DAYANANDA SAGAR COLLEGE OF ENGINEERING

Accredited by National Assessment & Accreditation Council (NAAC) with ’A’ Grade
(AICTE Approved, an Autonomous Institute Affiliated to VTU, Belagavi)
Shavige Malleshwara Hills, Kumaraswamy Layout, Bengaluru-560078
DEPARTMENT OF MECHANICAL ENGINEERING
(Accredited by NBA)

Certificate

Certified that the project report entitled ‘Design and Fabrication of PLC Operated Pick and
Place Robot’ is a bonafide work carried out by Mr. Shubham S Patil, bearing USN:
1DS15ME133, Mr. Srinidhi S V bearing USN: 1DS15ME140, Mr. Suhan S Joldal bearing
USN: 1DS15ME144, Mr. Tejas Kumar V bearing USN: 1DS15ME148 under the guidance of
Mr. Praveen D Jadhav, Assistant Professor, Department of Mechanical, Dayananda Sagar
College of Engineering, Bengaluru, in partial fulfilment for the award of Bachelor of
Engineering in Mechanical Engineering of the Visvesvaraya Technological University,
Belagavi.

Dr. R. Keshavamurthy Dr. C. P. S. Prakash

Professor & Head, Dept. of Mech. Engg Principal
Dayananda Sagar College of Engineering. Dayananda Sagar College of Engineering.
Bengaluru Bengaluru

Mr. Praveen D Jadhav

Assistant Professor, Dept. of Mech. Engg
Dayananda Sagar College of Engineering.
Bengaluru

SL.NO. Name of the Examiner Signature with Date

1.

2.

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 DECLARATION

We the below mentioned students hereby declare that the entire work embodied in the project
report entitled ‘Design and Fabrication of PLC Operated Pick and Place Robot’ has been
independently carried out by us under the guidance of Mr. Praveen D Jadhav, Professor,
Department of Mechanical Engineering, Dayananda Sagar College of Engineering,
Bengaluru, in partial fulfilment of the requirements for the award of Bachelor Degree in
Mechanical Engineering of Visvesvaraya Technological University, Belagavi.

I further declare that I have not submitted this report either in part or in full to any other
university for the award of any degree.

SL NO NAME USN SIGNATURE

1 SHUBHAM S PATIL 1DS15ME133
2 SRINIDHI S V 1DS15ME140
3 SUHAN S JOLDAL 1DS15ME144
4 TEJAS KUMAR V 1DS15ME148

Place: Bengaluru
Date:

ACKNOWLEDGEMENT

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We would like to express our heartfelt gratitude to Dr. C. P. S. PRAKASH, Principal, DSCE,
who has given us an opportunity to successfully complete our project.
It gives us an immense pleasure to thank Dr. R. KESHAVAMURTHY, Head of the
Department, Mechanical Engineering, DSCE, for his valuable advice and guidance which has
helped us complete our project.
This project would not have been profound without the persistent encouragement of our
beloved internal guide Mr. PRAVEEN D JADHAV, Assistant Professor, Department of
Mechanical Engineering, DSCE, whose sound technical knowledge helped us immensely
throughout our project. His symmetric approach towards documentation and discipline
towards work fostered us to put in better efforts. He with his immense experience also
predicted the forthcoming practical problems and mentored us to tackle these problems with
ease.
Finally we express our gratitude to all the teaching and non teaching staff, who has indirectly
helped us to complete this project successfully. Last but not the least we would like to thank
our parents for their blessings and love. We would also like to thank our friends for their
support and encouragement to successfully complete the task by meeting all the requirement.

ABSTRACT

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The more increase of Industries in developing countries, requirement of labors and workers
are more. To reduce the cost of labor force and to increase the manufacturing capacity of
industries, the advanced Robot arms are more needed. The aim is to eliminate the manual
control for minor chaos in the industries like picking an object and placing it elsewhere. One
type of Pick and place Robot commonly used in Industries is a Robotic manipulator or simply
a mechanical arm. It is an open or closed kinematic chain of rigid links interconnected by
movable joints. In some configurations, links can be considered to correspond to human
anatomy as Waist, Upper arm and Fore arm with joints at shoulder and elbow. At end of arm
a wrist joint connects an end effector which may be a tool and its fixture or a gripper or any
other device to pick and place an object. Robot was initially designed and Kinematic study of
various joints and links were performed and should be compared with the Theoretical
calculations. Once the kinematic study is done and give us the expected results, Fabrication
of the Robot is done. Various performance parameters are also checked.

