INTELLIGENT PICH AND PLACE ROBOT

WITH REMOTE CONTROL

Submitted in partial fulfillment of the requirement for the award of

DIPLOMA
IN
ECE ENGINEERING
BY

Under the guidance of----------------------------

2004-2005
DEPARTMENT OF MECHANICAL ENGINEERING
 CERTIFICATE

Register number: _________________________

This is to certify that the project report titled “INTELLIGENT

PICK AND PLACE ROBOT WITH REMOTE CONTROL”
submitted by the following students for the award of the diploma
engineering is record of bonafide work carried out by them.

Done by

Mr. /Ms._______________________________

In partial fulfillment of the requirement for the award of

Bachelor of Mechanical Engineering

During the Year – (2004-2005)

_________________ _______________
Head of Department Guide

Coimbatore –641651.
Date:

Submitted for the Board examination held on

___________
_________________ ________________
Internal Examiner External
Examiner
---------------------------------------------------------------------------------
 ACKNOWLEDGEMENT
---------------------------------------------------------------------------------

ACKNOWLEDGEMENT

At this pleasing moment of having successfully

completed our project, we wish to convey our sincere
thanks and gratitude to the management of our college
and our beloved chairman
…………………………………………………, who provided all
the facilities to us.
We would like to express our sincere thanks to our
principal ………………………………………, for forwarding
us to do our project and offering adequate duration in
completing our project.
We are also grateful to the Head of Department
Prof. …………………………………….., for her constructive
suggestions & encouragement during our project.

With deep sense of gratitude, we extend our earnest

& sincere thanks to our guide
…………………………………………………….., Department of
Mechanical for her kind guidance & encouragement
during this project.

We also express our indebt thanks to our TEACHING

and NON TEACHING staffs of MECHANICAL ENGINEERING
DEPARTMENT,……………………….(COLLEGE NAME).
---------------------------------------------------------------------------------

INTELLIGENT PICK AND PLACE

ROBOT WITH REMOTE
CONTROL
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---------------------------------------------------------------------------------

CONTENTS
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CONTENTS

CHAPTER NO PARTICULAS PAGE NO.

ACKNOWLEDGEMENT

1. SYNOPSIS

2. INTRODUCTION

3. COMPONENTS AND DESCRIPTION

4. DRAWINGS

5. ARRANGEMENTS

6. WORKING PRINCIPLE

7. ADVANTAGED AND DISADVANTAGES

8. APPLICATIONS

9. LIST OF MATERIAL

10. COST ESTIMATION

11. CONCLUSION
 BIBLIOGRAPHY
PHOTOGRAPHY

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Chapter-1
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--------------------------------------------------------------------------------------

SYNOPSIS
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CHAPTER-1

SYNOPSIS

The goal of this project was to implement the most efficient and way analyzing

robot. In our project, Robot is operated by battery energy. Battery is used to drive the

Robot D.C motor.

The FM transmitter and receiver circuit is used for this video camera robot. The

FM receiver circuit is fitted in the robot. The cordless FM transmitter circuit is used for

this project. The FM receiver circuit is having 10 relays. They are used to control

Relay 1 - Rotary motion in forward direction

Relay 2 - Rotary motion in reverse Direction

Relay 3 - Arm in upward movement

Relay 4 - Arm in downward movement

Relay 5 - Work piece clamping

 Relay 6 - Work piece releasing

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Chapter-2
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--------------------------------------------------------------------------------------

INTRODUCTION
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CHAPTER-2

INTRODUCTION

This is an era of automation where it is broadly defined as replacement of manual

effort by mechanical power in all degrees of automation. The operation remains an

essential part of the system although with changing demands on physical input as the

degree of mechanization is increased.

Degrees of automation are of two types, viz.

Full automation.

Semi automation.

In semi automation a combination of manual effort and mechanical power is

required whereas in full automation human participation is very negligible.

NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc., of these sources, pneumatics form an attractive medium for low cost automation.

Automation plays an important role in automobile.

Nowadays almost all the automobile vehicle is being atomized in order to product

the human being. The automobile vehicle is being atomized for the following reasons.

 To achieve high safety

 To reduce man power

 To increase the efficiency of the vehicle

 To reduce the work load

 To reduce the vehicle accident

 To reduce the fatigue of workers

 To high responsibility

 Less Maintenance cost

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Chapter-3
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COMPONENTS AND
DESCRIPTION
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CHAPTER-3

COMPONENTS AND DESCRIPTION

The major components of the intelligent pick and place robot with remote control

are,

Battery

P.M.D.C. Motor

Angle frame

Gear wheel Arrangement

FM transmitter and Receiver

1. BATTERY:
INTRODUCTION:

In isolated systems away from the grid, batteries are used for storage of excess

solar energy converted into electrical energy. The only exceptions are isolated sunshine

load such as irrigation pumps or drinking water supplies for storage. In fact for small

units with output less than one kilowatt.

