AN AUTOMATIC TRAFFIC CONES DISPENSER AND COLLECTOR ...

AN AUTOMATIC TRAFFIC CONES DISPENSER AND COLLECTOR

SYSTEM

SITI NOOR AISHAH BINTI MOHAMAD ARIFFIN

A project report submitted in partial

fulfilment of the requirement for the award of the

Degree of Master of Electrical Engineering

Faculty of Electrical and Electronic Engineering

Universiti Tun Hussein Onn Malaysia

JULY 2014

v

ABSTRACT

This project report is about to develop an automatic system for dispense

and collect the traffic cones by using manipulator which is robot arm. The

development of the robot arm which is five degree of freedom is the most

important part in this project in order to make this system become an automatic

system. A microcontroller PIC18F46K22 is used as the brain part of the robot

arm and C programming had been used to programme the microcontroller. For

the five joint parts of the robot arm, three different types of motor had been used

which are cube servo, dc motor and servo motor to represent five degree of

freedom of the robot arm. The sensor that had been used in this project is

potentiometer which is used for measurement to measure the position needs for

this robot arm. The size of traffic cones used is reduced to the smaller size which

is compatible with the size of the robot arm in this project.

.

vi

ABSTRAK

Laporan projek ini adalah berkaitan dengan pembangunan sistem automatik

untuk mengagihkan dan mengumpulkan kon lalu lintas dengan menggunakan

sistem yang lain iaitu lengan robot. Pembangunan lengan robot yang mempunyai

lima darjah kebebasan adalah bahagian yang paling penting dalam projek ini

untuk membuat sistem ini menjadi satu sistem automatik. Sejenis

mikropengawal PIC18F46K22 telah digunakan sebagai bahagian utama untuk

mengawal lengan robot dan pengaturcaraan C telah digunakan sebagai bahasa

bagi program untuk pengawal mikro. Bagi lima bahagian lengan robot yang

dihubungkan, tiga jenis motor telah digunakan iaitu servo kiub, dc motor dan

motor servo untuk mewakili lima darjah kebebasan lengan robot. Pengesan yang

telah digunakan dalam projek ini adalah potentiometer yang digunakan sebagai

pengukur untuk mengukur kedudukan lengan robot ini. Saiz kon lalu lintas telah

dikurangkan kepada saiz yang lebih kecil sesuai dengan saiz lengan robot yang

digunakan dalam projek ini.

.

vii

CONTENTS

CHAPTER TITLE PAGE

TITLE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF SYMBOLS AND ABBREVIATIONS xv