Table of Contents
DECLARATION.......................................................................................................................ii

iv
ACKNOWLEDGEMENT........................................................................................................iii
ABSTRACT..............................................................................................................................iv
Chapter 1....................................................................................................................................1
1. Introduction....................................................................................................................1
1.1. Background..............................................................................................................1
1.2. Project Aim and Objective.......................................................................................2
1.3. Scope........................................................................................................................2
1.4. Benefit of the Project...............................................................................................3
1.5. Problem Statement...................................................................................................3
Chapter 2....................................................................................................................................4
2. Literature survey............................................................................................................4
2.1. History.....................................................................................................................5
Chapter 3....................................................................................................................................6
3. Hardware Description....................................................................................................6
3.1. Pneumatic Cylinder..................................................................................................6
3.1.1. Single Acting Cylinders...................................................................................6
3.1.2. Double Acting Cylinder...................................................................................7
3.2. Arduino....................................................................................................................7
3.3. Programmable Logic Controller..............................................................................8
3.3.1. PLC Hardware..................................................................................................9
3.3.2. DVP-14SS2....................................................................................................12
3.4. Servo Motor...........................................................................................................13
3.4.1. DC Servo Motor.............................................................................................14
3.4.2. AC Servo Motor.............................................................................................15
3.5. Bevel Gear.............................................................................................................16
3.5.1. Straight Bevel Gear........................................................................................16
3.5.2. Spiral Bevel Gear...........................................................................................17
3.5.3. Zerol Bevel Gear............................................................................................17
3.6. Pneumatic Compressor..........................................................................................18
3.7. SMPS.....................................................................................................................19
3.8. Relays.....................................................................................................................21
3.9. Other Pneumatic Components...............................................................................22
3.9.1. FRL Unit – Filter Regulator Lubricator.........................................................22

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 3.9.2. Solenoid Operated Direction Control Valve..................................................23
Chapter 4..................................................................................................................................24
4. Overview Behaviour....................................................................................................24
4.1. Program Flow Chart...............................................................................................24
4.1.1. Arduino Algorithm.........................................................................................25
......................................................................................................................................25
Chapter 5..................................................................................................................................26
5. Methods and Methodology..........................................................................................26
5.1. Method...................................................................................................................26
5.1.1. Kinematic Study using D-H Algorithm..........................................................26
5.1.2. Simulation with Robo-Analyzer.....................................................................27
5.2. Methodology Flow Chart.......................................................................................28
5.3. Design....................................................................................................................29
5.4. Fabrication of Robot..............................................................................................30
Chapter 6..................................................................................................................................31
6. Construction and Working...........................................................................................31
6.1. Circuit Diagram.....................................................................................................31
Chapter 7..................................................................................................................................32
7. Programming................................................................................................................32
7.1. Motor Drive Programming....................................................................................32
Chapter 8..................................................................................................................................37
8. Costing.........................................................................................................................37
Conclusion............................................................................................................................37
Future Scope.........................................................................................................................37
References................................................................................................................................38

Table of Figures
Figure 1: Typical Pick and Place Robot...................................Error! Bookmark not defined.

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Figure 2: Single Acting Pneumatic Cylinder.............................................................................6
Figure 3: Double Acting Pneumatic cylinder.............................................................................7
Figure 4: Arduino.......................................................................................................................8
Figure 5: Programmable Logic Controller.................................................................................8
Figure 6: Block Diagram of PLC CPU Architecture.................................................................9
Figure 7: PLC Memory Utilization Map..................................................................................10
Figure 8:DVP-14SS2...............................................................................................................12
Figure 9: DVP-14SS2 Connections..........................................Error! Bookmark not defined.
Figure 10: Installed DVP PLC.................................................................................................12
Figure 11: Servo Motor............................................................................................................13
Figure 12: DC Servo Motor Assembly....................................................................................14
Figure 13: Working of DC Servo Motor..................................Error! Bookmark not defined.
Figure 14: AC Servo Motor.....................................................................................................15
Figure 15: Working of AC Servo Motor..................................Error! Bookmark not defined.
Figure 16: Straight Bevel Gear................................................................................................16
Figure 17: Spiral Bevel Gear....................................................................................................17
Figure 18: Zerol Bevel Gear....................................................................................................17
Figure 19: Pneumatic Compressor...........................................................................................18
Figure 20: Relay Pin Configuration.........................................................................................21
Figure 21: DC vs AC Relays....................................................Error! Bookmark not defined.
Figure 22: Attraction Type Relays...........................................Error! Bookmark not defined.
Figure 23: Induction Type Relays............................................Error! Bookmark not defined.
Figure 24: Solid State Relay.....................................................Error! Bookmark not defined.
Figure 25: Reed Relay..............................................................Error! Bookmark not defined.
Figure 26: Used Relay..............................................................Error! Bookmark not defined.
Figure 27: FRL Unit.................................................................Error! Bookmark not defined.
Figure 28: FLR Unit Description.............................................................................................22
Figure 29: Solenoid Operated DCV.........................................................................................23
Figure 30: Program Flow Graph..............................................................................................24
Figure 31: Aurdino Flow Graph...............................................................................................25
Figure 32: Methodology Flow Chart........................................................................................28
Figure 34:Isometric View of Design........................................................................................29
Figure 35: Front View of Design.............................................................................................29
Figure 36:Top View of Draft...................................................................................................29
Figure 37:Front View of Draft.................................................................................................29
Figure 38: Side View of Draft..................................................................................................29
Figure 39: Gear Meshing of Fabricated Robot........................................................................30
Figure 40: DC Motor of Fabricated Robot...............................................................................30
Figure 41: Front View of Robot Stand.....................................................................................30
Figure 42: Side View of Robot Stand......................................................................................30
Figure 43: Front View of Arm Assembly................................................................................30
Figure 44: Isometric View of Robot Arm Assembly...............................................................30
Figure 45: Circuit Diagram......................................................................................................31

