Lifting Mechanism or An Autonomous Line Tracking Robot.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
LIFTING MECHANISM FOR AN AUTONOMOUS LINE
TRACKING ROBOT
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours
by
NORRIS EZWAN BIN MOHAMAD NOR
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Lifting Mechanism For An Autonomous Line Tracking Robot
SESI PENGAJIAN: 2008/ 09 Semest er 2
Saya NORRIS EZWAN BIN MOHAMAD NOR
mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i
Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan ( √
)
SULIT
TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tet ap:
Cop Rasmi:
54-S Pauh Lima
16090 Kot a Bharu
Kelant an Darul Naim
Tarikh: _________________________
Tarikh: ____26 MAY 2009____
** Jika Laporan PSM ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi
berkenaan dengan menyat akan sekali sebab dan t empoh laporan PSM ini perlu dikelaskan sebagai
SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled Lifting Mechanism for an Autonomous Line
Tracking Robot is the results of my own research except as cited in references.
Signature
:
Author’s Name
:
Norris Ezwan bin Mohamad Nor
Date
:
22 May 2009
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineeringof UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering ( Robotics and Automation ) with Honours. The member of the
supervisory committee is as follows:
ABSTRACT
The purpose of this project is to design and develop a Gripping and Lifting
Mechanism for an Autonomous Line Tracking Robot for the ROBOCON 2009
competition. This robot will be programmed to move along a white line against a
green background. The robot base will be integrated with a lifting mechanism and
gripper to hold a drumstick to beat drums. The lifting mechanism will act as a
support for the gripper. The project involves data gathering, designing process,
fabricating and microcontroller programming. The design and fabricating phase are
involved in the development phase of the project. By using Solidworks, there are few
different designs are proposed. The best design among them will be chosen to be
fabricated. The mechanical and electronic parts for the project are finally developed.
But due to some technical problems that occur, the integration of the mechanical,
electrical and programming of the robot cannot be tested. Thus, the robot is tested
using direct current to the motor.
i
ABSTRAK
Tujuan projek ini adalah untuk merekabentuk dan membentuk Pencengkam dan
Mekanisma Pengangkat untuk Robot Berpandukan Mengikut Garisan untuk
pertandingan ROBOCON 2009. Robot ini akan diprogramkan supaya bergerak
mengikuti garisan putih yang berlatarkan hijau. Asas robot akan dipasangkan dengan
mekanisma pengangkat dan pencengkam untuk membawa kayu pemukul dram untuk
memukul dram. Mekanisma pengangkat akan bertindak sebagai sokongan bagi
pencengkam. Projek ini melibatkan pengumpulan maklumat, proses merekabentuk,
pembuatan, dan pemprograman microcontroller. Fasa merekabentuk dan pembuatan
adalah terlibat dalam fasa membentuk bagi projek ini. Dengan menggunakan
Solidworks, terdapat beberapa rekabentuk yang berlainan telah dibuat. Kesemua
bahagian mekanikal dan elektrikal untuk robot ini telah siap. Namum disebabkan
masalah teknikal, penggabungan antara mekanikal, elektrikal, dan programming
untuk robot ini tidak dapat diuji. Oleh yang demikian, ujian telah dilakukan dengan
membekalkan arus secara terus kepada motor.
ii
DEDICATION
I dedicate this project to my mother, Normah binti Ahmad for giving a lot of support,
brothers, lecturers and friends in supporting me in finishing this project.
