MINI PROJECT REPORT

DIGITAL ROBOTIC ARM

INTRODUCTION
Now days in this fast growing industrial age, every company needs speed in manufacturing to cope up with the customers requirements. Every industrialist cannot afford to transform his unit from manual to semi automatic or fully automatic as automation is not that cheap in India. The main objective of this project is to develop a versatile and low cost robotic arm which can be utilized in any industry to eliminate this problem. As of 2005, the robotic arm business is approaching a mature state, where they can provide enough speed, accuracy and ease of use for most of the applications. Vision guidance (aka machine vision) is bringing a lot of flexibility to robotic cells. However, the end effector attached to a robot is often a simple pneumatic, 2-position chuck. This does not allow the robotic cell to easily handle different parts, in different orientations. Hand-in-hand with increasing off-line programmed applications, robot calibration is becoming more and more important in order to guarantee a good positioning accuracy. Other developments include downsizing industrial arms for light industrial use such as production of small products, sealing and dispensing, quality control, handling samples in the laboratory. Such robots are usually classified as "bench top" robots. Robots are used in pharmaceutical research in a technique called High-throughput screening. Bench top robots are also used in consumer applications (micro-robotic arms). Industrial arms may be used in combination with or even mounted on automated guided vehicles (AGVs) to make the automation chain more flexible between pick-up and drop-off. The 2010 report from the International Federation of Robotics shows that Japanese companies lead the world in both stock and sales of multi-purpose industrial robots. The majority of installations are in the automobile sector. Our robotic arm is completely based on the digital electronics, which uses components like ICs, H Bridges and the robotic arm is mechanically made which is operated by geared dc The structure is designed in such a way that it is capable of lifting light loads. Our robotic arm is mainly used in the packaging department. motors. The motors are controlled by the H Bridge.

BLOCK DIAGRAM

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DIGITAL ROBOTIC ARM

Push button counter IC RingBridge IC H Monostable M Multivibrator 3 2 1 g 555 Timer LM 293D CD 4017

Figure 1: Block Diagram

BLOCK DIAGRAM DESCRIPTION

1. Push Button A push button is a simple switch mechanism for controlling some aspect of a machine or a process. Buttons are typically made out of hard material, usually plastic or metal. The surface is

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DIGITAL ROBOTIC ARM

usually flat or shaped to accommodate the human finger or hand, so as to be easily depressed or pushed. Buttons are most often biased switches, though even many un-biased buttons (due to their physical nature) require a spring to return to their un-pushed state. Here the clock is provided using a single push button. 2. Monostable Multivibrator A monostable multivibrator is a multivibrator in which one of the states is stable, but the other state is unstable (transient). A trigger causes the circuit to enter the unstable state. After entering the unstable state, the circuit will return to the stable state after a set time. Such a circuit is useful for creating a timing period of fixed duration in response to some external event. This circuit is also known as a one shot. Here, Monostable output is generated using a 555 timer IC. The Monostable multivibrator is designed to operate with a delay of 1 second. The output of Monostable is held in high position, till a trigger is applied using a push button. The output of Monostable is given as a clock to the ring counter IC CD 4017. 3. Ring Counter A ring counter is a type of counter composed of a circular shift register. The output of the last shift register is fed to the input of the first register. A straight ring counter connects the output of the last shift register to the first shift register input and circulates a single one (or zero) bit around the ring. For example, in a 4-register one-hot counter, with initial register values of 1000, the repeating pattern is: 1000, 0100, 0010, 0001, 1000... . Note that one of the registers must be pre-loaded with a 1 (or 0) in order to operate properly. Here, we have implemented the ring counter using the ring counter IC CD4017.CD4017 is a decade ring counter IC. It has 10 states. ie, Q0, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, and Q9. The output of the monostable multivibrator is given as the clock to the ring counter. The output of the ring counter is given to the H Bridge IC LM293D. 4. H Bridge An H bridge is an electronic circuit which enables a voltage to be applied across a load in either direction. These circuits are often used in robotics and other applications to allow DC motors to run forwards and backwards. H bridges are available as integrated circuits.