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Figure 46: Cylinder 1 Extension Stroke...................................Error! Bookmark not defined.
Figure 47: Cylinder 1 Retraction Stroke..................................Error! Bookmark not defined.
Figure 48: Cylinder 2 Extension Stroke...................................Error! Bookmark not defined.
Figure 49: Cylinder 2 Retraction Stroke..................................Error! Bookmark not defined.

Chapter 1

1. Introduction

Robotics researchers regularly furnish robot platforms with various new capabilities
that increase the potential applications and push the boundaries of autonomy. In

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 contrast, industrial automation is driven by the need to optimize throughput and
reliability. The hope is that, as multi-purpose robotic platforms become more
capable, they will be able to take over an increasing fraction of the tasks currently
handled by application specific, fixed installation automation, thereby granting all
applications greater levels of modularity and adapt ability. We are now watching an
acceleration of the rate at which research robotics feeds into engineering practice.

1.1. Background

Pick and Place robots are used in wide variety of material transfer applications.
Basically, the machine takes a product from one spot within the producing method
and places it into another location. A good example is a robot picking items off a
conveyor bet and placing them into packaging boxes. The typical pick and place
application require high amount of repetitive motion. Robots will eliminate human
operation of venturous tasks like chemical spraying or work. Pick and place robots
have high come on investment once consistent formed components or containers
area unit handled. Unlike human operators, robots also have the ability to work for
an extended time.

1.2. Project Aim and Objective

The aim of this project is to style AN autonomous automaton with complete system
permits the automaton wander concerning its atmosphere and to move with the sure
objects that it encounters. In order to attain the aim of this project, many objectives
area unit required to be completed.

i. To study the concept on how pick and place robot function and operate.

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 ii. To design the hardware for pick and place robot.

iii. To make the system run continuously with less rest

iv. To make an interface between the programming of robot arm and the sensors.

v. To make the robots gripper has the function of pick and place.

vi. To make the robot capable to stop at the desired location accurately.

1.3. Scope

To implement associate degree autonomous mobile golem that drive a vehicle with
none human interface. It build by micro controller, servo motors and infrared sensors
and all the program is up loaded into the controller to make its own decision and
determine the position. In order to design successful pick and place robot, scopes are
required to assist and guide the development of the project. The scope should be
identifies and planned to achieve the objective of the project successfully on the
time. The scopes for this project are:

i. To design a program that controls the robot movement.

ii. To design mechanical structure for the robot.

iii. To fabricate circuit board for the controller.

1.4. Benefit of the Project

i. It can show about the application among the PLC.

ii. Eliminates the usage of human power to pick up things.

iii. Prevent back pain/ back injuries due to picking up heavy loads by the operator.

iv. Increase productivity and efficiency.

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 1.5. Problem Statement

This pick and place robot being designed to ease the sorting process of heavy
materials. Usually the transfer process of the heavy materials is being carried out
using man power and if the transfer process is repeated for a period of time, it can
cause injuries to the operator. By victimization this explicit automaton, the operator
will no longer have to bent and lift up heavy loads thus preventing injuries and
increasing the efficiency of the work. Operator will make mistakes whether small or
big everyone in a while. In the industrial world, the trade cannot afford to require
quite mistakes. Every mistake is dear whether or not in time, cash and material.

Chapter 2

2. Literature survey
Sl No Author Year Topic Comments
1 Vishaka 2017 Development pf Pick and Place Industrial
Borkar Robot for Industrial Application applications of
Robots
2 Khin Moe 2016 Position Control Method for Kinematics
Myint Pick and Place Robot Arm for study of the

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 Object Sorting System Robotic arms
were learnt
3 Girish G Patil 2013 Vision Guided Pick and Place Various other
Robotic Arm System Based on actuation
SIFT methods were
studied
4 N Firthous 2013 Design and Implementation of Different types
Begum Pick and Place Robot with of motors used
Wireless Charging Application for Robots were
known
5 Mir Sajjad 2012 Automation of Mobile Pick and difference
Hussain Place Robotic System for Small performance
Talpur food Industry parameters of
Robot