Batteries seem to be the only technically and economically available storage

means. Since both the photo-voltaic system and batteries are high in capital costs. It is

necessary that the overall system be optimized with respect to available energy and local

demand pattern. To be economically attractive the storage of solar electricity requires a

battery with a particular combination of properties:

(1) Low cost

(2) Long life

(3) High reliability

(4) High overall efficiency

(5) Low discharge

(6) Minimum maintenance

(A) Ampere hour efficiency

(B) Watt hour efficiency

 We use lead acid battery for storing the electrical energy from the solar panel for

lighting the street and so about the lead acid cells are explained below.

LEAD-ACID WET CELL:

Where high values of load current are necessary, the lead-acid cell is the type most

commonly used. The electrolyte is a dilute solution of sulfuric acid (H₂SO₄). In the

application of battery power to start the engine in an auto mobile, for example, the load

current to the starter motor is typically 200 to 400A. One cell has a nominal output of

2.1V, but lead-acid cells are often used in a series combination of three for a 6-V battery

and six for a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be recharged.

The charge and discharge cycle can be repeated many times to restore the output voltage,

as long as the cell is in good physical condition. However, heat with excessive charge

and discharge currents shortends the useful life to about 3 to 5 years for an automobile
battery. Of the different types of secondary cells, the lead-acid type has the highest

output voltage, which allows fewer cells for a specified battery voltage.
CONSTRUCTION:

Inside a lead-acid battery, the positive and negative electrodes consist of a group

of plates welded to a connecting strap. The plates are immersed in the electrolyte,

consisting of 8 parts of water to 3 parts of concentrated sulfuric acid. Each plate is a grid

or framework, made of a lead-antimony alloy. This construction enables the active

material, which is lead oxide, to be pasted into the grid. In manufacture of the cell, a

forming charge produces the positive and negative electrodes. In the forming process, the

active material in the positive plate is changed to lead peroxide (pbo₂). The negative

electrode is spongy lead (pb).

Automobile batteries are usually shipped dry from the manufacturer. The

electrolyte is put in at the time of installation, and then the battery is charged to from the

plates. With maintenance-free batteries, little or no water need be added in normal

service. Some types are sealed, except for a pressure vent, without provision for adding

water.

The construction parts of battery are shown in figure.

CHEMICAL ACTION:

Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell

discharges, lead peroxide from the positive electrode combines with hydrogen ions to

form water and with sulfate ions to form lead sulfate. Combining lead on the negative

plate with sulfate ions also produces he sulfate. There fore, the net result of discharge is

to produce more water, which dilutes the electrolyte, and to form lead sulfate on the

plates.

As the discharge continues, the sulfate fills the pores of the grids, retarding

circulation of acid in the active material. Lead sulfate is the powder often seen on the

outside terminals of old batteries. When the combination of weak electrolyte and

sulfating on the plate lowers the output of the battery, charging is necessary.

On charge, the external D.C. source reverses the current in the battery. The

reversed direction of ions flows in the electrolyte result in a reversal of the chemical

reactions. Now the lead sulfates on the positive plate reactive with the water and sulfate

ions to produce lead peroxide and sulfuric acid. This action re-forms the positive plates

and makes the electrolyte stronger by adding sulfuric acid.

 At the same time, charging enables the lead sulfate on the negative plate to react

with hydrogen ions; this also forms sulfuric acid while reforming lead on the negative

plate to react with hydrogen ions; this also forms currents can restore the cell to full

output, with lead peroxide on the positive plates, spongy lead on the negative plate, and

the required concentration of sulfuric acid in the electrolyte.

The chemical equation for the lead-acid cell is

Charge

Pb + pbO₂ + 2H₂SO₄ 2pbSO₄ + 2H₂O

Discharge

On discharge, the pb and pbo₂ combine with the SO₄ ions at the left side of the

equation to form lead sulfate (pbSO₄) and water (H₂O) at the right side of the equation.

One battery consists of 6 cell, each have an output voltage of 2.1V, which are

connected in series to get an voltage of 12V and the same 12V battery is connected in

series, to get an 24 V battery. They are placed in the water proof iron casing box.
CARING FOR LEAD-ACID BATTERIES:

Always use extreme caution when handling batteries and electrolyte. Wear gloves,

goggles and old clothes. “Battery acid” will burn skin and eyes and destroy cotton and

wool clothing.

The quickest way of ruin lead-acid batteries is to discharge them deeply and leave

them stand “dead” for an extended period of time. When they discharge, there is a

chemical change in the positive plates of the battery. They change from lead oxide when

charge out lead sulfate when discharged. If they remain in the lead Sulfate State for a few

days, some part of the plate dose not returns to lead oxide when the battery is recharged.

If the battery remains discharge longer, a greater amount of the positive plate will remain

lead sulfate. The parts of the plates that become “sulfate” no longer store energy.

Batteries that are deeply discharged, and then charged partially on a regular basis can fail

in less then one year.