iii
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Table of Content
iv
List of Tables
vii
List of Figures
viii
List Abbreviations
xi
1. INTRODUCTION
1
1.1
Project Background
1
1.2
Problem Statement
2
1.3
Project Aim and Objectives
3
1.4
Scope
3
1.5
Project Benefits
4
2. LITERATURE REVIEW
6
2.1
Robot
6
2.2
Robot Construction
16
2.2.1
Robot Body
16
2.2.2
Power System
21
2.2.2.1
Batteries
21
2.2.2.2
Alternative Power Sources
25
2.2.3
Locomotion System
28
2.2.4
Electric motors
34
2.2.4.1
Types of Motor
35
2.2.5
Sensors
40
2.2.6
End-Effector
44
2.2.7
Lifting mechanism
50
2.2.8
Robot controller
55
2.2.9
Programming algorithm
57
2.3
Previous Projects
59
iv
3. METHODOLOGY
61
3.1
Starting the Project
61
3.2
Planning
62
3.2.1
Project Planning
62
3.2.2
Collecting Project Data
62
3.2.3
Data Analysis
63
3.2.4
Sufficiency
63
3.3
Designing
64
3.3.1
Designing Project
64
3.3.2
Part Selection
65
3.4
Construction
65
3.4.1
Fabrication
66
3.4.2
Robot Assembly
66
3.4.3
Robot Programming
66
3.4.4
Testing
67
3.5
Project End
67
4. DESIGN AND DEVELOPMENT
69
4.1
Designing
69
4.1.1
Base design
70
4.1.2
Design of The Lifting Mechanism
74
4.1.3
Design Summary
77
4.2
Developing the Robot Structure
78
4.2.1
Robot Mechanical Structure
78
4.2.2
Electrical Circuit
81
4.2.3
Programming Algorithm
86
4.3
Integration
89
5. TESTING AND ANALYSIS
91
5.1
Line Tracking Test
91
5.1.1
Sensor and Circuit Test
91
5.1.2
Robot Line Tracking Capability Test
95
5.2
Drum Beating Test
97
5.3
Result Analysis
99
v
6. DISCUSSION AND CONCLUSION
101
6.1
Discussion
101
6.2
Conclusion
102
6.3
Suggestion
102
REFERENCE
104
APPENDICES
106
vi
LIST OF TABLE
Table 2.1:
Type of industrial robot
9
Table 2.2:
Type of skeletal structure
17
Table 2.3:
Different types and shapes that a robot can be build with
19
Table 2.4:
Type of disposable batteries available in the market
22
Table 2.5:
Type of rechargeable batteries available in the market
23
Table 2.6:
Several robot type with different number of legs
31
Table 2.7:
Different type of available of DC motors
36
Table 2.8:
Several distinctions based on method of control for AC electric
motors
38
Table 2.9:
Types of AC motors
39
Table 2.10:
Type of sensor available in the industries
41
Table 2.11:
Classification of gripper principles of function according to form-fit
and force-fit options.
46
Table 2.12:
Option for contact surface design
47
Table 2.13:
Range of gripping option
48
Table 2.14:
Gripper types categorized by principle of drive
49
Table 2.15:
Types of lever class
51
Table 2.16:
Element of a microcontroller based on “The Microcontroller
Beginner’s Handbook” by Lawrence A. Duarte, a PROMPT
Publications.
56
Table 2.17:
Three main type of programming language
58
Table 4.1:
Method used in designing
69
Table 4.2:
Base design summary
76
Table 4.3:
Lifting mechanism summary
76
Table 4.4:
The PCB etching process
81
Table 4.5:
Steps in soldering components on a PCB
83
vii
LIST OF FIGURES
Figure 2.1:
Industrial robot in car production doing vehicle under body assembly 7
Figure 2.2:
The figure shows several AGVs loading and unloading good to their
respective destination
Figure 2.3:
12
Strawberry picking robot is one of the agriculture robot that exists in
the world today
Figure 2.4:
13
Telerobot is one of the tools used in a complicated and delicated
surgery that normal doctor use
14
Figure 2.5:
A military robot equip with guns and camera vision
15
Figure 2.6:
Roomba robot is one of the household robot used as a vacuum cleaner
developed by iRobot
15
Figure 2.7:
Different type and size of batteries
21
Figure 2.8:
This figure shows the ultra high pressure system used to develop
piezoelectric damping materials
26
Figure 2.9:
Modern wind turbine for utility scale power generation
27
Figure 2.10:
Photovoltaic module in sunlight generates direct current electricity
28
Figure 2.11:
Autonomous robot with wheels integrated with a Personal Digital
Figure 2.12:
Assistant
29
MiniROC developed using tracks as locomotion system.
34
Figure 2.13: Sequence on how a three bar magnet in a motor repel and attract
Figure 2.14:
When rotates A (input), the rope will coil over B and thus bringing
wheel C and weight up
Figure 2.15:
52
When effort applied in the input, the pulley A will rotate making it
easier to lift the weight.
Figure 2.16:
52
Example of an inclined plane. When effort (input) given to weight
from left, the weight will move to right (output).
Figure 2.17:
53
When block A move to right, the inclined plane of the block will push
block B and the weight upwards while block C is fixed.
Figure 2.18:
35
54
When the knob is rotate (input), the screw A will rotate and screw B
with the opposing thread will rotate upward thus lifting the weight
Figure 2.29:
below.
54
Visual navigated vehicle system using white line recognition
59
viii
Figure 2.20:
The miniature mobile robot Khepera
60
Figure 3.1:
Basic operation flow chart.
61
Figure 3.2:
Project planning elements.
62
Figure 3.3:
(a) Solidworks software for mechanical design; (b) PCBexpress
software for electric circuit board design.
64
Figure 3.4:
MPLAB programming software for microcontroller programming.
66
Figure 3.5:
Detailed process flow chart.
67
Figure 4.1:
Designing as an iterative procedure
68
Figure 4.2:
Base design 1.
