1 PROJECT REPORT on PICK AND PLACE ROBOT B.S. PATEL POLYTECHNIC, KHERVA Project group: Enrollment No : (1) Patel Charmin Rajendrakumar (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 EMAIL Charmin1997@yahoo.com 8401163001 2 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. TEAM NAME 14 YEAR 2014-2015 SIGNATURE OF STUDENT STUDENT PARTICULARS-2 FIRST NAME Parth 7 LAST NAME Chavda MOBILE NO. 1 EMAIL Parth.chavda.319@facebook.com 9978326421 2 ENROLLMENT NO. 126440319076 COLLEGE NAME B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY. A/12 Dharendranagar society, ADDRESS Naroda,Ahamdabad BRANCH MECHANICAL ENGINEERING SEMESTER 5th SEM. TEAM NAME 14 SIGNATURE OF STUDENT YEAR 2014–2015 8 STUDENT PARTICULARS-3 FIRST NAME Jay LAST NAME Chauhan MOBILE NO. 1. EMAIL JAYRAKESH30@Gmail.com 9586450846 2. 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. TEAM NAME 14 SIGNATURE OF STUDENT YEAR 2014-2015 9 STUDENT PARTICULARS-4 FIRST NAME Ravi LAST NAME Patel MOBILE NO. 1. EMAIL Ravipatel0302@gail.com 8128282656 2. 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. TEAM NAME 14 SIGNATURE OF STUDENT YEAR 2014-2015 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 1.1 KEY COMPONENTS OF ROBOTS. 1.2 ACTUATORS. 1.3 SENSORS. 2.1 INDUSTRIAL ROBOT. 2.2 AGRICULTURAL ROBOT. 2.3 TELE-ROBOT. 3.1 PICK & PLACE ROBOT. 3.2 FLEXIBLE PACKAGING. 3.3 CARTOONIG PROCESS. 3.4 ROTARY CARTOONING. 3.5 PALLETIZING & DEPALLETIZING. 3.6 PICK AND PLACE ROBOT. 3.7 SEALING ROBOTS. 3.8 BAG OPENING ROBOTS. 4.1 GRAPHICAL INTERFACE OF MATLAB WORKSPACE. 5.1 WORK SPACE LAYOUT. 5.2 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 IndoEuropean 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: Date Significance Descriptions of more than 100 machines First and automata, including a fire engine, a century wind organ, a coin-operated machine, and A.D. and a steam-powered engine, in Pneumatica earlier and Automata by Heron of Alexandria 1206 1495 1738 1898 1921 1930s 1948 1956 1961 1963 1973 1975 Created early humanoid automata, programmable automaton band Robot Name Inventor Ctesibius, Philo of Byzantium, Heron of Alexandria, and others Robot band, hand-washing automaton Al-Jazari , automated moving peacocks Mechanical Designs for a humanoid robot Leonardo da Vinci knight Mechanical duck that was able to eat, flap Jacques de Digesting Duck its wings, and excrete Vaucanson Nikola Tesla demonstrates first radioTeleautomation Nikola Tesla controlled vessel. First fictional automatons called "robots" Rossum's Karel Capek appear in the play R.U.R. Universal Robots Westinghouse Humanoid robot exhibited at the 1939 and Electric Elektra 1940 World's Fairs Corporation Simple robots exhibiting biological William Grey Elsie and Elmer behaviors Walter First commercial robot, from the Unimation company founded by George Unimate George Devol Devol and Joseph Engelberger, based on Devol's patents First installed industrial robot. Unimate George Devol First palletizing robot Palletizer Fuji Yusoki Kogyo First industrial robot with six KUKA Robot Famulus electromechanically driven axes Group Programmable universal manipulation PUMA Victor Scheinman arm, a Unimation product 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 Asimov’s robots and they are: 1. A robot should not injure a human being or, through inaction, allow a human to be harmed. 2. A robot must obey orders given by humans except when that conflicts with the First Law. 3. 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. 1.4 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. 2. 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) 3. ACTUATION Actuators are like the "muscles" of a robot, the parts which convert stored energy into movement. By far the most popular actuators are electric motors that spin a wheel or gear, and 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. FIG 1.2 ACTUATORS 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. 6. 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. 1 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. 2 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. 2.1.1 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. 2.1.2 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 warehouses, using wires or markers placed in the floor, or lasers, 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. 2.1.3 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 2.1 INDUSTRIAL ROBOT FIG 2.2 AGRICULTURAL ROBOT FIG 2.3 TELE ROBOT 19 2.1.4 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. 2.1.5 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. 2.2.1 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. 2.2.2 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. 