LIST OF APPENDICES xvii

CHAPTER 1 INTRODUCTION

1.1 Introduction

1.2 Project Background

1

2

1.3 Problem statement 3

1.4 Objectives 4

1.5 Scopes of Project 4

1.6 Thesis Organization 4

viii

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 6

2.2 Computer Controlled Robotic Arm 6

2.3 Loading-Unloading Path Optimization of

the AS/RS 7

2.4 Robot Arm Force Control through System

Linearization by Nonlinear Feedback 8

2.5 Fast pick and Place at Robot Singularities 9

2.6 Humanoid Robot System Design Based on

DC Reduction Servo Motor 10

2.7 Enhanced Position Sensing Device for

Mobile Robot Applications Using an

Optical Sensor 10

CHAPTER 3 METHODOLOGY

3.1 Introduction 12

3.2 Project Methodology 12

3.3 Hardware Overview 15

3.4 Developing Hardware and Software 17

3.4.1 Articulate/Revolute type of Robot

arm 17

3.4.2 Microcontroller 22

3.4.3 Actuator 24

3.4.3.1 Cube Servo 24

3.4.3.2 DC Motor 25

3.4.3.3 Servo motor 29

3.4.4 Potentiometer 30

3.4.5 End-effector (Gripper) 32

3.4.6 MPLAB X IDE 33

3.5 Hardware and Software Setup 34

3.6 Mathematical Modeling 36

3.6.1 Robot Arm Control System 36

ix

CHAPTER 4 RESULT AND ANALYSIS

4.1 Introduction 42

4.2 Result and Discussion 42

4.2.1 Basic Robot Arm Movement 42

4.2.2 Position Setting Program of Robot

Arm 48

4.2.3 Automatic Setting of Robot Arm

Movement 53

4.2.4 Position feedback of the Motor

System 61

CHAPTER5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 63

5.2 Recommendation 64

REFERENCES 65

APPENDICES A-B

x

LIST OF TABLES

TABLE NO TITLE PAGE

2.2 Position Error Reduction by Force Feedback 9

3.15 Specification of PIC18F46K22 23

3.34 Parameter of DC Motor 37

4.40 Proper position setting of the robot arm 59

xi

LIST OF FIGURES

FIGURE NO TITLE PAGE

2.1 Control circuit of robotic arm 7

2.3 Robot arm manipulator and straight path 9

2.4 The relation between the angle and the

pulse width

10

2.5 Position sensing device 11

3.1 Block diagram of this overall control

system

13

3.2 The overall flowchart for the methodology 14

3.3 Overall hardware overview for traffic

cones dispenser and collector system

15

3.4 The distance between traffic cones next to

each other

15

3.5 The control system for traffic cones

dispenser and collector system

16

3.6 Mini traffic cone 16

3.7 The spherical-shaped work envelope for

Articulate Robot

17

3.8 5 DOF for Articulate Robot Arm 18

3.9 Dimension of 5 DOF Robot Arm 18

3.10 Schematic diagram of the robot arm 19

3.11 PCB design component layout of the robot

arm

20

3.12 PCB layout of the robot arm for etching

process

20

xii

3.13 Robot arm development 21

3.14 40 Pins PIC18F46K22 microcontroller 22

3.16 Cube Servo 24

3.17 DC Motor 26

3.18 Closed loop control of DC Motor 26

3.19 MD10C type of motor driver 27

3.20 Duration of Pulse Width Signal 28

3.21 RC Servo Motor 29

3.22 SC08A type of motor driver 30

3.23 Potentiometer 31

3.24 Potentiometer construction 32

3.25 Gripper of the robot arm 32

3.26 MPLAB X IDE software 33

3.27 Hardware and software setup 34

3.28 Joysticks and PCD8544 LCD display as a

supporter hardware

35

3.29 Motor Driver MD10C for DC motor 35

3.30 Motor Driver SC08A for servo motor 35

3.31 Overall control system of the robot arm 36

3.32 DC motor circuit theory model 37

3.33 DC motor transfer function 37

3.35 System block diagram representing one dc

motor coupled with the mechanical load

39

3.36 Block diagram of the system 39

4.1 Arm 1 for base rotation (cube servo) 43

4.2 Minimum position for Arm 1 ‘0000’ 43

4.3 Maximum position for Arm 1 ‘0543’ 44

4.4 Arm 2 for up and down rotation (DC

motor)

44



4.7 PWM of the DC Motor recorded 45

xiii

4.8 Arm 3 for up and down rotation (cube

servo)

45

4.9 Minimum and maximum position of Arm

3

46

4.10 Arm 4 for gripper rotation (Servo motor) 46



4.13 Arm 5 for end-effector 47



4.16 Position setting stored in memory 48

4.17 Position setting program for Arm 1 49

4.18 Memory stored of position setting

program for Arm 1

49

4.19 Position setting program for Arm 2 DC

motor

49


program for Arm 2

50

4.21 Position setting program for Arm 3 50


program for Arm 3

50

4.23 Position setting program of servo motor

for Arm 4

51


program gripper rotation for Arm 4

51

4.25 Position setting program of gripper for

Arm 5

51

4.26

Memory stored of position setting

program for gripper of Arm 5

52

4.27 Memory stored for delay setting program 52

4.28 Menu setup 53

4.29 Delay is set to 50 ms 53

xiv

4.30 First step setting 54

4.31 The gripper had grip the traffic cone in

second step

54

4.32 Arm 2 lift up one of the traffic cones and

PWM of the motor had been showed in

this third step setting

55

4.33 Robot Arm had move to to place the

traffic cones

55

4.34 Fifth step setting 56

4.35 Robot arm move back to the initial

position to dispense another traffic cone

56

4.36 Robot arm grip another traffic cone 57

4.37 Robot arm rotate to to place another

traffic cone

57

4.38 Robot arm dispense another traffic cone

with 23 cm distance from another traffic

cone

58

4.39 Robot arm collect back the traffic cone

back into the storage

58

4.41 Position feedback for ARM 1 61



xv

LIST OF SYMBOLS AND ABBREVIATIONS

SYMBOL DESCRIPTION

cm - Centimetre

V - Voltage

rpm - Revolutions per Minute

ms - Miliseconds

emf - Electromotive Force

AS/RS - Automatic Storage/Retrieval System

EPROM - Erasable Programmable Read Only Memory

EEPROM - Electrically Erasable Programmable Read Only Memory

PIC - Programmable Integrated Circuit

IC - Integrated Circuit

DC - Direct Current

PWM - Pulse Width Modulation

DOF - Degree of Freedom

LCD - Liquid Crystal Display

PCB - Printed Circuit Board

RAM - Random Access Memory

CW - Clockwise

CCW - Counter Clockwise

xvi

RC - Radio Control

IDE - Integrated Development Environment

D-H - Danevit-Hartenberg

A - Ampere

Hz - Hertz

xvii

LIST OF APPENDICES

APPENDICES TITLE

APPENDIX A Gantt Chart for Master’s Project

APPENDIX B1 Robot Arm Program

APPENDIX B2 Position Simulation of the Robot Arm

1

CHAPTER 1

INTRODUCTION

In this first chapter it will focus on brief introduction of the project to be carried

out. The important overview or description in introduction including the project

background, problem statement, objective of the project, project scopes and thesis

organization are well emphasized in this chapter.