70
Figure 4.3:
KHEPERA by LAMI (Laboratoire de Microinfomatique)
70
Figure 4.4:
Base design 2.
71
Figure 4.5:
Autonomous light finder robot
71
Figure 4.6:
Base design 3
72
Figure 4.7:
Y-shape wall climbing robot
72
Figure 4.8:
Catapult design
73
Figure 4.9:
Catapult used in medieval era using the simple machine lever.
74
Figure 4.10:
Spinning Tower Design
74
Figure 4.11:
Totem pole
75
Figure 4.12:
Elevator Design
75
Figure 4.13:
Rotating restaurant tower.
76
Figure 4.14:
Sensor circuit
84
Figure 4.15:
Comparator LED-LRD circuit
84
Figure 4.16:
Power regulator circuit
84
Figure 4.17:
Circuit connected to battery
85
Figure 4.18:
Subprogram for line tracking: defining variables
86
Figure 4.19:
Subprogram for line tracking: programming for the sensor
87
Figure 4.20:
Final integration of robot mechanical structure
89
Figure 5.1:
The center of the sensor is placed on the white line
91
Figure 5.2:
Moving the sensor from left to right
92
Figure 5.3:
LDR L1, L2 and L3 is on the white line
92
Figure 5.4:
LDR L1, C and R1 is on the white line
93
ix
Figure 5.5:
LDR R1, R2 and R3 is on the white line
93
Figure 5.6:
LDR R3 is on the white line
94
Figure 5.7:
Robot at starting point
94
Figure 5.8:
Robot sensor placing on the white line checked using the comparator 95
Figure 5.9:
This figure shows that the robot diverted to the left side
95
Figure 5.10:
Robot turn to the right
96
Figure 5.11:
Initial condition of the lifting mechanisms
96
Figure 5.12:
The first lifting mechanism movement
97
Figure 5.13:
The second lifting mechanism rotates
97
Figure 5.14:
The third lifting is used to beat the top and bottom drums
98
Figure 5.15:
The middle drumstick beat the drum
98
x
LIST OF ABBREVIATIONS
ASIMO
-
Artificial Intelligence Robot
SGV
-
Self Guided Vehicles
AGV
-
Automated Guided Vehicles
UGV
-
Unmanned Ground Vehicles
SCARA
-
Selective Compliance Assembly Robot Arm
RAM
-
Random Access Memory
NASA
-
National Aeronautics and Space Administration
NiCd
-
Nickel Cadmium
AC
-
Alternating Current
DC
-
Direct Current
Pv
-
Photovoltaic
kW
-
Kilowatt
kWh
-
Kilowatt per hour
MW
-
Megawatt
LED
-
Light Emitting Diode
LDR
-
Light Dependent Resistor
FKP
-
Fakulti Kejuruteraan Pembuatan
UTeM
-
Universiti Teknikal Malaysia Melaka
ROBOCON
-
Robot Contest
xi
CHAPTER 1
INTRODUCTION
This chapter focuses on the introduction of the project. Introduction of the project
includes the project background, problem statement of the project, objectives, project
scope, and the benefits of the project.
1.1
Project Background
A robot is a device consisting of a motor and a computer-controlled mechanism that can
be programmed to do a variety of tasks and works automatically. Once the robot is
programmed, it can perform its tasks without any human supervision. There is various
type of robots available today. They are divided into three main types which is the
experimental robot, special purpose robot and the general purpose robot. The general
purpose robot is divided into the industrial robot and the service robot. The autonomous
robot that will be developed in this project is a service type of robot under the general
purpose robot type.
The two main focus of this project are on the navigation of the robot and the design and
development of the lifting mechanism for the robot. The robot is an autonomous type
where it will be pre-programmed using microcontroller program. The robot will move
from one point to another to perform specified tasks. The design of the lifting
mechanism of the robot depends on the task given. The robot will hold drumsticks so it
can beat drums with it. The lifting mechanism will be used to lift the drumsticks so it is
at the level where the drumstick can reach the drums. This is to enable the robot to beat
1
the drums. The robot will have to travel from starting point to the location of the drums
to beat the drums.
This autonomous robot will be navigated using line following method. The line
following is based on sensors that will sense and react to follow a line as a way or a road
for the robot to move from one point to another. The line is acts as a guide for the robot.
The line is a white tape with 30mm wide and located on a specific field built from vinyl
sheet which is dark in color. The contrast color of both the white tape and the dark color
field will factor for the robot to move along the white line.
1.2
Problem Statement
For the past years, several line following autonomous robots had been built and
available in the laboratory but so far none of them is suitable to perform the tasks stated
in the ROBOCON 2009 rule book. In the rule book, it is stated that the robot gripper will
need to hold at least one drumstick to beat all the three drums. The problems that need to
be concern are:
(a)
Unsuitable robot base size
The line following robot base made for the previous ROBOCON is not suitable to be
used for the current ROBOCON theme that it require a smaller sized robot. The
maximum size of the robot base is 420mm × 500mm.