Check your batteries on a regular basis to be sure they are getting charged. Use a

hydrometer to check the specific gravity of your lead acid batteries. If batteries are

cycled very deeply and then recharged quickly, the specific gravity reading will be lower

than it should because the electrolyte at the top of the battery may not have mixed with

the “charged” electrolyte.

 Check the electrolyte level in the wet-cell batteries at the least four times a year

and top each cell of with distilled water. Do not add water to discharged batteries.

Electrolyte is absorbed when batteries are very discharged. If you add water at this time,

and then recharge the battery, electrolyte will overflow and make a mess.

Keep the top of your batteries clean and check that cables are tight. Do not tighten

or remove cables while charging or discharging. Any spark around batteries can cause a

hydrogen explosion inside, and ruin one of the cells, and you.

On charge, with reverse current through the electrolyte, the chemical action is

reversed. Then the pb ions from the lead sulfate on the right side of the equation re-form

the lead and lead peroxide electrodes. Also the SO₄ ions combine with H₂ ions from the

water to produce more sulfuric acid at the left side of the equation.

CURRENT RATINGS:

Lead-acid batteries are generally rated in terms of how much discharge currents

they can supply for a specified period of time; the output voltage must be maintained

above a minimum level, which is 1.5 to 1.8V per cell. A common rating is ampere-hours

(A.h.) based on a specific discharge time, which is often 8h. Typical values for

automobile batteries are 100 to 300 A.h.

 As an example, a 200 A.h battery can supply a load current of 200/8 or 25A, used

on 8h discharge. The battery can supply less current for a longer time or more current for

a shorter time. Automobile batteries may be rated for “cold cranking power”, which is

related to the job of starting the engine. A typical rating is 450A for 30s at a temperature

of 0 degree F.

Note that the ampere-hour unit specifies coulombs of charge. For instance, 200

A.h. corresponds to 200A*3600s (1h=3600s). the equals 720,000 A.S, or coulombs. One

ampere-second is equal to one coulomb. Then the charge equals 720,000 or 7.2*10^5ºC.

To put this much charge back into the battery would require 20 hours with a charging

current of 10A.

The ratings for lead-acid batteries are given for a temperature range of 77 to 80ºF.

Higher temperature increase the chemical reaction, but operation above 110ºF shortens

the battery life.

Low temperatures reduce the current capacity and voltage output. The ampere-

hour capacity is reduced approximately 0.75% for each decreases of 1º F below normal

temperature rating. At 0ºF the available output is only 60 % of the ampere-hour battery

rating.
 In cold weather, therefore, it is very important to have an automobile battery unto

full charge. In addition, the electrolyte freezes more easily when diluted by water in the

discharged condition.

SPECIFIC GRAVITY:

Measuring the specific gravity of the electrolyte generally checks the state of

discharge for a lead-acid cell. Specific gravity is a ratio comparing the weight of a

substance with the weight of a substance with the weight of water. For instance,

concentrated sulfuric acid is 1.835 times as heavy as water for the same volume.

Therefore, its specific gravity equals 1.835. The specific gravity of water is 1, since it is

the reference.

In a fully charged automotive cell, mixture of sulfuric acid and water results in a

specific gravity of 1.280 at room temperatures of 70 to 80ºF. as the cell discharges, more

water is formed, lowering the specific gravity. When it is down to about 1.150, the cell is

completely discharged.

Specific-gravity readings are taken with a battery hydrometer, such as one in

figure (7). Note that the calibrated float with the specific gravity marks will rest higher in

an electrolyte of higher specific gravity.

 The decimal point is often omitted for convenience. For example, the value of

1.220 in figure (7) is simply read “twelve twenty”. A hydrometer reading of 1260 to

1280 indicates full charge, approximately 12.50 are half charge, and 1150 to 1200

indicates complete discharge.

The importance of the specific gravity can be seen from the fact that the open-

circuit voltage of the lead-acid cell is approximately equal to

V = Specific gravity + 0.84

For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an

example. These values are for a fully charged battery.

CHARGING THE LEAD-ACID BATERY:

The requirements are illustrated in figure. An external D.C. voltage source is

necessary to produce current in one direction. Also, the charging voltage must be more

than the battery e.m.f. Approximately 2.5 per cell are enough to over the cell e.m.f. so

that the charging voltage can produce current opposite to the direction of discharge

current.
 Note that the reversal of current is obtained just by connecting the battery VB and

charging source VG with + to + and –to-, as shown in figure. The charging current is

reversed because the battery effectively becomes a load resistance for VG when it higher

than VB. In this example, the net voltage available to produce charging currents is 15-

12=3V.

A commercial charger for automobile batteries is essentially a D.C. power supply,

rectifying input from the AC power line to provide D.C. output for charging batteries.

Float charging refers to a method in which the charger and the battery are always

connected to each other for supplying current to the load. In figure the charger provides

current for the load and the current necessary to keep the battery fully charged. The

battery here is an auxiliary source for D.C. power.