1.1 Introduction

In modern technology society the issues of safety is very important in a

daily life. The safety here refers on the prevention someone from having serious

injury when the person is doing the construction process on the road. The process

of placing traffic cones to close a lane on a highway involves a worker placing or

dispenses the cones from a work platform and collects the cones back altogether

into the storage. Usually this scenario occurs on the highway where the truck moves

forward in the closed lane along the highway while the worker on the work

platform will dispense and collect the cones. But, with this situation the workers

would be exposed in danger situation while doing dispensing and collecting the

traffic cones along the highway.

Loading or unloading the load like traffic cones can be done from the

storage by using suitable manipulator that will be working automatically in order to

dispense and collect the traffic cones outside or inside the storage. By using this

2

manipulator, it can reduce human risk encountered from danger situation while

dispenses and collects the traffic cones in the busiest highway. The manipulator

plays a very predominant role in manufacturing technology due to their advantages

such as simplicity, large load capacity, high stiffness, quick dynamic response and

high accuracy. The conventional machining equipment due to machine complex

shape of objects is not sufficient [1].

With the development of technologies, the manipulators such as robots are

used in a wide variety of material transfer applications. A robot is a re-

programmable multifunctional manipulator designed to move material, parts, tools

or specialized devices through variable programmed motions for performance of a

variety tasks. These tasks either replace or enhance human work, such as in

manufacturing, construction or manipulation of heavy or hazardous materials. The

robots also have the ability to work for an extended time.

Pick and place robot is one of the categories of the robot arm. The robot arm

system is widely used in variety of material transfer applications such as in

production, processing, product transportation, domestic services and other fields. It

is because it has some advantages such as high efficiency, precise repeated

movements and has good carrying capacity [2].

1.2 Project Background

This project is about modelling a robot arm manipulator and control system

of the robotic arm using microcontroller as the controller based system. The cube

servo, dc motor and servo motor are used to represent the link or joints of the robot.

The project is focusing on robot arm system that can operate for dispense and

collect the traffic cones. For this case, the end effectors or gripper is very important

to grab the traffic cones. It is because the different shape of the material is being

used, the end effectors of the robot had to be changed as well to suit the material

handling. The function of the gripper is to grasp object, usually the work part and

hold it during the work cycle [3]. The storage is used to store the stacking traffic

3

cones before loading and unloading traffic cones process on the road take place by

pick and place robot arm system.

1.3 Problem Statement

In real world, the distance for construction progress at the highway usually

takes about half of kilometer or more. It is a very long distance to put the traffic

cones along the highway so it needs a lot of traffic cones line up along during the

constructions process. Usually the traffic cones have almost the same difference

distance next to each other which is about 5 meters long distance next to each

cones. A lot of manpower involves in placing the traffic cones along the highway

for example the one who drive the truck, one person who dispense and collect the

traffic cones on the road and one person who is on the truck to handle storage and

retrieval of traffic cones in the truck. This project will reduce the manpower

involves and their tiredness in placing the traffic cones because it is an automatic

system. The robot arm system will be applied in this project in order to have an

automatic traffic cones dispenser and collector system

This robot arm is being designed to ease the process of dispensing and

collecting of traffic cones to close a lane on a highway for the construction progress

on the road or any other cases that might use traffic cones. Usually this transfer

process of the traffic cones is being carried out using man power and it is being

repeated for a period of time. So by using this automatic system it can increase the

efficiency of work and can save the time of working.

The workers might be exposed in danger situation while dispensing and

collecting the traffic cones along the highway and it can cause injuries to the

workers. It is because the working environment is very dangerous to the workers on

the busiest highway where the workers placing the traffic cones is far from each

other along the highway and it has high risk and may lead to an accident occur to

the workers. By using this particular robot, the workers will no longer have to bend

and lift up this heavy traffic cones that might lead to an accident because of

negligence or not responsible drivers on the highway. It is very important to work

4

in safety environment by using automatic traffic cones collector and dispenser

system because it can reduce the risk level of dangerous to the workers.

1.4 Objectives

The main objectives of the project are:

i. To design the robotic arm control system that can perform traffic cones

dispenser and collector system.

ii. To determine the proper position of the robot for dispensing and collecting

the traffic cones.

iii. To develop computer control for microcontroller for this control system.

1.5 Scopes of Project

The scopes of this project are:

i. Understanding the concept of robotic function and movement as

implementation from related subjects such as robotics and control systems.

ii. Design the robot arm that can perform dispensing and collecting the traffic

cones.

iii. Determine the proper position for robot performance in order to dispense

and collect the traffic cones.

iv. Developing a controller algorithm for this control system by using

microcontroller.

1.6 Thesis Organization

This project report has been structured and was carefully planned to give a better

explanation for the overall project. This thesis is divided into five chapters and

organized as follows:

5

Chapter 1: Explain briefly about the introduction, objectives, and the

organizational of the thesis.