2.1. History

In 1898, Nikola Tesla engineered the primary mechanical device driven guided boat,
which can be regarded as the original prototype of all modern day uninhabited aerial
vehicles and precision guided weapons. Records state that it's the primary among all
remotely controlled vehicles in air, land or sea. It was supercharged by lead-acid
batteries and an electrical drive motor. The vessel was designed in such a way that it
could be maneuverer alongside a target using instructions received from a wireless
remote-control transmitter. Once in its position, a command would be sent to detonate
an explosive charge contained within the boat’s forward compartment. The weapon’s
guidance device introduced a secure communications link between the pilot’s
managementler and therefore the surface running torpedo in a shot to assure that

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 control can be maintained even in the presence of electronic counter measures.
Wireless managementled remote-controlled vehicles that area unit used these days
generally use RF circuits for motion and control. But RF circuits suffer from the
disadvantage of restricted operating vary which ends up in restricted management. As
RF circuits’ follows LOS (Line of sight) approach, it fails miserably in NLOS (Non-
Line of Sight) conditions involving obstacles and barriers. To overcome these, one
method was proposed by Awab Farikh et al, (2010) which typically makes use of the
DTMF technology along with a microcontroller-based circuit for manoeuvre and
control of these unmanned robotic vehicles. Similarly, Ashish Yadav et al, (2012) also
proposed the construction of an unmanned vehicle which could be especially used for
ground combat using a similar technology. Recently, Sabuj Das Gupta et al (2013)
mentioned very well concerning however the strategy represented in can be enforced
employing a microcontroller by providing the mandatory circuit details and the
software code.

Chapter 3

3. Hardware Description

3.1. Pneumatic Cylinder

Pneumatic cylinders area unit the mechanical devices that use propellant as their
power supply to supply the force within the mutual arm. These area unit made up of
premium quality nickel-plated brass, aluminium, steel, stainless steel and various
other materials depending upon the job specifications, stroke length and level of

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loads, humidity & temperature. It uses the stored potential energy of compressed air
and convert it into kinetic energy as the air expands in an attempt to reach
atmospheric pressure.

3.1.1. Single Acting Cylinders

Single-acting cylinders use the pressure imparted by compressed gas to make a

drive, generally in outside direction, and a spring to return to the "home"
position. These cylinders have restricted extension and counseled for
applications..

Figure 1: Single Acting Pneumatic Cylinder

3.1.2. Double Acting Cylinder

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 Double-acting cylinders use the force of compressed gas to maneuver in each
extend and retract strokes.These cylinders have 2 ports to permit air in, one for
out-stroke and one for in-stroke.

Figure 2: Double Acting Pneumatic cylinder

3.2. Arduino

The key features are −

 Arduino boards are able to read analog or digital input signals from different
sensors and turn it into an output such as activating a motor, turning LED
on/off, connect to the cloud and many other actions.
 You can control your board functions by sending a set of instructions to the
microcontroller on the board via Arduino IDE (referred to as uploading
software).
 Unlike most previous programmable circuit boards, Arduino does not need an
extra piece of hardware (called a programmer) in order to load a new code onto
the board.
 You can simply use a USB cable.
 Additionally, the Arduino IDE uses a simplified version of C++, making it
easier to learn to program.
 Finally, Arduino provides a standard form factor that breaks the functions of
the micro-controller into a more accessible package.

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 Figure 3: Arduino

3.3. Programmable Logic Controller

Figure 4: Programmable Logic Controller

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Programmable logic controllers (PLCs) are utilized in trade in one kind or another for
the past twenty over years. The PLC is designed as a replacement for the hardwired
relay and timer logic to be found in traditional control panels, where PLC provides
ease and flexibility of control based on programming and executing logic instructions.
The internal functions like timers, counters and shift registers making sophisticated
control possible using even the smallest PLC.

The structure of a PLC are often divided into four components. They are input/output
modules, central process unit (CPU), memory and programming terminal.

3.3.1. PLC Hardware

Figure 5: Block Diagram of PLC CPU Architecture

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 Programmable logic controllers square measure purposeful computers consisting of
3 useful areas: process, memory and input/output. Input conditions to the PLC
square measure detected then hold on in memory, wherever the PLC performs the
programmed logic directions on these input states. Output conditions square measure
then generated to drive associated instrumentation. The action taken depends
altogether on the management program command in memory.

• Central Processing Unit (CPU)

Virtually all fashionable PLCs square measure microprocessor-based, employing a

'micro' because the system central processing unit. Some larger PLCs additionally
use extra microprocessors to manage complicated, long functions like mathematical
process, three-term PID management, etc.

 Memory

All PLCs contain each RAM and computer storage in variable amounts relying upon
the planning of the PLC. The use of a PLC's memory is determined again by the
design of the unit. However, all PLC recollections may be divided into a minimum
of 5 major areas.