(b)
Programming algorithm
The available line following robot is only programmed for the task of ROBOCON 2008
and not programmed for the task of ROBOCON 2009.
2
(c)
Unsuitable lifting mechanism
The existing lifting mechanism is not proper to lift the drumstick and to complete the
task of beating the drums.
1.3
Project Aim and Objectives
The aim of this project is to build an autonomous line tracking robot with a lifting
mechanism holding 3 drumsticks. This is according to the specifications of a traveler
robot to compete in the ROBOCON 2009 competition.
To achieve this, these objectives need to be fulfilled:
(a)
To design and develop an autonomous robot consisting of a lifting mechanism
and a line following robot base for ROBOCON 2009
(b)
To develop electric circuit hardware that is able to integrate the sensors and
electric motors with microcontroller for the robot base
(c)
1.4
To program the robot to achieve line following task
Scope
The scope of this project includes:
(a)
Lifting device
The lifting device will be build depending on the task of ROBOCON 2009. The lifting
device should be able to lift the drumstick to the point of reaching the conter of the drum
so that the drumstick can beat the drum. The lifting device can lift two drumstick at one
time to cut the time of beating all the three drums.
3
(b)
Line following robot base
The line following robot base will be built with focusing the precision of the movement.
The speed will also be the main issue when building the robot base.
(c)
Electronic circuit
An electronic circuit is built with the function that integrate the sensors and major
consideration for ease of repair
(d)
Programming
The robot programming will be developed according to the ROBOCON 2009
requirements of a traveler robot will different strategies to achieve the defined task
1.5
Project Benefits
The project is beneficial to several entities including:
(a)
Industries
The autonomous robot can be an early stage for mobile industrial mechanical robot arm.
This technology can automate and thus reducing the use of forklifts or pallet jack that
need man power to operate it.
4
(b)
Environment
This robot only uses battery power to operate it. It does not consume oil or petrol like a
forklift does. It is environment friendly and safe from any hazardous chemical.
(c)
People
In the future, the mobile robot technology wills benefits people’s lives that are going to
become more futuristic, surrounded by automated machines.
5
CHAPTER 2
LITERATURE RIVIEW
This chapter focuses on the data collecting from various resources for the project.
Previous project that almost resembles this project is also discusses here.
2.1
Robot
A book Published by Macmillan, 1985 entitle ‘Introduction to Robotics’ written by
Arthur J. Critchl tells that in Czech language, the word “robota” means a worker
providing compulsory service, forced labor, or work. The robot is built with the
capability of performing a various type of human tasks. It is a mechanical device that is
capable of being programmed to do a task automatically. Once it is programmed, the
human operator do not need of operating the machine because the robot only needs
supervision from time to time and not the whole time. Most robots are built that
resembles an anthropomorphic (human-like) appearance. It is a special combination of
motors, solenoids, wires, and assorted electronic odd ends. It is a mechanical that is
integrated with electrical components. Most robots nowadays have five important
capabilities which is:
(a)
To move from one point to another point.
(b)
To be able to handle any sorts of objects.
(c)
To be able to reprogram
(d)
Built multifunctional
(e)
Practical and efficient for different environments
6
The creators of robot have long creating and manipulating with the idea of robots, a term
that can broadly be defined as an artificial human being. In the past years, humans only
fantasized about them but today, many types of robots are a reality built to serve
mankind. For example, there are industrial robots, toy robots that entertain us,
exploration robots, medical robots, robots used in agriculture, to increasingly humanoid
robots being created for the service sector, whether helping with the manufacturers in
some industry, to do some chores in the home or as caregivers for the elderly and the
handicapped. Given below are some of the types of robots that have been conceived:
(a)
Industrial Robots
Figure 2.1: Industrial robot in car production doing vehicle under body assembly
(courtesy of
http://people.msoe.edu/~alhubaila/images/Industrial_Robotics_in_car_production.jpg)
Most of the industry today utilized robots in manufacturing products. Any job that
involves accuracy, speed, repitative, endurance, and reliability is done by robots. This is
7
because humans are fatigue. The use of robot in the industry is increasing to increase the
productivity of products. Industrial robots are an electro-mechanical device that
comprising of mechanical structure of cast and fabricated construction. It is also an
independent servo system that is able to power each axis. It is integrated to a computer
based controller used to control the program for the robot. All programs can be stored in
the hard drive and RAM of the robots that is available. Most of them have hand tooling
or a gripper system integrated along the robot arm. There are different types of industrial
robots available which is common in the industries. These types are
8
LIFTING MECHANISM FOR AN AUTONOMOUS LINE
TRACKING ROBOT
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours
by
NORRIS EZWAN BIN MOHAMAD NOR
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Lifting Mechanism For An Autonomous Line Tracking Robot
SESI PENGAJIAN: 2008/ 09 Semest er 2
Saya NORRIS EZWAN BIN MOHAMAD NOR
mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i
Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan ( √
)
SULIT
TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tet ap:
Cop Rasmi:
54-S Pauh Lima
16090 Kot a Bharu
Kelant an Darul Naim
Tarikh: _________________________
Tarikh: ____26 MAY 2009____
** Jika Laporan PSM ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi
berkenaan dengan menyat akan sekali sebab dan t empoh laporan PSM ini perlu dikelaskan sebagai
SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled Lifting Mechanism for an Autonomous Line
Tracking Robot is the results of my own research except as cited in references.