It may be of interest to note that an automobile battery is in a floating-charge

circuit. The battery charger is an AC generator or alternator with rectifier diodes, driver

by a belt from the engine. When you start the car, the battery supplies the cranking

power. Once the engine is running, the alternator charges he battery. It is not necessary

for the car to be moving. A voltage regulator is used in this system to maintain the output

at approximately 13 to 15 V.
 The constant voltage of 24V comes from the solar panel controlled by the charge

controller so for storing this energy we need a 24V battery so two 12V battery are

connected in series.

It is a good idea to do an equalizing charge when some cells show a variation of

0.05 specific gravity from each other. This is a long steady overcharge, bringing the

battery to a gassing or bubbling state. Do not equalize sealed or gel type batteries.

With proper care, lead-acid batteries will have a long service life and work very

well in almost any power system. Unfortunately, with poor treatment lead-acid battery

life will be very short.

3. D.C. MOTOR (PERMANENT MAGNET):

DESCRIPTION OF DC MOTOR

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor is

placed in a magnetic field, it experiences a magnetic force whose direction is given by

Fleming’s left hand rule.

 When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or

series wound or compound wound motors.

FLEMING’S LEFT HAND RULE:

Keep the force finger, middle finger and thumb of the left hand mutually

perpendicular to one another. If the fore finger indicates the direction of magnetic field

and middle finger indicates direction of current in the conductor, then the thumb indicates

the direction of the motion of conductor.

PRINCIPLE OF OPERATION OF DC MOTOR:

Figure I show a uniform magnetic field in which a straight conductor carrying no

current is placed. The conductor is perpendicular to the direction of the magnetic field.

In figure II the conductor is shown as carrying a current away from the viewer, but

the field due to the N and S poles has been removed. There is no movement of the

conductor during the above two conditions. In figure III the current carrying conductor is

placed in the magnetic field. The field due to the current in the conductor supports the

main field above the conductor, but opposes the main field below the conductor.
 Movement of

Conductor

N S

Magnetic flux current carrying

Conductor

The result is to increase the flux density in to the region directly above the

conductor and to reduce the flux density in the region directly below the conductor. It is

found that a force acts on the conductor, trying to push the conductor downwards as

shown by the arrow. If the current in the conductor is reversed, the strengthening of flux

lines occurs below the conductor, and the conductor will be pushed upwards (figure-IV).

Now consider a single turn coil carrying a current as shown in the above figure. in

view of the reasons given above, the coil side A will be forced to move downwards,

whereas the coil side B will be forced to move upwards. The forces acting on the coil

sides A and B will be of same magnitude. But their direction is opposite to one another.

As the coil is wound on the armature core which is supported by the bearings, the

armature will now rotate. The commutator periodically reverses the direction of current

flow through the armature. Therefore the armature will have a continuous rotation.
 A simplified model of such a motor is shown in figure VI. The conductors are

wound over a soft iron core. DC supply is given to the field poles for producing flux.

The conductors are connected to the DC supply through brushes

Let's start by looking at the overall plan of a simple 2-pole DC electric motor. A

simple motor has 6 parts, as shown in the diagram below.

 An armature or rotor

 A commutator

 Brushes

 An axle

 A field magnet

 A DC power supply of some sort

 An electric motor is all about magnets and magnetism: a motor uses magnets to

create motion. If you have ever played with magnets you know about the fundamental

law of all magnets: Opposites attract and likes repel. So if you have 2 bar magnets with

their ends marked north and south, then the North end of one magnet will attract the

South end of the other. On the other hand, the North end of one magnet will repel the

North end of the other (and similarly south will repel south). Inside an electric motor

these attracting and repelling forces create rotational motion.

In the diagram above and below you can see two magnets in the motor, the

armature (or rotor) is an electromagnet, while the field magnet is a permanent magnet

(the field magnet could be an electromagnet as well, but in most small motors it is not to

save power).

Electromagnets and Motors:

To understand how an electric motor works, the key is to understand how the

electromagnet works. An electromagnet is the basis of an electric motor. You can

understand how things work in the motor by imagining the following scenario. Say that

you created a simple electromagnet by wrapping 100 loops of wire around a nail and

connecting it to a battery. The nail would become a magnet and have a North and South

pole while the battery is connected.

 Now say that you take your nail electromagnet, run an axle through the middle of

it, and you suspended it in the middle of a horseshoe magnet as shown in the figure

below. If you were to attach a battery to the electromagnet so that the North end of the

nail appeared as shown, the basic law of magnetism tells you what would happen: The

North end of the electromagnet would be repelled from the north end of the horseshoe

magnet and attracted to the south end of the horseshoe magnet.

The South end of the electromagnet would be repelled in a similar way. The nail

would move about half a turn and then stop in the position shown.