Chapter 2: Contains literature review from the past works that related for this

project. It consists of computer controlled robotic arm, loading-

unloading path optimization of the AS/RS, robot arm force control

through system linearization by nonlinear feedback, fast pick and

place at robot singularities, humanoid robot system design based on

dc reduction servo motor and lastly the journal about enhanced

position sensing device for mobile robot applications using an

optical sensor.

Chapter 3: Explain on project methodology that shows the flow of the methods

used. The design of robotic arm, microcontroller, actuator, sensor

and the object that used in this project which is traffic cones are also

being discussed.

Chapter 4: Present the results, analysis and discussion obtained from the

project. All the pictures, data equations obtained and the graphs

obtained from oscilloscope are also included.

Chapter 5: Conclusion is made based on the discussion in earlier chapter and

suggestion about future development must be regarding to this study

by developing a new approach.

6

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

In this chapter it will discuss published information in a particular subject area

within a certain time period. The research focuses on mostly about robot arm

including microcontroller, actuator and sensor to move the robot and desired

positions required.

2.2 Computer Controlled Robotic Arm

From the research of a journal that had been done by Ahuja N. and

Sreedaran R. (2003), from Indian Institute of Technology described about how an

automated mechanical arm is develop by using C language programming to control

the operation of robot arm [4]. The software for this robotic arm is written in a high

level language converted into a Hex code and burnt onto the EPROM of the PIC.

The data stored the reference values and appropriate signals and sent it to the motor

driver IC’s. This data then actuate the motors to bring the gripper to the specified

coordinates and it will grip or release the object.

In order to control the robot arm to take the feedback signals and to actuate

the motors the IC had been programmed. This IC communicates with the computer

via the serial port at a specified baud rate. There is an advantage in using serial port

compared to parallel port which is it makes the hardware machine become

independent.

The figure shows how the electronic control and the feedback of the circuit

controlling this Robotic Arm. The programmable

while the output of the

2.3 Loading-Unloading Path Optimization of the AS/RS

The journal is about the optimization of loading

AS/RS and improves

Retrieval Systems (AS/RS) is very important in modern logistics

economize on land, reduce the labor intensity, improve

storage system and many more. It will shorten the moving distance for loading and

unloading the goods,

operating time or energy consumption

used in this paper [5].

The modeling of the loading

products warehouse with n items is executed according to the loading

order and the time, T which consumed by the stacker can be expressed as:


Figure 2.1: Control circuit of robotic arm


Robotic Arm. The programmable PIC is connected to the computer

he output of the PIC is connected to the DC motor driver IC.

Unloading Path Optimization of the AS/RS

journal is about the optimization of loading-unloading

AS/RS and improves the loading-unloading efficiency. Automated Storage and

Retrieval Systems (AS/RS) is very important in modern logistics nowadays

economize on land, reduce the labor intensity, improves the automation level of the

age system and many more. It will shorten the moving distance for loading and

unloading the goods, improve the ware location utilization and reduc

energy consumption. The method of genetic algorithm

].

The modeling of the loading-unloading path optimization of the finished

products warehouse with n items is executed according to the loading


7



is connected to the computer

unloading path of the

Automated Storage and

nowadays. It may

the automation level of the

age system and many more. It will shorten the moving distance for loading and

reduce the stacker

genetic algorithm is being

unloading path optimization of the finished

products warehouse with n items is executed according to the loading-unloading


8

� =�� ,�

�

� �+��,�� , n�is�even�number

��

� �

��,��

� �+��,�� + ��,��, n�is�odd�number

�"#�

� �

$

Where Tk,0 represents the time needed by the stacker to make a round trip

between the current shelves number and the origin while Tin k, out k represents the

time needed by the stacker to move from the current loading location to the next

unloading location. On the other hand Tn,0 represents the time needed by the stacker

to return to the origin after delivering the last shelves.

2.4 Robot Arm Force Control Through System Linearization by Nonlinear

Feedback

From the research of a journal that had been done by Tarn T.J., Bejczy A.K.

and Yun X. from the department of Systems Science and Mathematics, Washington

University describes that a new dynamic force control method of robot arms is

developed based on differential geometric feedback linearization technique of

nonlinear time-varying systems [6].

At the robot wrist the method uses active force-moment measurements. The

computer simulations show that the proposed controller improves the position error.

The controller design has the following features which is the main features is the

dynamics of the robot arm is fully considered in the process of deriving the

feedback law, the control algorithm is independent of tasks to be performed. It

shows that the controller is an intelligent. The table shows force feedback can

reduce the position error occur by the robot.

Table 2.2

2.5 Fast pick and Place at Robot Singularities

This journal had been done by

National University that investigates whether singular configurations may be good

sites for high-speed pick or place operations. From

accomplish the pick and place task because it allows the robot to keep some o

kinetic energy and it can lead to faster cycle times [

Singularities can be defined as

of two or more robot axes resulting in unpredictable robot motion and velocities

The singularities usually

has more axes than nec

certain configurations that require extremely high joint rates to move at some

nominal speed.