Signature
:
Author’s Name
:
Norris Ezwan bin Mohamad Nor
Date
:
22 May 2009
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineeringof UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering ( Robotics and Automation ) with Honours. The member of the
supervisory committee is as follows:
ABSTRACT
The purpose of this project is to design and develop a Gripping and Lifting
Mechanism for an Autonomous Line Tracking Robot for the ROBOCON 2009
competition. This robot will be programmed to move along a white line against a
green background. The robot base will be integrated with a lifting mechanism and
gripper to hold a drumstick to beat drums. The lifting mechanism will act as a
support for the gripper. The project involves data gathering, designing process,
fabricating and microcontroller programming. The design and fabricating phase are
involved in the development phase of the project. By using Solidworks, there are few
different designs are proposed. The best design among them will be chosen to be
fabricated. The mechanical and electronic parts for the project are finally developed.
But due to some technical problems that occur, the integration of the mechanical,
electrical and programming of the robot cannot be tested. Thus, the robot is tested
using direct current to the motor.
i
ABSTRAK
Tujuan projek ini adalah untuk merekabentuk dan membentuk Pencengkam dan
Mekanisma Pengangkat untuk Robot Berpandukan Mengikut Garisan untuk
pertandingan ROBOCON 2009. Robot ini akan diprogramkan supaya bergerak
mengikuti garisan putih yang berlatarkan hijau. Asas robot akan dipasangkan dengan
mekanisma pengangkat dan pencengkam untuk membawa kayu pemukul dram untuk
memukul dram. Mekanisma pengangkat akan bertindak sebagai sokongan bagi
pencengkam. Projek ini melibatkan pengumpulan maklumat, proses merekabentuk,
pembuatan, dan pemprograman microcontroller. Fasa merekabentuk dan pembuatan
adalah terlibat dalam fasa membentuk bagi projek ini. Dengan menggunakan
Solidworks, terdapat beberapa rekabentuk yang berlainan telah dibuat. Kesemua
bahagian mekanikal dan elektrikal untuk robot ini telah siap. Namum disebabkan
masalah teknikal, penggabungan antara mekanikal, elektrikal, dan programming
untuk robot ini tidak dapat diuji. Oleh yang demikian, ujian telah dilakukan dengan
membekalkan arus secara terus kepada motor.
ii
DEDICATION
I dedicate this project to my mother, Normah binti Ahmad for giving a lot of support,
brothers, lecturers and friends in supporting me in finishing this project.