You can see that this half-turn of

motion is simple and obvious because of

the way magnets naturally attract and

repel one another. The key to an electric

motor is to then go one step further so

that, at the moment that this half-turn of

motion completes, the field of the

electromagnet flips. The flip causes the

electromagnet to complete another half-turn of motion.

 You flip the magnetic field simply by changing the direction of the electrons

flowing in the wire (you do that by flipping the battery over). If the field of the

electromagnet flipped at just the right moment at the end of each half-turn of motion, the

electric motor would spin freely.

The Armature:

The armature takes the place of the nail in an electric motor.

The armature is an electromagnet made by coiling thin wire

around two or more poles of a metal core. The armature has an

axle, and the commutator is attached to the axle. In the diagram

above you can see three different views of the same armature:

front, side and end-on. In the end-on view the winding is eliminated to make the

commutator more obvious. You can see that the commutator is simply a pair of plates

attached to the axle. These plates provide the two connections for the coil of the

electromagnet.
The Commutator and brushes:

The "flipping the electric field" part of an electric motor is

accomplished by two parts: the commutator and the brushes. The

diagram at the right shows how the commutator and brushes work

together to let current flow to the electromagnet, and also to flip

the direction that the electrons are flowing at just the right

moment. The contacts of the commutator are attached to the axle

of the electromagnet, so they spin with the magnet. The brushes are just two pieces of

springy metal or carbon that make contact with the contacts of the commutator.

Putting It All Together:

When you put all of these parts together, what you have is a complete electric motor:
 In this figure, the armature winding has been left out so that it is easier to see the

commutator in action. The key thing to notice is that as the armature passes through the

horizontal position, the poles of the electromagnet flip. Because of the flip, the North

pole of the electromagnet is always above the axle so it can repel the field magnet's North

pole and attract the field magnet's South pole.

If you ever take apart an electric motor you will find that it contains the same pieces

described above: two small permanent magnets, a commutator, two brushes and an

electromagnet made by winding wire around a piece of metal. Almost always, however,

the rotor will have three poles rather than the two poles as shown in this article. There are

two good reasons for a motor to have three poles:

It causes the motor to have better dynamics. In a two-pole motor, if the

electromagnet is at the balance point, perfectly horizontal between the two poles of

the field magnet when the motor starts; you can imagine the armature getting

"stuck" there. That never happens in a three-pole motor.

Each time the commutator hits the point where it flips the field in a two-pole

motor, the commutator shorts out the battery (directly connects the positive and

negative terminals) for a moment. This shorting wastes energy and drains the

battery needlessly. A three-pole motor solves this problem as well.

 It is possible to have any number of poles, depending on the size of the motor and

the specific application it is being used in.

2. FRAME STAND:

This is made upof M.S. This is used as a body of the vehicle. The front and rear

wheels are fitted bellow this bottom frame with the help of end bearings.

3. GEAR WHEEL ARRANGEMENT:

There are two types of gear arrangement is used for this project. They are,

Spur Gear Arrangement - Forward and Reverse direction of motor

SPUR GEAR:

The spur gears, which are designed to transmit motion and power between parallel

shafts, are the most economical gears in the power transmission industry.
 APPLICATION:

 Material handling

 Feed drives

 Machine tools

 Conveyors

 Marine hoists

4. IR TRANSMITTER AND RECEIVER CIRCUIT:

TRANSMITTER

KEY BOARD

ANTENNA

UM FM
91215 TRANSMITTER
B
 DESCRIPTION

The message to be communicated has to be first converted into an electrical signal

by the help of a suitable transducer. The electrical signal so obtained has to be suitable

processed and amplified before being fed to the channel. The information signal called

the modulating signal is used to modulate a high frequency sine wave signal. The type of

modulation depends on the requirements.

The carrier signal generated by the oscillator goes to the RF output power

amplifiers through the buffer and RF amplifiers. The RF amplifier sends the signal

containing all bands of frequencies.

RECEIVER

ANTENNA

FM CD4013
RECEIVER CM8870 CD4067
DESCRIPTION

Practically all receivers today are super heterodyne. The RF amplifier is tuned to

the required incoming frequency. The output of the RFA is combined with the local

oscillator voltage and normally converted into a signal of lower fixed frequency. This IF

signal contains the same modulation as the original carrier. It is then amplified and

detected to obtain information.

A fixed frequency difference is maintained between the local oscillator and RF

frequency with the help of capacitance tuning. IF stage consists of a number of

transformers which provides a large gain. The characteristics of the IFA are kept

independent of the frequency to which the receiver is tuned, so that the sensitivity of the

super heterodyne remains fairly uniform throughout its tuning range. The various blocks

of super heterodyne receiver is explained as follows.

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Chapter-4
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DRAWINGS
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--------------------------------------------------------------------------------------

Chapter-5
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ARRANGEMENTS
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 CHAPTER-8
ARRANGEMENTS

The construction of remote controlled pick and place robot consists of a frame

which is used for mounting the components such as D.C motor, Battery and gear

wheel. The front and back wheels are fitted in the base of the frame. The front

wheel is fixed by the bolt and nut. The rear wheel is fitted with the help of shaft,

bearings and bearing cap. The gear wheel (spur) is fixed in this shaft for rotary

movement of the arm with gripper arrangement.