Figure

Table 2.2: Position Error Reduction by Force Feedback

Fast pick and Place at Robot Singularities

s journal had been done by Kieffer J.C and Cahill A.J. from Australian


speed pick or place operations. From these singularities

accomplish the pick and place task because it allows the robot to keep some o

kinetic energy and it can lead to faster cycle times [7].

Singularities can be defined as a condition caused by the collinear alignment

of two or more robot axes resulting in unpredictable robot motion and velocities

The singularities usually occurs when robot axes are redundant which means that it

more axes than necessary to cause the same motion or when the robot is in


Figure 2.3: Robot arm manipulator and straight path.

9

Position Error Reduction by Force Feedback

from Australian


these singularities, it can

accomplish the pick and place task because it allows the robot to keep some of its

a condition caused by the collinear alignment

of two or more robot axes resulting in unpredictable robot motion and velocities.

when robot axes are redundant which means that it

or when the robot is in


2.6 Humanoid Robot System Design Based on DC Reduction Servo Motor

In this journal it describes about how DC reduction servo motor is used to

humanoid robot system that consist of mechanical part and control part syst

Servo motor is used to drive each joint [

The DC reduction servo motor has 3

one power supply line and one ground line

servo motor and another one line is the control signal

signal from the controller.

shown in graph below:

Figure 2.4: The relation between the angle and the pulse width

2.7 Enhanced Position Sensing Device for

an Optical Sensor

This journal describes about smooth position detection capabilities is

needed. Built device was attached to a mobile robot so that the robot can be driven

from the position information of the rotary encode

sensing device. The results to validate the applicability of the proposed concept

from both rotary encoder and optical device are presented in this paper [

In these paper rotary encoders is used to measure rotary angles, l

movement, speed, velocity, distance and position. Rotary encoders are sensors that

generate digital feedback signals in response to movement and convert that

Humanoid Robot System Design Based on DC Reduction Servo Motor


humanoid robot system that consist of mechanical part and control part syst

Servo motor is used to drive each joint [8].

The DC reduction servo motor has 3 input lines. The two lines which are

r supply line and one ground line provide power for the DC reduction

motor and another one line is the control signal line which receives the PWM

signal from the controller. The relation between the angle and the pulse width is

shown in graph below:

: The relation between the angle and the pulse width

Enhanced Position Sensing Device for Mobile Robot Applications Using

an Optical Sensor



from the position information of the rotary encoder and the new optical position


from both rotary encoder and optical device are presented in this paper [

In these paper rotary encoders is used to measure rotary angles, l



10

Humanoid Robot System Design Based on DC Reduction Servo Motor


humanoid robot system that consist of mechanical part and control part system.

input lines. The two lines which are

provide power for the DC reduction

which receives the PWM

The relation between the angle and the pulse width is

: The relation between the angle and the pulse width

Mobile Robot Applications Using



r and the new optical position


from both rotary encoder and optical device are presented in this paper [9].

In these paper rotary encoders is used to measure rotary angles, linear



movement of a mechanical position of a tool or signal into an electrical signal that

is measurable [10].

Figure 2.4 above shows the basic block diagram of the position sensing

device. External device can be a computer, microcontroller or

Therefore a new interface was developed

between the main microcontroller and the optical sensing device.


Figure 2.5: Position sensing device

above shows the basic block diagram of the position sensing

device. External device can be a computer, microcontroller or any other controller.

Therefore a new interface was developed in order to keep the communication

microcontroller and the optical sensing device.

11


above shows the basic block diagram of the position sensing

any other controller.

order to keep the communication

12

CHAPTER 3

METHODOLOGY

3.1 Introduction

In order for a project to be successful, a good methodology is very

important to show the flow of the methods used. The design process is also must be

provided in this chapter. The design of robotic arm, microcontroller, actuator,

sensor and cones object that used in this project are also being discussed.

3.2 Project Methodology

All the information regarding the problem to dispense and collect the traffic

cones issues is being gathering in order to develop an automatic controller system.

The researches have been design and implement after gathering information from

the internet and journals. The block diagram, flowchart, schematic and layout

diagram to develop this automatic traffic cones dispenser and collector system are

showed in the figure.

13

Figure 3.1: Block diagram of this overall control system

The Figure 3.1 shows the block diagram for the overall control system. A

microcontroller circuit is being used as the basic circuit to control the motor which

is actuator of the robot arm. The computer had been used to program the

microcontroller in order to move the robot arm to the desired object.

The programmed from the computer had been embedded to the

microcontroller by using pickit3 burner. The microcontroller will control the robot

arm doing dispensing of the traffic cones from the storage and collect the traffic

cones back to the storage system.

The PIC18F46K22 microcontroller had been used in this project. For the

actuator, three different types of motor had been used which are cube servo, dc

motor and servo motor had been used to represent each joint of the robot arm

(plant). Potentiometer is used for measurement in this project to measure the

position needs for this robot arm.

The flowchart in Figure 3.2 shows the overall step of methodology in

completing this project. It is start with collecting all the data and information in

background of studies about robot arm hardware and C programming language

software is used as the controller of the robot. From gathering the information, how

the robot arm can be able to perform and grip the traffic cones has been explored.