Figure 6: PLC Memory Utilization Map

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 Executive Memory

The software or government memory for the PLC is usually in computer storage
since, once programmed and developed by the manufacturer, it seldom wants
dynamic . It is the one that really will the scanning during a PLC. The software may
be a special machine language program that runs the PLC. It instructs the chip to
scan every user instruction, helps the microprocessor to interpret user programmed
symbols and instructions, keeps track of all the I/O status, and is responsible for
maintaining/monitoring the current status of the health of the system and all its
components.

 System Memory
In order for the operating system to function, a section of the memory is allotted for
system administration. As the executive program performs its duties, it often
requires a place to store intermediate results and information. A section of RAM is
put in for this purpose. Normally this space is assigned to be used of the software
solely and isn't accessible to the user for programming. It might be thought of as a
scratch pad for the software to doodle on as necessary. Some PLCs use this space for
storing the knowledge that passes between computer programmer and software,

 I/O Status Memory

Another portion of RAM is allotted for the storage of current I/O standing. Every
single input/output module has been allotted thereto a specific location inside the
input/output image table. The location within the input and output image tables are
identified by addresses, each location has its own unique address. During the
execution of user program, the microprocessor scans the user program and interpret
the user commands, the status of input modules used are read from the input image
table (not directly from the input module itself).

 Data Memory

Whenever timers, counters, mathematics and process parameters are required, an

area of memory must be set aside for data storage. The data storage portion of
memory is allotted for the storage of such things as timers or counter pre-

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 set/accumulated values, arithmetic instruction information and results, and
alternative miscellaneous information and information which can be utilized by any
information manipulation functions within the user program.

3.3.2. DVP-14SS2

Figure 7:DVP-14SS2 Figure 9: Installed DVP PLC

The DVP-SS2 Series is Delta Electronics' second generation of slimline industrial

PLCs. The DVP-14SS211R options high speed counters, a flexible serial port, real-
time monitoring and an expansion bus that allows matching modules to be mounted
on the right side of the PLC without external wiring.

The DVP-14SS211R supports pelvic inflammatory disease loops with automatic

calibration for method management applications. The junction transistor outputs
enable high speed pulse generation for servo or stepper motor motion management .

Applications Specifications:

Power: 20.4 to 28.8 VDC

Digital Inputs: 8 inputs, 24 VDC sink or source¹

Digital Outputs: 6 relay outputs

Output Rating: 1.5A each output

Communication Port: RS-232 and RS-485, Modbus ASCII/RTU master or slave

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 Program Capacity: 8 k steps

IO Points: Up to 238 via expansion modules

Software Up/Down Counters: Any input, up to 10 kHz on a single input

Software Quadrature Inputs: 2 - X4/X5 (5 kHz) and X6/X7 (5 kHz)

Hardware Up/Down Counters: 2 - X0 and X2, both 20 kHz

Hardware Quadrature Inputs: 2 - X0/X1 and X2/X3, both 10 kHz

Hardware Pulse/PWM Outputs: None

3.4.Servo Motor

Figure 8: Servo Motor

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 A servomotor could be a mechanism|positioner|actuator} or linear actuator that
permits for precise management of angular or linear position, rate and acceleration. It
consists of an acceptable motor coupled to a sensing element for position feedback. It
additionally needs a comparatively subtle controller, usually an infatuated module
designed specifically to be used with servomotors. Servomotors don't seem to be a
selected category of motor though the term servomotor is commonly wont to see a
motor appropriate to be used during a closed-loop system. A servo motor is one in all
the wide used variable speed drives in industrial production and method automation
and building technology worldwide. Although servo motors don't seem to be a
selected category of motor, they're supposed and designed to use in motion
management applications that need high accuracy positioning, quick reversing and
exceptional performance.

3.4.1. DC Servo Motor

A DC servo motor consists of atiny low DC motor, feedback potentiometer, gearbox,

motor drive electronic circuit and electronic feedback control loop. It is additional or
less almost like the conventional DC motor. The stator of the motor consists of a
cylindrical frame and the magnet is attached to the inside of the frame..

xxii
 Figure 9: DC Servo Motor Assembly

The rotor consists of brush and shaft. A electric switch and a rotor metal supporting
frame ar connected to the surface of the shaft and therefore the coil winding is
involute within the rotor metal supporting frame. A brush is made with AN coil coil
that provides the present to the electric switch. At the rear of the shaft, a observeor is
made into the rotor so as to detect the rotation speed. With this construction, it is
simple to design a controller using simple circuitry because the torque is proportional
to the amount of current flow through the armature. And also, the fast polarity of the
management voltage decides the direction of torsion developed by the motor. Types
of DC servo motors embrace series motors, shunt control motor, split series motor,
and permanent magnet shunt motor. Working Principle of DC Servo Motor

3.4.2. AC Servo Motor

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 AC servo motors ar essentially two-phase cage induction motors and ar used for low
power applications. Nowadays, 3 part cage induction motors are changed such they'll
be employed in high power servo systems. The main distinction between a customary
split-phase induction motor and AC motor is that the cage rotor of a servo motor has
created with diluent conducting bars, so that the motor resistance is higher.