The D.C motor is coupled with this rotating arm arrangement with proper welding.

Another D.C motor is coupled with arm lifting arrangement of the rotating

column.

The power for driving the motor is taken from the battery. The battery is charged

through battery charger. The lead acid D.C 12 Volt battery is used for our project.

The receiver circuit is fixed inside the vehicle. The receiver is having 10 relays.

These relays output are connected to the D.C motor. The FM transmitter is kept

outside the vehicle due to remote operation.

--------------------------------------------------------------------------------------

Chapter-6
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

WORKING PRINCIPLE
--------------------------------------------------------------------------------------
 CHAPTER-9
WORKING PRINCIPLE

In our project lead-acid battery is used. The lead-acid batteries output is given to

the FM receiver circuit. FM Receiver is having 10 relays, they are connected to the three

D.C motor in Forward and reverse rotation of operation.

Relay 1 - Rotary motion in forward direction

Relay 2 - Rotary motion in reverse Direction

Relay 3 - Arm in upward movement

Relay 4 - Arm in downward movement

Relay 5 - Work piece clamping

Relay 6 - Work piece releasing

FM TRANSMITTER (CODE GENERATION)

OPERATION:

When a button on the keyboard is pressed two tones corresponding to that key is

generated. The tones corresponding to that key is generated.

 SCHEMATIC DIAGRAM OF TRANSMITTER

150Ω ON/OFF + 9V

100 μF
25 V
KEY BOARD 3.3 V
ZENER

1 2 315 3

16
4 5 6
3.57954M Hz
17
μM CRYSTAL ANTENNA
15 4
7 8 9
91215B

18 7
* # FM
14 TRANSMITER

13
12 1k

2 5 1
 The tones generated are fed to IC UM9121 5B which is an encoder, it converts the

messages into electrical signals and feeds them to the FM transmitter. The FM transmitter

thereafter transmits the signal with atmosphere as the medium (or) channel, via a

telescopic antenna which provides point to point links. The range of operation of the

circuit depends on the range of operation of the FM transmitter employed in the circuit.

Thus the signal is transmitted from the keyboard corresponding to the relay to be

triggered. Therefore transmission can be done in an efficient manner using this circuit.

FM TRANSMITTER

FM transmission can be done by two methods

1) Where frequency modulated waves can be directly produced by varying the master

oscillator frequency, in this case L-C oscillator is used (drift in frequency).

2) Where a crystal oscillator is used which phase is modulated by the audio signals

(drift free frequency).

 In this project, FM transmission is done such that the signal transmitted falls between

the desired bandwidth limits. In this case the frequency deviation is produced in

proportion to the amplitude of the signal received. The resulting FM wave is than passed

through a number of frequency multiplier stages. These sages not only raise the center

frequency of the signal but the frequency deviation is multiplied by the same factor as

well. The modulated wave is then amplified by the class C power amplifier and then

transmitted.

A part of frequency multiplier stage is fed to the AFC circuit in order to make

correction in case of any drift in the center frequency due to changes in the circuit

parameters. Thus change in center frequency can be correct and transmission by the FM

transmitter can be made accurate.

 FM TRANSMITTER

ANTENNA
SWITCH

100 k 2.2 pF

15 pF

BF200BT

10 915 pF

+ 9V
11 8
-
12
470 pF 330Ω 7

13 μM 6

14 91215B 5

15 4

16 3

17 2

Vref 18 1 Vdd
 Vss Vref

S₆ X₀

S₅ Vcc

S₄ GND

S₃ OSC₂

S₂ OSC

S GND

S₀ GND

TONE DIALING (DTMF)

Dual Tone Multi – Frequency is the method employed in the transmitter part of the

circuit. The user by means of this method will be able to control the operations of

different relays. The keypad normally consists of 12 keys representing numbers 0 to 9 and

the symbols * and # employed for special purposes.

 When a key is pressed the electronic circuit generates two tones corresponding to

that key. It key 5 is pressed, tones of 770 and 1336 Hz will be generated. DTMF, now

being the most common method replacing rotary dials has the following advantages.

ADVANTAGES:

1) Dialing is very fast as compared to pulse dialing.

2) It uses solid state circuits for tone generation and detection.

3) After the call has been connected, it can be used for low speed data transmission.

4) It is more compatible with electronically controlled exchanges.

RECEIVER (DECODER)

OPERATION:

The transmitted signals are received by an FM receiver which receives all

incoming signals within a particular bandwidth. The reception is also done with the help

of telescopic antennas. The signal obtained is fed to IC 8870P which is a decoder. This

IC converts the signal to its original form. It gives binary output corresponding to the

signal received from the transmitter. This 4 bit binary number is fed to IC4067, which is a

4 to 16 line decoder IC.

