways in which a robot arm can move
in the particular direction.

In the case of typical industrial robots, because a

manipulator is usually an open kinematic chain,
and because each joint position is usually defined
with a single variable, the number of joints equals
the number of degrees of freedom.

We can use the arm to get the idea of degrees of

freedom. Keeping the arm straight, moving it
from shoulder, we can move in three ways. Up-
and-down movement is called pitch. Movement to
the right and left is called yaw. By rotating the
whole arm as screwdriver is called roll. The
shoulder has three degrees of freedom. They are
pitch, yaw and roll.

FIG 5.2 DEGREE OF

FREEDOM.

Moving the arm from the elbow only, holding the shoulder in same position constantly. The
elbow joint has the equivalent of pitch in shoulder joint, thus the elbow has one degree of
freedom. Now moving the wrist straight and motion less, we can bend the wrist and up and
down, side to side and it can also twist a little. The lower arm has the same three degrees of
freedom. Thus the robot has totally seven degrees of freedom. Three degrees of freedom are
sufficient to bring the end of a robot arm to any point within its workspace, or work envelope
in three dimensions.
31

CHAPTER 6

WORKS TO BE DONE

6.1 SELECTION OF PARTS

Various components of appropriate specifications should be selected so as to complete the

fabrication and assembly of the Robot. If the selection is not done properly then the proper
working of the robot cannot be obtained. It includes the parts like selection of actuators,
motors, sensors etc. Thus the selection procedure of various components is also an important
issue for the project work.

6.2 COMPLETION OF MODEL

Future work is to fabricate and manufacture the complete body structure of the robot, then the
assembly of all the manufactured parts are to be done so that the required load is lifted and
been transported to the targeted place.

6.3 PROGRAMMING

Programming of the Pick and place Robot is to be done using a suitable Programming
Language. The Robot is to been interfaced with the computer by the programmed software,
which will guide the robot to do its job for which it is been programmed. There are numbers
of various programming languages available now a days in the market, so the appropriate
programming language is to be selected for the programming purpose and the programming is
to be done.
FIG 6.1 BLOCK DIAGRAM OF INTERFACING OF ROBOT WITH COMPUTER.
32

6.4 INTERFACING WITH THE COMPUTER

In the industrial design field of human-machine interaction, the user interface is where
interaction between humans and machines occurs. The goal of interaction between a human
and a machine at the user interface is effective operation and control of the machine, and
feedback from the machine which aids the operator in making operational decisions.

A user interface is the system by which people (users) interact with a machine. The user
interface includes hardware (physical) and software (logical) components. User interfaces
exist for various systems, and provide a means of:

Input, allowing the users to manipulate a system,

Output, allowing the system to indicate the effects of the users' manipulation

After completion of the model of the pick and place robot and selection of programming
language both should be interfaced. The interfacing of robot and computer using the software
is the most important thing in the project. It should be interfaced using trial and error method,
and then final movement should be set using the softwares. The movement of robot should
be precisely managed causing no harm to the operator, and also the batteries which are to be
moved from one station to another.
33

Advantages

Accuracy and Pick and Place Robots:

Robots are outfitted with wide reaches and slim arms, steady repeatability and precise
tooling - all of which allows them to be extremely accurate. This high precision capability
makes them a good match for pick and place applications.

Flexible Pick and Place:

One of the main advantages of robotics is flexibility. Pick and place robots are easily
programmable. They are able to accommodate multiple changes in product shape and
type. In addition, robots provide a high level of movement flexibility.

Increase Consistency with Pick and Place:

Pick and place robot systems have the ability to improve product quality and cycle time.
Robotic movements are regulated, so the results are always the same. Quality is improved
because of this regularity. Furthermore, this consistency allows the processes to take
place.

Robots are Space-Efficient:

Because they are designed with compact bases, pick and place robots are ideal if you are
looking to conserve floor space. Robots can be programmed to move within strict work
envelope limits - leading to even better use of space.

Robots Maximize Safety:

Pick and place applications can be physically demanding. They are labor-intensive,
repetitive, and monotonous. Depending on the weight and size of a part, moving it from
one place to another can be very demanding work. Pick and place robots are unaffected by
the stresses of the application. They are able to work without taking breaks or making
mistakes.

Save with Pick and Place Robots:

Incorporating pick and place robots can effectively cut your costs. Robotic precision and
reliability allow for less wasted material and more efficient use of time. Plus, the initial
investment in robots is quickly recouped - making pick and place robots an extremely
cost-effective solution.
34

The Disadvantages of Industrial Robots:

Expense:

The initial investment to integrated automated robotics into your business is

significant, especially when business owners are limiting their purchases to new robotic
equipment. The cost of robotic automation should be calculated in light of a business'
greater financial budget. Regular maintenance needs can have a financial toll as well.

ROI:

Incorporating industrial robots does not guarantee results. Without planning, companies
can have difficulty achieving their goals.

Expertise:

Employees will require training program and interact with the new robotic equipment.
This normally takes time and financial output.

Safety:

Robots may protect workers from some hazards, but in the meantime, their very presence
can create other safety problems. These new dangers must be taken into consideration.
35

Robot By Application

Material handling

packaging

Raping

As a welder/ curter

and many more application

References

RK Mittal and IJ Nagarath Robotics and Control BITS Pilani, 2003

Ratheesh Rajan Foundation Studies for an Alternate Approach to Motion Planning of

Dynamic Systems M.S.E., the University of Texas at Austin, 2001

Richard E. Pattis. Karel the Robot: A Gentle Introduction to the Art of Programming.
John Wiley & Sons, 1981. ISBN 0-471-59725-2.

The MathWorks Inc. MATLAB 7.0 (R14SP2). The MathWorks Inc., 2005.

Nam Sun Wang, Department of Chemical & Bimolecular Engineering, University of

Maryland
www.robotis.com

www.asmedl.org/robotics

www.wikipedia.org/wiki/Robotics

http://www.robologix.com

www.seattlerobotics.org/encoder/aug97/basics.html
36

Estimation

Sr no
Name
Nos
Rate
Total

1.
Base plate
1
200
200

2.
Aluminum angels 25mm
5mtr
150
750

3.
Aluminum flat 25mm
3mtr
150
450
4.
Gear motors
4
500
2000

5.
Worm gear
4
100
400

6.
Wire
10mtr
50
500

7.
Switch for motor
4
50
200

8.
Power supply / battery
1
800
800
9.
Hardware material
1
800
800

6100