iii
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Table of Content
iv
List of Tables
vii
List of Figures
viii
List Abbreviations
xi
1. INTRODUCTION
1
1.1
Project Background
1
1.2
Problem Statement
2
1.3
Project Aim and Objectives
3
1.4
Scope
3
1.5
Project Benefits
4
2. LITERATURE REVIEW
6
2.1
Robot
6
2.2
Robot Construction
16
2.2.1
Robot Body
16
2.2.2
Power System
21
2.2.2.1
Batteries
21
2.2.2.2
Alternative Power Sources
25
2.2.3
Locomotion System
28
2.2.4
Electric motors
34
2.2.4.1
Types of Motor
35
2.2.5
Sensors
40
2.2.6
End-Effector
44
2.2.7
Lifting mechanism
50
2.2.8
Robot controller
55
2.2.9
Programming algorithm
57
2.3
Previous Projects
59
iv
3. METHODOLOGY
61
3.1
Starting the Project
61
3.2
Planning
62
3.2.1
Project Planning
62
3.2.2
Collecting Project Data
62
3.2.3
Data Analysis
63
3.2.4
Sufficiency
63
3.3
Designing
64
3.3.1
Designing Project
64
3.3.2
Part Selection
65
3.4
Construction
65
3.4.1
Fabrication
66
3.4.2
Robot Assembly
66
3.4.3
Robot Programming
66
3.4.4
Testing
67
3.5
Project End
67
4. DESIGN AND DEVELOPMENT
69
4.1
Designing
69
4.1.1
Base design
70
4.1.2
Design of The Lifting Mechanism
74
4.1.3
Design Summary
77
4.2
Developing the Robot Structure
78
4.2.1
Robot Mechanical Structure
78
4.2.2
Electrical Circuit
81
4.2.3
Programming Algorithm
86
4.3
Integration
89
5. TESTING AND ANALYSIS
91
5.1
Line Tracking Test
91
5.1.1
Sensor and Circuit Test
91
5.1.2
Robot Line Tracking Capability Test
95
5.2
Drum Beating Test
97
5.3
Result Analysis
99
v
6. DISCUSSION AND CONCLUSION
101
6.1
Discussion
101
6.2
Conclusion
102
6.3
Suggestion
102
REFERENCE
104
APPENDICES
106
vi
LIST OF TABLE
Table 2.1:
Type of industrial robot
9
Table 2.2:
Type of skeletal structure
17
Table 2.3:
Different types and shapes that a robot can be build with
19
Table 2.4:
Type of disposable batteries available in the market
22
Table 2.5:
Type of rechargeable batteries available in the market
23
Table 2.6:
Several robot type with different number of legs
31
Table 2.7:
Different type of available of DC motors
36
Table 2.8:
Several distinctions based on method of control for AC electric
motors
38
Table 2.9:
Types of AC motors
39
Table 2.10:
Type of sensor available in the industries
41
Table 2.11:
Classification of gripper principles of function according to form-fit
and force-fit options.
46
Table 2.12:
Option for contact surface design
47
Table 2.13:
Range of gripping option
48
Table 2.14:
Gripper types categorized by principle of drive
49
Table 2.15:
Types of lever class
51
Table 2.16:
Element of a microcontroller based on “The Microcontroller
Beginner’s Handbook” by Lawrence A. Duarte, a PROMPT
Publications.
56
Table 2.17:
Three main type of programming language
58
Table 4.1:
Method used in designing
69
Table 4.2:
Base design summary
76
Table 4.3:
Lifting mechanism summary
76
Table 4.4:
The PCB etching process
81
Table 4.5:
Steps in soldering components on a PCB
83
vii
LIST OF FIGURES
Figure 2.1:
Industrial robot in car production doing vehicle under body assembly 7
Figure 2.2:
The figure shows several AGVs loading and unloading good to their
respective destination
Figure 2.3:
12
Strawberry picking robot is one of the agriculture robot that exists in
the world today
Figure 2.4:
13
Telerobot is one of the tools used in a complicated and delicated
surgery that normal doctor use
14
Figure 2.5:
A military robot equip with guns and camera vision
15
Figure 2.6:
Roomba robot is one of the household robot used as a vacuum cleaner
developed by iRobot
15
Figure 2.7:
Different type and size of batteries
21
Figure 2.8:
This figure shows the ultra high pressure system used to develop
piezoelectric damping materials
26
Figure 2.9:
Modern wind turbine for utility scale power generation
27
Figure 2.10:
Photovoltaic module in sunlight generates direct current electricity
28
Figure 2.11:
Autonomous robot with wheels integrated with a Personal Digital
Figure 2.12:
Assistant
29
MiniROC developed using tracks as locomotion system.
34
Figure 2.13: Sequence on how a three bar magnet in a motor repel and attract
Figure 2.14:
When rotates A (input), the rope will coil over B and thus bringing
wheel C and weight up
Figure 2.15:
52
When effort applied in the input, the pulley A will rotate making it
easier to lift the weight.
Figure 2.16:
52
Example of an inclined plane. When effort (input) given to weight
from left, the weight will move to right (output).
Figure 2.17:
53
When block A move to right, the inclined plane of the block will push
block B and the weight upwards while block C is fixed.
Figure 2.18:
35
54
When the knob is rotate (input), the screw A will rotate and screw B
with the opposing thread will rotate upward thus lifting the weight
Figure 2.29:
below.
54
Visual navigated vehicle system using white line recognition
59
viii
Figure 2.20:
The miniature mobile robot Khepera
60
Figure 3.1:
Basic operation flow chart.
61
Figure 3.2:
Project planning elements.
62
Figure 3.3:
(a) Solidworks software for mechanical design; (b) PCBexpress
software for electric circuit board design.
64
Figure 3.4:
MPLAB programming software for microcontroller programming.
66
Figure 3.5:
Detailed process flow chart.
67
Figure 4.1:
Designing as an iterative procedure
68
Figure 4.2:
Base design 1.