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DIGITAL ROBOTIC ARM

An H bridge is built with four switches (solid-state or mechanical). When the switches S1 and S4 are closed (and S2 and S3 are open) a positive voltage will be applied across the motor. By opening S1 and S4 switches and closing S2 and S3 switches, this voltage is reversed, allowing reverse operation of the motor. LM293D is a motor driver IC which can rotate the motor in both clockwise and anticlockwise direction depending on the inputs. There are two logic level compatible inputs A & B and two outputs A & B. If input A is brought to high, output A goes high and output B goes low. Thus the If input B is driven, the motor rotates in opposite direction. If both inputs are low, the motor is not driven and the circuit consumes no power. If both inputs are brought high, the motor is shorted and braking occurs.

motor rotates in one direction.

5. Robotic arm structure Robotic arm is basically a chain of rigid links interconnected by movable joints. The arm is connected to the end effectors. The end effectors may be a tool and its fixture, or a gripper or any other device to do work. The end effector is similar to the human hand with or without fingers. The most essential robot peripheral is the end effector, or end-of-arm-tooling. The common examples of end effectors include welding devices (such as MIG-welding guns, spot-welders, etc.), spray guns and also grinding and grippers (devices that can grasp an object, usually electromechanical or pneumatic). End effectors are frequently highly complex, made to match the handled product and often capable of picking up an array of products at one time. They may utilize various sensors to aid the robot system in locating, handling, and positioning products. Robot used here is a jointed arm configuration.

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DIGITAL ROBOTIC ARM

CIRCUIT DIAGRAM

Figure 2: Circuit Diagram

CIRCUIT DIAGRAM DESCRIPTION

The circuit for digital robotic arm is shown above. The circuit consists mainly of the following components. 1. Monostable Multivibrator 2. CD 4017 Ring counter IC

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DIGITAL ROBOTIC ARM

3. LM 293D Motor driver IC 4. Push button 5. Power supply 6. DC motor 7. Voltage regulator IC 7805 8. Other ICs are 7411 and 7432 Monostable output is generated using a 555 timer IC. The Monostable multivibrator is designed to operate with a delay of 1 second. The output of Monostable is held in high position; till a trigger is applied using a push button. The output of monostable multivibrator is taken from pin 3. The output of Monostable is given as a clock to the IC CD 4017. CD4017 is a decade ring counter IC. It has 10 states. i.e, Q0, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8 and Q9. By default Q0 is always 1. Pin 14 is clock, and the output of monostable multivibrator is connected to this pin. CD4017 is negative edge triggered IC.MR is the master reset pin. E is the enable pin which is active low. Here two CD 4017 is cascaded, since the total sequence required is 12. IC 7432 is an OR IC, it combines the various combinations. The output of the ring counter is given to the H Bridge IC LM293D. It is a motor driver IC, which can rotate the motor in both clockwise and anticlockwise direction depending on the input to pins 2, 7 and 10, 15 in pairs. So the motor to be operated is connected to pins 3, 6 and 11, 14.

Pin diagram of 555 timer IC

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DIGITAL ROBOTIC ARM

Figure 3: Pin Diagram of 555 Timer

Pin diagram of CD4017

Figure 4: Pin Diagram of CD 4017 Here two CD 4017 is cascaded, since the total sequence required is 12. IC 7432 is an OR IC, it combines the various combinations. Pin details of LM7432

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DIGITAL ROBOTIC ARM

Figure 5: Pin Diagram of LM 7432

IC 7411 is a three input AND IC. AND gate is used to give clock to second ring counter IC CD 4017.There is a DPDT switch used to reset the ring counter, it is connected to master reset of both the counters. Pin details of LM7411

Figure 6: Pin Diagram of 7411

Pin details of LM293D

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DIGITAL ROBOTIC ARM

It is a motor driver IC, which can rotate the motor in both clockwise and anticlockwise direction depending on the input to pins 2, 7 and 10, 15 in pairs. So the motor to be operated is connected to pins 3, 6 and 11, 14.