Figure 10: AC Servo Motor

Working Principle of AC Servo Motor

The schematic diagram of servo system for AC two-phase induction motor is shown
within the figure below. In this, the reference input at that the motor shaft needs to
maintain at an explicit position is given to the rotor of system generator as
mechanical input alphabetic character. This rotor is connected to the electrical input
at rated voltage at a hard and fast frequency.

3.5. Bevel Gear

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 Bevel gears have teeth cut on conical blanks and a gear pair can connect nonparallel
intersecting shafts. bevel gears are used for motor transmission different drives valve
control and mechanism instruments.

3.5.1. Straight Bevel Gear

Straight bevel gears have, as implied in their name, a straight tooth form cut parallel
to the come axis., which if extended would pass through a point of intersection on
the shaft axis. Bevel gears are normally mounted on shafts that are at 90º to each
other, but bevel gears can be designed for other angles. Straight bevel gears can be
noisy due to the abrupt meshing means that there can be a high impact stress if the
teeth are used under heavy loads or at high speeds, ehich can lead to possibility of
tooth breakage and gear failure. Straight bevel usually only suitable for speeds up to
5m/s.

Figure 11: Straight Bevel Gear

3.5.2. Spiral Bevel Gear

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 Spiral bevel gears have curved teeth that are formed along a spiral angle to the cone
axis. The most common spiral angle is 35ºwith a pressure angle of 20º. The
advantage of spiral bevel gears over straight teeth is that the gears engage more
gradually, with contact commencing at one end of the tooth which increases until
there is contact across the full length of the tooth. As a result of the smoother
operation, spiral bevel gears tend to be quieter and can have a smaller diameter for
the same load capacity than straight bevel gears. Spiral bevel gears are
recommended for pitch line speeds in the range from 5 to 40 m/s.

Figure 12: Spiral Bevel Gear

3.5.3. Zerol Bevel Gear

Figure 13: Zerol Bevel Gear

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 Zerol bevel gears have a tooth kind that's snaky however with a zero-spiral angle.
They represent an intermediate category between straight and spiral bevel gears.
Zero gears are generally smoother and quieter than straight bevel gears, but they do
produce side loads.

3.6.Pneumatic Compressor

Figure 14: Pneumatic Compressor

Every compressed-air system begins with a mechanical device - the supply of air
flow for all the downstream instrumentality and processes. The main parameters of
any compressor ar capability, pressure, horsepower, and duty cycle. It is vital to
recollect that capability will the work; pressure affects the speed at that work is
completed. Adjusting Associate in Nursing air compressor's discharge pressure
doesn't modification the compressor's capability - even supposing many of us appear
to believe it'll.

There ar variety of basic compressor styles - and variations of them - on the market
nowadays. They all constitute 2 general categories: positive displacement and
dynamic. Although the in operation specifications for 2 differing types of air
compressors could also be terribly similar on the surface, alternative installation and

xxvii
 performance factors will build one style superior to the other in a real-world
application. Let's review some of the basic designs and terminology.

Reciprocating compressors ar positive-displacement units that lure a charge of air so

physically scale back the area that range it, causing its pressure to increase.
Reciprocating units, commonly called piston compressors, use a piston, cylinder,
and valve arrangement. Their operation is incredibly kind of like the acquainted ICE,
but they simply trap and compress the air without adding fuel to explode it. Note that
whenever air is compressed, heat is generated. Proper cooling of the internal parts of
any air compressor is a critical part of its design.

There ar 3 basic choice choices that has got to be created concerning reciprocatory
compressors:

• single- or double-acting operation,

• single- or multi-stage configuration, and

• air or water cooling.

3.7. SMPS

A switched-mode power offer (SMPS) is Associate in Nursing electronic circuit that

converts power exploitation change devices that ar turned on and off at high
frequencies, and storage components such as inductors or capacitors to provide
power once the change device is in its non-conduction state.

Switching power provides have high potency and ar wide utilized in a spread of
equipment, including computers and other sensitive equipment requiring stable and
efficient power supply.

A switched-mode power offer is additionally referred to as a switch-mode power

offer or switching-mode power offer.

xxviii
Switched-mode power provides ar classified in step with the kind of input and
output voltages. The four major categories are:

• AC to DC

• DC to DC

• DC to AC

• AC to AC

The input DC offer from a rectifier or battery is fed to the electrical converter
wherever it's turned on and off at high frequencies of between twenty kilohertz and
two hundred KHz by the switching MOSFET or power transistors. The high-
frequency voltage pulses from the electrical converter ar fed to the electrical device
coil, and the secondary AC output is rectified and smoothed to produce the required
DC voltages. A electric circuit monitors the output voltage and instructs the
feedback circuit to regulate the duty cycle to keep up the output at the specified
level.