70
Figure 4.3:
KHEPERA by LAMI (Laboratoire de Microinfomatique)
70
Figure 4.4:
Base design 2.
71
Figure 4.5:
Autonomous light finder robot
71
Figure 4.6:
Base design 3
72
Figure 4.7:
Y-shape wall climbing robot
72
Figure 4.8:
Catapult design
73
Figure 4.9:
Catapult used in medieval era using the simple machine lever.
74
Figure 4.10:
Spinning Tower Design
74
Figure 4.11:
Totem pole
75
Figure 4.12:
Elevator Design
75
Figure 4.13:
Rotating restaurant tower.
76
Figure 4.14:
Sensor circuit
84
Figure 4.15:
Comparator LED-LRD circuit
84
Figure 4.16:
Power regulator circuit
84
Figure 4.17:
Circuit connected to battery
85
Figure 4.18:
Subprogram for line tracking: defining variables
86
Figure 4.19:
Subprogram for line tracking: programming for the sensor
87
Figure 4.20:
Final integration of robot mechanical structure
89
Figure 5.1:
The center of the sensor is placed on the white line
91
Figure 5.2:
Moving the sensor from left to right
92
Figure 5.3:
LDR L1, L2 and L3 is on the white line
92
Figure 5.4:
LDR L1, C and R1 is on the white line
93
ix
Figure 5.5:
LDR R1, R2 and R3 is on the white line
93
Figure 5.6:
LDR R3 is on the white line
94
Figure 5.7:
Robot at starting point
94
Figure 5.8:
Robot sensor placing on the white line checked using the comparator 95
Figure 5.9:
This figure shows that the robot diverted to the left side
95
Figure 5.10:
Robot turn to the right
96
Figure 5.11:
Initial condition of the lifting mechanisms
96
Figure 5.12:
The first lifting mechanism movement
97
Figure 5.13:
The second lifting mechanism rotates
97
Figure 5.14:
The third lifting is used to beat the top and bottom drums
98
Figure 5.15:
The middle drumstick beat the drum
98
x
LIST OF ABBREVIATIONS
ASIMO
-
Artificial Intelligence Robot
SGV
-
Self Guided Vehicles
AGV
-
Automated Guided Vehicles
UGV
-
Unmanned Ground Vehicles
SCARA
-
Selective Compliance Assembly Robot Arm
RAM
-
Random Access Memory
NASA
-
National Aeronautics and Space Administration
NiCd
-
Nickel Cadmium
AC
-
Alternating Current
DC
-
Direct Current
Pv
-
Photovoltaic
kW
-
Kilowatt
kWh
-
Kilowatt per hour
MW
-
Megawatt
LED
-
Light Emitting Diode
LDR
-
Light Dependent Resistor
FKP
-
Fakulti Kejuruteraan Pembuatan
UTeM
-
Universiti Teknikal Malaysia Melaka
ROBOCON
-
Robot Contest
xi
CHAPTER 1
INTRODUCTION
This chapter focuses on the introduction of the project. Introduction of the project
includes the project background, problem statement of the project, objectives, project
scope, and the benefits of the project.
1.1
Project Background
A robot is a device consisting of a motor and a computer-controlled mechanism that can
be programmed to do a variety of tasks and works automatically. Once the robot is
programmed, it can perform its tasks without any human supervision. There is various
type of robots available today. They are divided into three main types which is the
experimental robot, special purpose robot and the general purpose robot. The general
purpose robot is divided into the industrial robot and the service robot. The autonomous
robot that will be developed in this project is a service type of robot under the general
purpose robot type.
The two main focus of this project are on the navigation of the robot and the design and
development of the lifting mechanism for the robot. The robot is an autonomous type
where it will be pre-programmed using microcontroller program. The robot will move
from one point to another to perform specified tasks. The design of the lifting
mechanism of the robot depends on the task given. The robot will hold drumsticks so it
can beat drums with it. The lifting mechanism will be used to lift the drumsticks so it is
at the level where the drumstick can reach the drums. This is to enable the robot to beat
1
the drums. The robot will have to travel from starting point to the location of the drums
to beat the drums.
This autonomous robot will be navigated using line following method. The line
following is based on sensors that will sense and react to follow a line as a way or a road
for the robot to move from one point to another. The line is acts as a guide for the robot.
The line is a white tape with 30mm wide and located on a specific field built from vinyl
sheet which is dark in color. The contrast color of both the white tape and the dark color
field will factor for the robot to move along the white line.
1.2
Problem Statement
For the past years, several line following autonomous robots had been built and
available in the laboratory but so far none of them is suitable to perform the tasks stated
in the ROBOCON 2009 rule book. In the rule book, it is stated that the robot gripper will
need to hold at least one drumstick to beat all the three drums. The problems that need to
be concern are:
(a)
Unsuitable robot base size
The line following robot base made for the previous ROBOCON is not suitable to be
used for the current ROBOCON theme that it require a smaller sized robot. The
maximum size of the robot base is 420mm × 500mm.