+

Controller Actuator Plant

Measurement -

Desired

trajectory

Actual

trajectory

14

Figure 3.2: The overall flowchart for the methodology

Start

Hardware setup

Designing of robot arm

Integrate hardware and

software

Background Study

Development of the C programming

Able to grip

traffic cones

Conclusion

End

Result & Analysis

No

Yes

15

3.3 Hardware Overview

The hardware overview in the figure below shows the information about

this project. The robot is placed on the road/highway model in order to dispense

traffic cones outside from storage and collect back to the storage.

The traffic cones had been stack up in the storage and the distance between

traffic cones and the manipulator which is robot arm is 23 centimeters (cm). On the

other hand, the distance between the traffic cones next to each other also are

adjustable to 23 cm difference.

Figure 3.3: Overall hardware overview for traffic cones dispenser and collector

system

Figure 3.4: The distance between traffic cones next to each other

In the figure 3.5, it can

while the programmed in the computer

system.

Figure 3.5: The control system for traffic cones dispenser and collector system

There are various type dimensions of traffic cones that use on the highway.

In this project the traffic cones that had been used is reduce to smaller size

compared to the actual size of traffic cones. The mini traffic cones that had been

used in this project are made by

the task for dispenses

, it can be seen that the microcontroller will control the robot arm

programmed in the computer will be the control unit for the whole

: The control system for traffic cones dispenser and collector system




ct are made by manila card material in order for robot arm to

the task for dispenses and collects the traffic cones.

Figure 3.6: Mini traffic cone

16

that the microcontroller will control the robot arm

be the control unit for the whole

: The control system for traffic cones dispenser and collector system




in order for robot arm to do

3.4 Developing Hardware and Software

3.4.1 Articulate/Revolute type of

In this project

has five degree of freedom (DOF)

has five rotary joints

manipulator and the elbow

movement in a compact space. The articulated robot arm has the spherical

work envelope. The advantage for using this type of articulate robot arm is it c

reach above or below obstacles

also has largest work area for least work space

point.

Figure 3.7: The spherical

The robot arm

traffic cones out from the

the storage. The figure 3.8 shows the total five DOF including end

robot arm in this project.

Hardware and Software

/Revolute type of Robot arm

n this project the robot arm type used is articulate or revolute

degree of freedom (DOF). This type of robot resembles human arm

rotary joints. Two common revolute designs are the elbow ty

he elbow type configuration provides relatively large freedom

movement in a compact space. The articulated robot arm has the spherical

work envelope. The advantage for using this type of articulate robot arm is it c

reach above or below obstacles because of spherical-shaped work envelope. It is

argest work area for least work space and has two or four ways to reach a

: The spherical-shaped work envelope for Articulate Robot.

The robot arm had been placed on the road/highway in order t

traffic cones out from the storage or collect the traffic cones on the road back in

The figure 3.8 shows the total five DOF including end-

robot arm in this project.

17

or revolute robot arm that

type of robot resembles human arm that

are the elbow type

type configuration provides relatively large freedom of

movement in a compact space. The articulated robot arm has the spherical-shaped

work envelope. The advantage for using this type of articulate robot arm is it can

shaped work envelope. It is

wo or four ways to reach a

shaped work envelope for Articulate Robot.

in order to dispense the

storage or collect the traffic cones on the road back into

-effector of the

18

Figure 3.8: 5 DOF for Articulate Robot Arm.

The traffic cones are stored on the storage box, so the robot arm will

pickups the traffic cones one by one and positions them on a road/highway model at

pre-determined positions. The robot arm could lay a long line traffic cones along

the road and because of six axes robot arm, the traffic cones are able to pick up and

placed accurately. When collect the traffic cones, the robotic arm grips the traffic

cones on the road, picks them up and stacks them on the storage box.

The position setting of the robot is very important in this project in order for

robot arm can grab the traffic cones. The potentiometer is used to detect the

position needs for the robot to reach the object and it acts as a sensor in this project.

The figure 3.9 below shows the dimension of the robot arm for this project.

Figure 3.9: Dimension of 5 DOF Robot Arm.

The figure 3.

the robot arm. The power circuit

attached to voltage regulator

ground of the LM1117

cube servo that connect directly to the microcontroller pins

is connected to motor driver and then motor driver

servo connections, each

driver and connected to the

pin from each motor, LCD

seen on the schematic.

Figure 3.

3.10 shows the schematic diagram for these overall

The power circuit that used in this project is 12V power

attached to voltage regulator LM1117 with a 10uF capacitor hooked to output

1117 to keep a steady 5V DC. There are 3 wires coming out from

cube servo that connect directly to the microcontroller pins. The 2 wires

connected to motor driver and then motor driver is connected to the PIC pins. For

ach servo has 3 wires also coming out and it is connected to the

driver and connected to the power source, ground and microcontroller

motor, LCD screen and joysticks is tied to a unique pin on the

seen on the schematic.