Advantages of switched-mode power supplies:

• Higher efficiency of 68% to 90%

• Regulated and reliable outputs regardless of variations in input supply voltage

• Small size and lighter

• Flexible technology

• High power density

Disadvantages:

• Generates electromagnetic interference

• Complex circuit design

• Expensive compared to linear supplies

xxix
3.8. Relays

Relays square measure the first protection additionally as change devices in most of
the management processes or equipments. All the relays answer one or additional
electrical quantities like voltage or current specified they open or shut the contacts or
circuits. A relay could be a change device because it works to isolate or modification
the state of an electrical circuit from one state to a different.

Classification or the categories of relays rely upon the perform that they're used.
Some of the classes embody protecting, reclosing, regulating, auxiliary and
monitoring relays.

Protective relays ceaselessly monitor these parameters: voltage, current, and power;
and if these parameters violate from set limits they generate alarm or isolate that
particular circuit. These styles of relays square measure accustomed shield
equipments like motors, generators, and transformers, and so on.

Figure 15: Relay Pin Configuration

xxx
3.9. Other Pneumatic Components

3.9.1. FRL Unit – Filter Regulator Lubricator

Figure 16: FLR Unit Description

FRL Operation

It is imperative that a filter, regulator, lubricator (FRL) be employed when running

pneumatic tools. The air should be clean, dry, and lubricated to maximize life and
performance of the pneumatic tool. Maximum pressure for the FRL is 120 psi. Use
Nonfluid Oil® Air Lubricant

This product mixes with water and via the Air Lubricator is introduced as a mist in
the air stream to provide lubrication. Nonfluid lubricating oil is sold by Reed as
UPOIL #97583, 16 ounces.

Operation

Connect the airlines to the FRL. The direction of the air flow is indicated by arrows
on the top of the FRL. With the pneumatic tool connected and in the off position,
turn on the supply air to the FRL. Check the level of fluids in the clear bowls on the
bottom of the Air Filter and Air Lubricator.

xxxi
3.9.2. Solenoid Operated Direction Control Valve

Figure 17: Solenoid Operated DCV

Solenoid operated valves differ from manually and hydraulically pilot-operated

valves in that they are electrically controlled as opposed to using complex
mechanical linkages or bulky hydraulic pilot lines to actuate the valve. Using coil
valves may end up during a a lot of easier installation, with the resulting cost savings
being an additional benefit.

Sun coil operated directional valves area unit utilized in circuits wherever 2-way, 3-
way, and 4-way functions are required. Sun offers each direct acting and pilot
operated, and are available in poppet and spool configurations.

Pilot flow capability valves, rated 0.25 gpm (1 L/min), are available in 2-way and 3-
way functions. Full flow capability valves, rated up to 12 gpm (45 L/min), are
available in 2-way, 3-way, 4-way, and 6-way functions. High capability pilot-
operated valves, rated up to 120 GPM (480 L/min), are available in 2-way, normally
open and normally closed versions. All full flow and high capability versions area
unit accessible with Sun’s 77* series (round) solenoid/coil assemblies. Pilot flow
capability valves are accessible with the smaller 760 series (square) solenoid/coil
assemblies.

xxxii
Chapter 4

4. Overview Behaviour

4.1. Program Flow Chart

Battery

Motor
Drive

Arduino

input

PLC

Arm
Assembly

Gripper

Figure 18: Program Flow Graph

xxxiii
 4.1.1. Arduino Algorithm

Power from Battery Power from USB Port

Actuates Motor Drive Module Actuates Arduino Board

Switch On

Operation

Motor Rotate
Speed j=127.5

Switch Off

Figure 19: Aurdino Flow Graph

xxxiv
Chapter 5

5. Methods and Methodology

5.1.Method

 Theoretical study DENAVIT-HARTENBERG algorithm

 Simulation RoboAnalyzer
 Design and Fabrication
 Components and Fixture design
 Automation using PLC board with the PLC power supply unit and programming the
PLC with all the sensors workability.