Figure 7: Pin Diagram of LM 293D

Figure 8: Simple H Bridge Circuit

IC LM 293D is commonly called as H bridge. It has two logic level compatible inputs A & B and two outputs A & B.Its operation can be stated as: If input A is brought to high, output A goes high and output B goes low. Thus the motor rotates in one direction. If input B is driven, the motor rotates in opposite direction. If both inputs are low, the motor is not driven and the circuit consumes no power. If both inputs are brought high, the motor is shorted and braking occurs.

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DIGITAL ROBOTIC ARM

Figure 9: Simple H Bridge Circuit

Now a particular sequence is obtained at the output, and the motor rotates in the specified direction. In the circuit the four motors indicate the operation of the robotic arm manipulator. Robotic arm structure Robotic arm is basically a chain of rigid links interconnected by movable joints. The arm is connected to the end effectors. The end effectors may be a tool and its fixture, or a gripper or any other device to do work. The end effector is similar to the human hand with or without fingers. The common examples of end effectors include welding devices (such as MIG-welding guns, spot-welders, etc.), spray guns and also grinding and grippers (devices that can grasp an object, usually electromechanical or pneumatic). End effectors are frequently highly complex, made to match the handled product and often capable of picking up an array of products at one time. They may utilize various sensors to aid the robot system in locating, handling, and positioning products. Robot used here is a jointed arm configuration.

WORKING
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DIGITAL ROBOTIC ARM

The working can be explained as, the power supply is provided from a 12volt battery. The push button is connected to the trigger pin; i.e. pin 2 of the 555 timer. 555 timer acts as a monostable multivibrator. The clock so generated from Monostable is given as clock to both ring counters. The Q0 pin is always logic high by default, so it is not used for sequencing. Else it is connected to ENABLE of second ring counter. Each time the push button is pressed the logic high state. i.e, logic 1 is transversed to the next stages. Eight output pins of first CD4017 is used, other four sequences are taken from second CD 4017the pins. The twelve sequences in order are: 1. Base rotates to the source 2. Elbow turns down 3. Wrist turns down 4. Gripper closes (picking) 5. Wrist up 6. Elbow up 7. Base rotate to target 8. Elbow down 9. Wrist down 10. Gripper opens (placing) 11. Wrist up 12. Elbow down Q6 Q7 Q8 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q5

There are four motors to be operated. They are gripper (Mg), wrist (M1), elbow (M2), and base (M3).The motor driver IC can rotate each motor in clockwise and anticlockwise direction. The clock to the CD4017 will make the decade counter IC to work as a ring counter. At a time only any one of the output of counter is high, and so only one motor operates, also when one of the motors operates all others are stopped. The combinations are taken using OR gate 7432. When Q1 is high, the base motor rotates to the source. Q1 is directly given to IN1 of LM 293D. In the next pulse, Q2 is high. So Q2 and Q8 are ORed and given to IN3. IN2 is given from Q7. IN4 is given from ORed combination of Q6 and Q4. Once Q8 is high, Q9, ENABLE and clock of first CD 4017 are ANDed and given to the clock of second CD 4017.