Figure 3.10: Schematic diagram of the robot arm

19

overall five axes of

12V power supply that

hooked to output and

There are 3 wires coming out from

. The 2 wires DC motor

to the PIC pins. For

is connected to the

microcontroller. Every signal

is tied to a unique pin on the PIC as

From the schematic diagram, the printed circuit board (PCB) had been

designed by using Altium software for connection of all the components to

integrate the hardware part of this robot arm. Figure 3.11 and 3.12 below show the

PCB design and layout of the robot arm:

Figure 3.11

Figure 3.12




layout of the robot arm:

Figure 3.11: PCB design component layout of the robot arm

Figure 3.12: PCB layout of the robot arm for etching process

20




of the robot arm

for etching process

21

Figure 3.13: Robot arm development

START

Mechanical Module

Design concept

Robotic arm structure

Part Assemble

Mechanism Test

Electronic Module

Circuit and PCB design

Circuit Assemble

Circuit Test

Programming Module

Write a program based on tasks

Program Test

Testing and troubleshooting

END

No

Yes

No

No

Yes

Yes

Figure 3.13 shows the flowchart for robot arm development for this project.

It can be categorized into three parts which are mechanical module, electronic

module and programming module.

arm mechanism and electronic cir

program development

to locate the arm at the desired position.

3.4.2 Microcontroller

Microcontrollers

the designer to interface

anything else required

For this project,

project. This microcontroller

write-erase until thousand times.

kilobyte program memory to save the position desired for the movement of the

robot in order to do dispensing and collecting the traffic cones.

will be program by C language in the computer

Figure 3.

shows the flowchart for robot arm development for this project.


module and programming module. The project starts by design and constructing of

arm mechanism and electronic circuit for the mechanism. Then it continues with

program development by C programming. Application of the potentiometer

to locate the arm at the desired position.

3.4.2 Microcontroller

Microcontrollers can be defined as robot brains. Microcontrollers

the designer to interface sensors, specialized control electronics together

g else required for the project and contain the overall logic of the robot.

For this project, PIC18F46K22 microcontroller had been used for this

This microcontroller use FLASH memory technology so that

erase until thousand times. This microcontroller has 40 pin


do dispensing and collecting the traffic cones. This microcontroller

by C language in the computer as a controller of the system

Figure 3.14: 40 Pins PIC18F46K22 microcontroller

22

shows the flowchart for robot arm development for this project.


The project starts by design and constructing of

cuit for the mechanism. Then it continues with

of the potentiometer is used

Microcontrollers can allow

together along with

and contain the overall logic of the robot.

had been used for this

use FLASH memory technology so that it can be

40 pin and has 64


microcontroller

the system.

23

The table 3.15 shows the details specifications for microcontroller

PIC18F46K22. It has the best memory to store the program and save the best

position in this PIC for robot arm movement in this project.

Table 3.15: Specification of PIC18F46K22

PARAMETER NAME VALUE

Program Memory Type Flash

Program Memory (KB) 64

CPU speed (MIPS) 16

RAM Bytes 3,896

Data EEPROM (bytes) 1024

Digital Communication Peripherals 2-UART, 2-A/E/USART, 2-SPI, 2-

I2C2-MSSP(SPI/I2C)

Capture/Compare/PWM Peripherals 2 CCP. 2 ECCP

Timers 3 X 8-bit, 4 X 16-bit

ADC 28 ch, 10-bit

Comparators 2

Temperature Range (C) -40 to 125

Operating Voltage Range (V) 1.8 to 5.5

Pin Count 40

XLP Yes

Cap Touch Channels 28

3.4.3 Actuator

In this project there

types of motor chosen are very important to build the joints of robot arm. All

aspects and criteria must be considered in order to make sure that robot arm can

move to the desired position required.

3.4.3.1 Cube Servo

There are two cube servos that

in this project and the type of cube servos that are used is G15 Cube Servo.

Cube Servo is a modular type smart serial servo which incorporates gear reducer,

has high torque DC motor and can control circuit

It has its own high strength and can sustain high external force.

rotate 360° with resolution up to 0.33°.

This cube servo is the best type of motor

project, cube servo is used because it is suitable for position control of the robot

arm. Other than that, c

daisy chain connection to

In this project there are three different types of motor had been use.



move to the desired position required.

There are two cube servos that are used for robot arm at first and third DOF

in this project and the type of cube servos that are used is G15 Cube Servo.


has high torque DC motor and can control circuitry with networking functionality.

It has its own high strength and can sustain high external force. It is also able to

rotate 360° with resolution up to 0.33°.

This cube servo is the best type of motor to use for robotics model.

servo is used because it is suitable for position control of the robot

arm. Other than that, cube servo uses serial half duplex communication and a

daisy chain connection to multiple servos to create a servo network on a single line.

Figure 3.16: Cube Servo

24

are three different types of motor had been use. The



at first and third DOF

in this project and the type of cube servos that are used is G15 Cube Servo. G15


ry with networking functionality.