2.2.3 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. 2.2.4 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. 2.2.5 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. 2.2.6 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. 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. FIG 3.1 PICK & PLACE ROBOT FIG 3.2 FLEXIBLE PACKAGING 3.1.3 Cartooning machines Cartooning machines erect boxes from flat sheets of 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. FIG 3.3 CARTONING PROCESS 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 equipped with suction cups that move in a continuous rotary motion. Rotary cartoners utilize a "pick-and-carry" motion to move cartons. FIG 3.4 ROTARY CARTONING 21 3.1.5 PALLETIZING AND DEPALLETIZING Palletizing is the process of placing packages on a pallet alternatively removing them from a pallet (depalletizing). Palletizing machines use vacuum pumps, suction cups and other pneumatic components. These machines typically pick up multiple boxes at a time and place them on a stack (or remove them from a stack). FIG 3.5 PALLETIZING & DEPALLETIZING 3.1.6 AUTOMATED PICK & PLACE ROBOTS The use of specialized machines for high speed pick-andplace of small items with suction cups is very common in the electronics and consumer industries. This application is typically characterized by short cycle times, high acceleration forces and large variations on the parts to be handled. 3.1.7 SEAL MACHINES During the pouch/bag forming phase vacuum is often applied to transport belts that help provide a grip on both sides of the pouch/bag material. The vacuum belt moves the pouch material from a web roll into position to receive the product from the filler. Holes in the belt allow vacuum to hold the pouch while the belt is rotating and the pouch is been removed. FIG 3.6 PICK & PLACE FIG 3.7 SEALING ROBOTS 3.1.8 BAG OPENING Vacuum and suction cups are used to pick and open paper and plastic bags. Suction cups with stiffer bellows and a soft sealing lip are preferred in these quite often high-speed applications. FIG 3.8 BAG OPENING ROBOTS 22 3.2 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. 3.3 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. 1. Direct interaction is used for hap tic or tale-operated devices, and the human has nearly complete control over the robot's motion. 2. Operator-assist modes have the operator commanding medium-to-high-level tasks, with the robot automatically figuring out how to achieve them. 3. 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. 1. Teleportation: - A human controls each movement; each machine actuator change is specified by the operator. 2. Supervisory: - A human specifies general moves or position changes and the machine decides specific movements of its actuators. 3. Task-level autonomy: - The operator specifies only the task and the robot manages itself to complete it. 4. Full autonomy: - The machine will create and complete all its tasks without human interaction. 4.1.3 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. 3. 4. 5. move (Karel moves by one square in the direction he is facing), turn left (Karel turns 90 ° left), put beeper (Karel puts a beeper on the square he is standing at), 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: 1. The Robot should not be programmed such that it should damage the Battery while holding it in its gripper. 2. 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. 3. 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. 4. 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. 5.2 DESIGNING OF WORKSPACE The designing of work space have been done by keeping following points in mind:1. 2. 3. 4. 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 software’s. 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 1. 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. 2. 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. 3. 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. 4. 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. 5. 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. 6. 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: 1. 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. 2. ROI: Incorporating industrial robots does not guarantee results. Without planning, companies can have difficulty achieving their goals. 3. Expertise: Employees will require training program and interact with the new robotic equipment. This normally takes time and financial output. 4. 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 1. 2. 3. 4. 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
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