5.1.1. Kinematic Study using D-H Algorithm

xxxv
 1 0 0 0.23 0 −1 0 0

[
Link 1=
0 0.724 −0.724 0
0 0.724 0.724 0.055
0 0 0 1
] [
Link 2=
1 0 0 0.35
0 0 1 0.35
0 0 0 1
]
0 −1 0 0

[
Link 3=
1 0 0 0.32
0 0 1
0 0 0
0
1
]
5.1.2. Simulation with Robo-Analyzer

xxxvi
 Figure 20: RoboAnalyzer Output

5.2.Methodology Flow Chart

Literature Survey

Problem
Statement

Theoretical Study Design and Simulation

xxxvii
 D-H Algorithm Robo Analyser

Kinematic Study Position and Orientation

Fabrication

Performance Study

Result and Conclusion

Figure 21: Methodology Flow Chart

5.3. Design

Figure 22:Isometric View of Design Figure 23: Front View of Design

xxxviii
 Figure 24:Top View of Draft Figure 25:Front View of Draft

Figure 26: Side View of Draft

5.4. Fabrication of Robot

Figure 27: Gear Meshing of Fabricated Robot Figure 28: DC Motor of Fabricated Robot

xxxix
 Figure 29: Front View of Robot Stand Figure 30: Side View of Robot Stand

Figure 31: Front View of Arm Assembly Figure 32: Isometric View of Robot Arm Assembly

Chapter 6

6. Construction

6.1. Circuit Diagram

xl
 Figure 33: Circuit Diagram

Chapter 7

xli
7. Programming

7.1. Motor Drive Programming

#include <SoftwareSerial.h>// import the serial library

const int in_1B = 8 ;

const int in_1A = 9 ;

const int in_2A = 7 ;

const int in_2B = 6;

SoftwareSerial Genotronex(13,12); // RX, TX

char BluetoothData; // the data given from Computer

void setup()

pinMode(in_1B, OUTPUT) ; //Logic pins are also set as output

xlii
 pinMode(in_1A, OUTPUT) ; //Logic pins are also set as output

pinMode(in_2A, OUTPUT) ; //Logic pins are also set as output

pinMode(in_2B, OUTPUT) ; //Logic pins are also set as output

Serial.begin(9600);

Genotronex.begin(9600);

void loop()

if (Serial.available())

BluetoothData = Serial.read();

Serial.println(BluetoothData);

if (BluetoothData == 'F') //forward

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 1);

digitalWrite(in_2A, 1);

digitalWrite(in_2B, 0);

if (BluetoothData == 'B') //backward

xliii
 {

digitalWrite(in_1A, 1);

digitalWrite(in_1B, 0);

digitalWrite(in_2A, 0);

digitalWrite(in_2B, 1);

if (BluetoothData == 'R') //long right

digitalWrite(in_1A, 1);

digitalWrite(in_1B, 0);

digitalWrite(in_2A, 1);

digitalWrite(in_2B, 0);

if (BluetoothData == 'L') //long left

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 1);

digitalWrite(in_2A, 0);

xliv
 digitalWrite(in_2B, 1);

if (BluetoothData == 'S') //stop

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 0);

digitalWrite(in_2A, 0);

digitalWrite(in_2B, 0);

if (BluetoothData == 'I') // sharp forward right

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 1);

digitalWrite(in_2A, 1);

digitalWrite(in_2B, 0);

if (BluetoothData == 'G') //sharp forwrd left

xlv
 digitalWrite(in_1A, 1);

digitalWrite(in_1B, 0);

digitalWrite(in_2A, 0);

digitalWrite(in_2B, 1);

if (BluetoothData == 'J') // backward right

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 1);

digitalWrite(in_2A, 0);

digitalWrite(in_2B, 0)

if (BluetoothData == 'H') // backward left

digitalWrite(in_1A, 0);

digitalWrite(in_1B, 0);

digitalWrite(in_2A, 1);

digitalWrite(in_2B, 0);

}}}

Chapter 8

xlvi
 8. Costing

Budget Amount
a) Materials / Consumables 10000.00
b) Labor 500.00
c) Travel 500.00
d) Report 2000.00
e) Miscellaneous 10000.00
Total 14000

Conclusion

The report contains a awfully totally different mixture of studies varied from
software package to hardware. This is AN autonomous mechanism arm with a 3
dimensional reach that might mechanically find ANd decide an object. Then it might
place it during a destination and alter the orientation as mere by the user.

Future Scope
• We can provide voice feedback system.
• We can add camera and sensors to this project.

References

[1] P. Veerabhadram, “Applications of Robots in medicine,” pp. 1-4, 2006.

xlvii
[2] W. Sharpe, Mechanical properties of MEMS materials, CRC Press.

[3] M. F. Ashby, Materials selection in mechanical design, U K: Oxford, 1999.

[4] M. F. A. a. D. Jones, Engineering materials: An introduction to their properties and

applications, U K: Oxford, 1980.

[5] W. D. Nix, Mechanical properties of thin films, 1989.

[6] ASHITAVA GHOSHAL , "Robotics - Fundamental concepts and anlaysis", Dehradun,

2008.

[7] GANESH S HEGDE, "A Text book on Industrial Robotics", Mangalore: Deepthi
Publications, 2004.

[8] M. S. H. Talpur, “"Automation of mobile pick and place robotic system for a small food
industries",” International conference on Robotics, p. 5, 2012.

[9] K. M. MYINT, “"Positiion control method for pick and place robot arm for object sorting
system",” IEEE, p. 6, 2009.

xlviii