It is also able to

use for robotics model. For this

servo is used because it is suitable for position control of the robot

ervo uses serial half duplex communication and allows

multiple servos to create a servo network on a single line.

REFERENCES

[1] Huang X. & He G. (2009). “Closed-form Direct Position Analysis of the

General Stewart-Gough Manipulator Robot”, Proceedings IEEE

International Conference on Mechatronics and Automation.

[2] Huang G.S., Tung C.K., Lin H.C. & Hsiao S.H. (2011). “Inverse

Kinematics Analysis Trajectory Planningfor a Robot Arm”, Proceedings of

8th Asian Control Conference.

[3] Ali H., Seng T.C., Hoi L.H & Elshaikh M. (2012). “Development of Vision-

Based Sensor of Smart Gripper for Industrial Applications”, 8th

International Colloqium on Signal Processing and its Applications.

[4] Ahuja N. & Sreedaran R. (2003). “Computer Controlled Robotic Arm”,

Proceedings of the 16th IEEE Symposium on Computer Based Medical

System.

[5] Guiliang Z. & Fei T. (2010). “Loading-Unloading Path Optimization of the

AS/RS”, Huaiyin Institute of Technology and University of Technology,

China, 978-1-4244-8778-3/10 IEEE.

[6] Tarn T.J., Bejczy A.K. & Yun X. “Robot arm Force Control Through

System Linearization by Nonlinear Feedback”, Department of Systems

Science and Mathematics, Washington University St. Louis.

[7] Kieffer J.C. & Cahill A.J. “Fast Pick and Place at Robot Singularities”,

Australian National University Canberra, ACT 0200, Australia.

[8] Guo H., Mao Z. & Zhang J. “Humanoid Robot System Design Based on DC

Reduction Servo Motor”, Beijing Union University, China.

[9] Harsha A.M., Abeykoon S., Udawatta L., Dunuweera M.S., Gunasekara

R.T., Fonseka M. & Gunasekara S.P. (2011). “Enhanced Position Sensing

Device for Mobile Robot Applications Using an Optical Sensor”,

Proceedings of IEEE International Conference on Mechatronics.

[10] Mahn C. (2010). “Optimize the Life and Performance of Rotary Encoders

through Correct Mounting”, Pulp and Paper Industry Technical Conference

(PPIC).

[11] Cui Y., Shi P. & Hua J. (2010). “Kinematics analysis and simulation of a 6-

DOF humanoid robot manipulation”, IEEE Informatics in Control,

Automation and Robotics (CAR), 2nd International Asia Conference on,

vol. 2, pp. 246-249.

[12] Takaya K. (2003). “Digital Control Review of Analog Controller Design”,

University of Saskatchewan, Electrical Engineering, EE480.3.

[13] Gou Z., Sun Y. & Yu H. (2010). “Inverse Kinematics Equation of 6-DOF

Robot Based on Geometry projection and simulation”, School of

Mechatronic Engineering, Changchun University of Technology, 2010

International Conference on Computer, Mechatronics, Control and

Electronic Engineering (CMCE).

[14] Zhou J. & Yu Y. (2010). “Simulation and Control of Reconfigurable

Modular Robot Arm Based on Close-Loop Real-Time Feedback”, Computer

Engineering and Technology (ICCET), 2010 2nd

International Conference

on, Vol. 3, pp. V3-35-V3-40.

[15] Aung C.H., Lwin K.T & Myint Y.M (2008). “Modeling Motion Control

System for Motorized Robot Arm using MATLAB”, World Academy of

Science Engineering and Technology.

[16] Xu D.,Calderon C.A.A., Gan J.Q. & Hu H. (2005). “An Analysis of the

Inverse Kinematics for a 5 DOF Manipulator”, International Journal of

Automation and Computing.

[17] Agrawal R., Kabiraj K. & Sigh R. (2012). “Modelling a Controller for an

Articulated Robotic Arm”, Intelligent Control and Automation.

[18] Ovy E.G., Seeraji S., Ferdous S.M. & Rokonuzzaman M. (2011). “A Novel

Design of an ATmega32L Microcontroller Based Controller Circuit for the

Motion Control of a Robot Arm Actuated by DC Motor”, Multidisciplinary

Journals in Science and Technology, Journal of Selected Areas in Robotics

and Control (JSRC).

[19] Huang X. & He G. (2009). “Closed-form Direct Position Analysis of the

Genereal Stewart-Gough Manipulator Robot”, Proceedings of the IEEE

International Conference on Mechatronics and Automation.

[20] Su H.J. & McCarthy J.M. (2005). “Dimensioning a Constrained Parallel

Robot to Reach a Set of Task Positions”, Proceedings of IEEE International

Conference on Robotics and Automation.

AN AUTOMATIC TRAFFIC CONES DISPENSER AND COLLECTOR ...

Documents

Transcript of AN AUTOMATIC TRAFFIC CONES DISPENSER AND COLLECTOR ...