 Depending on the binary input, one of the outputs of IC4067 will go high

and the corresponding relay will be activated. This mode has to be held until another

deactivating signal is passed, in order to hold this mode a flip flop IC – CD4013 is

connected to IC 4067. IC – CD4013 holds this mode until another deactivating signal is

fed to the system.

Therefore ON & OFF operation of all relays can be controlled by using this logic.

The whole system can be reset by pressing the (*) button in the transmitter part of the

circuit.
 RECEIVER

AUDIO SUPPLY + 9V
FM
RECEIVER
OUT

0.1Μf 14

CD 4013

10 13
10 kΩ

3.57945 M Hz 100
μF
+9V

7 8 1 4 10 18 24 4 5
2 11 10
120 kΩ 2 CD 4013
11 CD 4067 15
CM8870P 12 14
3 13 13 12 6 7
14 8 7 6 5 4 3 2 23 22 21 SET

16 17 5 6 9 15
220 kΩ 1 kΩ

LED ( Q - Q₀ )
0.1 μF
9V
 S₃ GND
13 12
S₂ S
14 11
EN S₀
15 10
X₅ X₀
16 9
X₄ X
17 8
X₃ X₂
18 7
X₂ IC 4067 X₃
19 6
X X₄
20 5
X₀ X₅
21 4
X₉ X₆
22 3
X₈ X₇
23 2
Vcc Y
24 1

+ OE 10 9 Vss

Q 11 8 OSC₂
Q₂ 12 7 OSC

Q₃ 13 6 IC
IC 8870
Q₄ 14 5 IC

STD 15 4 Vref

ES 16 3 Gs

ST/G 17 2 Vin –

Vdd 18 1 Vin +
 2 SET 8 7 GND

2D 9 6 1 SET

2 RST 10 5 1D

1 RST 11 IC 4013 4 2 CLK

/ 2Q 12 3 1 CLK

2Q 13 2 / 1Q

Vcc 14 1 1Q

FM RECEIVER

These receivers are normally of superhetrodyne type employing double frequency

conversion. The circuit is designed with view to VHF or UHF operation. The RF and IF

sages are designed to have adequate bandwidth to accommodate frequency modulated

signals. The IF signals are passed through the limiter before applied to the discriminator

for conversion into audio signals. The purpose of having a limiter stage is to give the

discriminator stage, if signals of constant amplitude but having frequency deviation. The

limiter circuit is operated such that during the positive half cycle of the input signal, the

amplifier goes into saturation and during the negative half cycle the amplifier goes to

cutoff. This is done in order to obtain an output when the signal is not coming. To

overcome this, squelch or mute circuits are used.

 FM RECEIVER
+
470 MF
-

502 204

104 4 MF 10.7 MHz

20 MF 0.4
4 MF

4 MF
30 29 28 27 26 25 24 23 22 21 20
NC 19 18 17 16

CXA 10195 100 kΩ ANTENNA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

33 pF 33 pF

10.7 MHz 3.3 pF 27pF 330 E

102 102
330E 4 MF 150 E 150E
203 27 pF 5T 330 E

203

330E
 De-emphasis circuits are used to ensure that the received signals are restored

to their respective levels as in the original modulating signal transmitted. Therefore by

using FM receivers efficient reception is made possible and the signal can be

demodulated I order to obtain the original transmitted signal.

SUPERHETRODYNE RECEIVER

Mixer:

Also known, as frequency changer is a non-liner resistance having two sets of

input terminals and one output terminal.

Local Oscillator:

The type of local oscillator selected for a particular type of receiver depends on

factors such as frequency of operation, stability, tuning range etc. The usual short wave

receivers, i.e., up to 36 MHz, use mostly the Armstrong or Hartley oscillator. For

frequencies in VHF range and above, Colpitts, Ultra Audio, or clamp oscillators are used.

All these oscillators mentioned use a single LC tuned circuit, which determines its

frequency of operation high stability, is demanded from the oscillators for good receiver

performance. For this AFC or a frequency synthesizer can be used.

 The medium wave broadcast extends from 540 to 1650 KHz width and an IF

frequency of 455 KHz. Usually the local oscillator is designed to have a frequency,

which is higher than signal frequency by the intermediate frequency. Thus the oscillator

should have range from 540 + 450 = 995 KHz to 1650- _ 455 = 2105 KHz.

Thus gives a maximum to minimum ratio of 2:2:1. Consider now the case if the

local oscillator frequency had been designed less than signal frequency by it. This would

have resulted in local oscillator range from 85 to 1195 KHz giving a maximum to

minimum ratio of about 14:1. The usual tuning capacitors available have a capacitance

ratio of approximately 10:1, resulting in a frequency ratio of 3:2:1 thus a ratio of 2:2:1

required for the local oscillator operating above the signal frequency remains well with in

the limit imposed by the tuning capacitor, whereas the other system with ratio of 14:1

cannot be covered by the oscillator in one sweep.