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ENABLE is given by Q0. Q3 of first and Q1 of second CD 4017 are ANDed and thus provides IN1 of second LM 293D. Q5 of first and Q3 of second CD 4017 are ANDed. Thus provides IN2 of second LM 293D. IN3 is the Q4 of first CD4017. IN4 is the Q2 of second.Base motor is connected between OUT1 and OUT2. Elbow motor is connected between OUT3 and OUT4. Wrist motor is connected between OUT1 and OUT2 of second LM 293D. Gripper motor is connected between OUT3 and OUT4 of second LM 293D. The working of the circuit based on sequence can be briefly described as follows: When the push button is pressed, the first clock arrives at ring counter IC and by default Q0 output is HIGH. At the next clock input, Q1 is HIGH and the specified operation is base rotating to the source. At the next clock input, Q2 becomes HIGH. So the elbow rotates down. In the next clock input, the Q3 is HIGH and then the wrist turns down. Now the gripper is near to the object to be picked. So when Q4 is HIGH, gripper closes. i.e, the picking process is completed. Now by the next clock, Q5 is HIGH and the wrist turns upward. When Q6 is HIGH, the elbow turns upward and by high at Q7, the base is rotated to the target.Q8 HIGH will turn the elbow downward and now the output are taken from the next IC CD4017.Q1 of second ring counter is made HIGH. So the wrist is turned downward.When Q2 is HIGH, gripper opens and places the object at the desired position.Q3 HIGH will make the wrist up and Q4 HIGH will make the elbow up.For the next set of operations, the same operations are performed in sequence. In case of any emergency or in case of any faults, an additional reset button is attached. By resetting the circuit, the arm stops the current operation being performed and starts from beginning.

COST ESTIMATION
COMPONENT RATE (Rs) QTY PRICE (Rs)

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DIGITAL ROBOTIC ARM

LM L293D CD 4017 LM 555 LM 7805 LM 7432 LM 7411 DPDT Switch DC Geared Motor Push Button PVC Pipe (1) Switch Board U-Clamp T-Joint Screws Wire

125 50 8 15 10 10 100 300 5 125 100 5 7.50 2 5

2 2 1 1 1 1 1 4 1 2m 1 1 10 2 25 10m

250 100 8 15 10 10 100 1200 5 250 100 200 50 15 50 50

Soldering iron (25W) 200

ADVANTAGES
1. It reduces the complexity in manufacturing process. 2. Increase the production speed in the industry.
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3. Robots increase the work place safety. i.e. the workers are moved to the role of supervisors. 4. Product quality is improved. 5. Financial saving.

DISADVANTAGES
1. The system doesnt guarantees the result, if the load limit exceeds. 2. Employees require training in interacting with new equipment. 3. If power supply fails in between the sequence execution, it is not possible to complete the sequence operation. But the sequence starts from the initial condition.

APPLICATIONS

INDUSTRIAL FIELD 1. Pick and place robotic arm 2. Milling 3. Drilling 4. Packing MEDICAL FIELD 1. Surgerical assistance

FUTURE SCOPE
It is possible to convert DIGITAL ROBOTIC ARM from manual to automatic. Here we are providing clock manually, instead of this if we could provide the clock automatically on time basis, the problem can be eliminated.
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The clock section is replaced by a sensing system. The transmitting section is a light source. A disc with 8 holes is made. The disc is rotated using a motor, whose speed can be controlled as per our requirements. The light is transmitted through each hole of the disc at particular intervals. The receiving section consists of a phototransistor.

CONCLUSION
Our robotic arm is completely based on digital electronics which uses components like ICs, H Bridges and the robotic arm is mechanically made and is operated by using geared DC motors. The structure is designed in such a way that it is capable of lifting light loads. Our robotic arm is mainly used in the packaging department.
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The manually controlled robotic arm can be changed to automatic control if the clock section is replaced by a sensing system. The transmitting section is a light source. A disc with 8 holes is made. The disc is rotated using a motor, whose speed can be controlled as per our requirements. The light is transmitted through each hole of the disc at particular intervals. The receiving section consists of a phototransistor. The DIGITAL ROBOTIC ARM was designed and implemented successfully. The circuit was designed as per the specifications and the requirements. The working conditions and the various constraints were properly studied before going through the designing steps. Currently this project is manually controlled.

REFERENCE
http://www.fairchildsemi.com/tree/logic/gates/ http://www.datasheetcatalog.com/nationalsemiconductor/1/ http://www.societyofrobots.com/robot_arm_tutorial.shtml http://www.rapidonline.com/netalogue/specs/82-0192.pdf

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APPENDIX

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