(b)
Programming algorithm
The available line following robot is only programmed for the task of ROBOCON 2008
and not programmed for the task of ROBOCON 2009.
2
(c)
Unsuitable lifting mechanism
The existing lifting mechanism is not proper to lift the drumstick and to complete the
task of beating the drums.
1.3
Project Aim and Objectives
The aim of this project is to build an autonomous line tracking robot with a lifting
mechanism holding 3 drumsticks. This is according to the specifications of a traveler
robot to compete in the ROBOCON 2009 competition.
To achieve this, these objectives need to be fulfilled:
(a)
To design and develop an autonomous robot consisting of a lifting mechanism
and a line following robot base for ROBOCON 2009
(b)
To develop electric circuit hardware that is able to integrate the sensors and
electric motors with microcontroller for the robot base
(c)
1.4
To program the robot to achieve line following task
Scope
The scope of this project includes:
(a)
Lifting device
The lifting device will be build depending on the task of ROBOCON 2009. The lifting
device should be able to lift the drumstick to the point of reaching the conter of the drum
so that the drumstick can beat the drum. The lifting device can lift two drumstick at one
time to cut the time of beating all the three drums.
3
(b)
Line following robot base
The line following robot base will be built with focusing the precision of the movement.
The speed will also be the main issue when building the robot base.
(c)
Electronic circuit
An electronic circuit is built with the function that integrate the sensors and major
consideration for ease of repair
(d)
Programming
The robot programming will be developed according to the ROBOCON 2009
requirements of a traveler robot will different strategies to achieve the defined task
1.5
Project Benefits
The project is beneficial to several entities including:
(a)
Industries
The autonomous robot can be an early stage for mobile industrial mechanical robot arm.
This technology can automate and thus reducing the use of forklifts or pallet jack that
need man power to operate it.
4
(b)
Environment
This robot only uses battery power to operate it. It does not consume oil or petrol like a
forklift does. It is environment friendly and safe from any hazardous chemical.
(c)
People
In the future, the mobile robot technology wills benefits people’s lives that are going to
become more futuristic, surrounded by automated machines.
5
CHAPTER 2
LITERATURE RIVIEW
This chapter focuses on the data collecting from various resources for the project.
Previous project that almost resembles this project is also discusses here.
2.1
Robot
A book Published by Macmillan, 1985 entitle ‘Introduction to Robotics’ written by
Arthur J. Critchl tells that in Czech language, the word “robota” means a worker
providing compulsory service, forced labor, or work. The robot is built with the
capability of performing a various type of human tasks. It is a mechanical device that is
capable of being programmed to do a task automatically. Once it is programmed, the
human operator do not need of operating the machine because the robot only needs
supervision from time to time and not the whole time. Most robots are built that
resembles an anthropomorphic (human-like) appearance. It is a special combination of
motors, solenoids, wires, and assorted electronic odd ends. It is a mechanical that is
integrated with electrical components. Most robots nowadays have five important
capabilities which is:
(a)
To move from one point to another point.
(b)
To be able to handle any sorts of objects.
(c)
To be able to reprogram
(d)
Built multifunctional
(e)
Practical and efficient for different environments
6
The creators of robot have long creating and manipulating with the idea of robots, a term
that can broadly be defined as an artificial human being. In the past years, humans only
fantasized about them but today, many types of robots are a reality built to serve
mankind. For example, there are industrial robots, toy robots that entertain us,
exploration robots, medical robots, robots used in agriculture, to increasingly humanoid
robots being created for the service sector, whether helping with the manufacturers in
some industry, to do some chores in the home or as caregivers for the elderly and the
handicapped. Given below are some of the types of robots that have been conceived:
(a)
Industrial Robots
Figure 2.1: Industrial robot in car production doing vehicle under body assembly
(courtesy of
http://people.msoe.edu/~alhubaila/images/Industrial_Robotics_in_car_production.jpg)
Most of the industry today utilized robots in manufacturing products. Any job that
involves accuracy, speed, repitative, endurance, and reliability is done by robots. This is
7
because humans are fatigue. The use of robot in the industry is increasing to increase the
productivity of products. Industrial robots are an electro-mechanical device that
comprising of mechanical structure of cast and fabricated construction. It is also an
independent servo system that is able to power each axis. It is integrated to a computer
based controller used to control the program for the robot. All programs can be stored in
the hard drive and RAM of the robots that is available. Most of them have hand tooling
or a gripper system integrated along the robot arm. There are different types of industrial
robots available which is common in the industries. These types are
8