RADIO FREQUENCY SECTION

The radio frequency section provides efficient coupling from the antenna input

terminals of the receiver to the first stage of RF amplifier so as to amplify the incoming

signal before the bit frequency is changed. Its main functions are:
 To provide selectivity against image and IF signals.

 To provide an efficient coupling between the antenna and first stage of the RF

amplifier.

 To provide discrimination or selectivity against image and IF signals.

 A super heterodyne receiver has a number of advantages, which makes it a

unanimous choice for a large number of receiver applications.

--------------------------------------------------------------------------------------

Chapter-7
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

ADVANTAGES & DISADVANTAGES

--------------------------------------------------------------------------------------
 CHAPTER-8

ADVANTAGES AND DISADVANTAGES

ADVANTAGES

 Emissions are greatly decreased.

 It can reduce dependency on fossil fuels because they can run on alternative fuels.

 Special lightweight materials are used to reduce the overall robot weight.

 Pick and place arm is Attached

 Robot direction is controlled by the remote control.

DISADVANTAGES

 High Initial cost.

 Charger circuit is used to charging the battery.

--------------------------------------------------------------------------------------

Chapter-8
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

APPLICATIONS
--------------------------------------------------------------------------------------
 CHAPTER-8

APPLICATIONS

1. Materials handling

2. Machine loading and unloading

3. Open field work.

4. Remote area Analyzing Application

5. It is also used in research application

--------------------------------------------------------------------------------------

Chapter-9
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

LIST OF MATERIALS
--------------------------------------------------------------------------------------
 CHAPTER-9

LIST OF MATERIALS

SL. NO. NAME OF THE PARTS MATERIAL QUANTITY

1 FM transmitter circuit Electronic 1
2 D.C. Motor (12 V) Aluminium 3
3 Bearing with bearing cap Steel 2
4 FM receiver with antenna Electronic 1
5 Battery Lead-acid 1
6 Spur Gear M.S 2
7 Connecting Wire Cu 2 meter
8 Bolt & Nut M.S 12
9 Shaft M.S 1
10 Frame Stand and sheet Metal M.S 1
11 Pick and Place Arm M.S 1
12 Wheel Rubber 4
13 Wheel Arrangement Nylon 4

--------------------------------------------------------------------------------------

Chapter-10
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------

COST ESTIMATION
--------------------------------------------------------------------------------------

CHAPTER-10

COST ESTIMATION

1. MATERIALS COST:

SL. NO. NAME OF THE PARTS MATERIAL QUANTITY AMOUNT (Rs)

1 FM transmitter circuit Electronic 1
 2 D.C. Motor (12 V) Aluminium 2
3 Bearing with bearing cap Steel 4
4 FM receiver with antenna Electronic 1
5 Battery Lead-acid 1
6 Spur Gear M.S 2
7 Connecting Wire Cu 2 meter
8 Bolt & Nut M.S 12
9 Shaft M.S 1
10 Frame Stand and sheet M.S 1

Metal
11 Pick and place arm M.S 1
12 Wheel Rubber 4
13 Wheel Arrangement Nylon 4

TOTAL =

2. LABOUR COST:

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =

3. OVERHEAD CHARGES:

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

=
 Overhead Charges = 20% of the manufacturing cost

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

Total cost for this project =

--------------------------------------------------------------------------------------

Chapter-11
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------

CONCLUSION
--------------------------------------------------------------------------------------
CHAPTER-11

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

purchasing, assembling and machining while doing this project work. We feel that the

project work is a good solution to bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time successfully.

The INTELLIGENT PICK AND PLACE ROBOT WITH REMOTE CONTROL is

working with satisfactory conditions. We are able to understand the difficulties in

maintaining the tolerances and also quality. We have done to our ability and skill making

maximum use of available facilities.

 In conclusion remarks of our project work, let us add a few more lines about our

impression project work.

Thus we have developed a “INTELLIGENT PICK AND PLACE ROBOT WITH

REMOTE CONTROL” which helps to know how to achieve low cost analyzing robot

with remote control operation. By using more techniques, they can be modified and

developed according to the applications.

--------------------------------------------------------------------------------------

BIBLIOGRAPHY
--------------------------------------------------------------------------------------

BIBLIOGRAPHY

AUTOMOBILE ENGG. - N.M AGGARWAL

S.K.KATARIA & SONS

ADVANCES IN AUTOMOBILE ENGG. - S.SUBRAMANIAM

THEORY & PERFORMANCE OF - J.B.GUPTA

ELECTRICAL MACHINES - S.K.KATARIA & SONS

PRINCIPLES OF ELECTRICAL

ENGINEERING AND ELECTRONICS - V.K.METHTA

CYBER REFERANCE:

www.howstuffworks.com

www.visionengineer.com

www.tpup.com
--------------------------------------------------------------------------------------
 PHOTOGRAPHY
--------------------------------------------------------------------------------------

PHOTOGRAPHY