Design A Up Side Down Robot Gripper.
i Faculty Of Electrical Engineering
Universiti Teknikal Malaysia Melaka
DESIGN A UP SIDE DOWN ROBOT GRIPPER SITI ZULAIHA BINTI YUSOFF
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ii “I hereby declared that I have read through this report and found that it has comply the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering
(Power Electronic and Drive)
Signature : ………
Supervisor’s Name : EN FARIZ BIN ALI @ IBRAHIM
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iii “I hereby that this report is a result of my own work except for the excepts that have
been cited clearly in the references”
Signature : ………
Name : SITI ZULAIHA BINTI YUSOFF Date : 7 MEI 2008
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iv ABSTRACT
Robot is usually using in industries technology especially in heavy industries. Robot is popular by replacing human to do some work who is dangerous to do by human, for example is chemical work, Electro Static Discharge (ESD) working area, lift heavy thing and many more. So, when using the robot we can do everything without any obstacle. The chemical work will bring unhealthy environment and threaten our operator when handle the chemical work. It gives some trouble when they have to lift for mixed up the chemical in the mixture for produce product. Its look simple work, but the work is danger for human. In other case, it will bring bad feedback for human body. The above case bring uncomfortable and danger situation on the working area. This up side down robot gripper will solve the problem. The up side down robot gripper is design for liquid pour application in and o complete task for Robocon to score point easily. The special criteria for this robot compare with others gripper robot is this robot can rotate the wrist and pour liquid. The other gripper robot only can move up side down and grip thing. The function of this robot is lift up and pour the liquid or chemical. The gripper will grip the can of liquid and lift it up and the robot wrist will rotate 180 degrees to pour the liquid. Power window motor use in this robot for up side down movement. The stepper motor help the gripper to grip the can. Through this robot, hopefully the liquid pour application will be improve to make working area more safety for our workers.
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v ABSTRAK
Robot biasanya digunakan dalam teknologi industri terutama di dalam industri berat. Robot adalah popular bagi menggantikan manusia untuk melakukan beberapa kerja yang adalah berbahaya untuk dilakukan oleh manusia, sebagai contoh adalah kerja kimia, kawasan kerja yang sensitive kepada charge,Electro Static Discharge (ESD), mengangkat barang berat dan banyak lagi. Dengan kehadiran robot, manusia boleh melakukan segala-galanya tanpa sebarang halangan. Kerja kimia akan membawa tidak sihat terhadap alam sekitar dan mengancam pengendali apabila melakukan kerja kimia. Ia memberi kesan buruk terhadap mereka yang terpaksa melakukan kerja kimia untuk menghasilkan produk. Ia nampak mudah tetapi sebenarnya kerja itu adalah sangat merbahaya untuk manusia. Dalam hal lain, ia akan membawa kesan yang tidak baik untuk badan manusia. Kes di atas memberi keadaan tidak selesa dan keadaan bahaya di kawasan kerja. Up side down robot gripper akan menyelesaikan masalah ini. Up side down robot gripper adalah direka bentuk untuk mengatasi masalah penuangan cecair dalam industry berat dan melengkapkan untuk Robocon untuk mendapat markah dengan mudah. Kriteria khas untuk perbandingan robot ini dengan lain-lain gripper robot adalah robot ini boleh memutar pergelangan tangan dan menuang cair. Lain- lain gripper robot hanya boleh mengangkat dan cengkaman benda. Fungsi robot ini adalah untuk mengangkat dan menuang cecair ataupun bahan kimia. Gripper cengkaman akan mengangkat cecair dan pergelangan robot akan berputar sebanyak 180 darjah untuk menuang cecair. Penggunaan motor tingkap kuasa dalam robot ini adalah untuk pergerakan atas, bawah,kedepan, belakang, kiri dan kanan.Motor peringkat juga digunakan untuk gripper mencengkam sesuatu benda. Melalui robot ini, semoga aplikasi menuang cecair akan bertambah baiki untuk memberi perlindungan yang lebih pada kawasan kerja serta pekerja-pekerja.
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TABLE OF CONTENT
CHAPTER TOPIC PAGES
PROJECT TITLE CONFESSION
i ii
ABSTRACT iii
ABSTRAK iv
TABLE OF CONTENT v
LIST OF FIGURE vi
LIST OF APPENDIX viii
INTRODUCTION
I Introduction 1
1.1 Problem Statement 2
1.2 Project Objective 2
1.3 1.4
Scope of Project Methodology Project
3 3
II
LITERATURE REVIEW Introduction
6 2.1
2.2
Gripper Robot Background The Similarities Case Study
7 8
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2.2.2 Canada Arm 2.2.3 Articulated Robot 2.2.4 Vision Arm
9 10 10 III 3.1 3.2 3.3
METHODOLOGY AND RESEARCH General Methodology Literature Review Hardware Development 12 14 14 IV 4.1 4.2 4.3 4.4 4.5 4.6
SOFTWARE DEVELOPMENT PIC16F877
4.1.1 Input And Output Pin Overview 4.1.2 Input/output pin configuration PIC16F877A Basic Circuit
4.2.1 Power Supply 4.2.2 Oscillator Software
Introduction To The Programming PIC16F877A
Simulation Basic Circuit Programming Development 4.6.1 Programming 4.6.2 Project Simulation
15 16 17 19 19 20 21 21 22 24 24 27
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V
5.1
5.2
HARDWARE DEVELOPMENT Electrical Part
5.1.1 DC Motor Driver 5.1.2 Voltage Regulator 5.1.3 Power Supply 5.1.3.1 Type Of Battery Mechanical Part
5.2.1 Chassis
5.2.2 Power Window Motor 5.2.3 Gripper
5.2.4 Wheel
5.2.5 Joystick Controller
28 28 29 29 29 31 32 32 33 33 34
5.3 Hardware Development 35
VI
6.1
RESULT AND DISCUSSION
Operation Of Up Side Down Robot Gripper 38
VII
6.2 6.3
6.1.1 Flowchart Operation Voltage Regulator Analysis Discussion CONCLUSION AND RECOMENDATION 39 42 43 7.1 7.2 Conclusion Recommendation REFERENCES 44 45 46
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LIST OF FIGURE
NO TITLE PAGE
1.1 2.2. 2.3 2.4
Flowchart of Development Project Canada Arm
Articulated Robot Vision Arm Robot
5 9 10 11 3.1 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5.1 5.2 5.3a 5.3b 5.4 5.5 5.6 Methodology Flowchart PIC Overview
PIC Input/Output Pin Overview PIC Basic Circuit
Voltage Regulator, Convert 9V- 5V
Suggestion Connection On The Microcontroller Program In Micro C Software
DC Motor Control Simulation Running Light Simulation Project Simulation
DC Motor Driver Circuit
Voltage Regulator 9V-5V Circuit Type Of Battery
Battery Chassis Body
Power Window Motor (DC Motor) Gripper 13 16 17 19 19 20 22 23 23 27 28 29 30 31 32 32 33
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5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14a 5.14b 5.14c 6.1 6.2 Wheel
Connection In The Joystick Controller
Connection From Joystick To PIC Basic Circuit Wheel Attached With Power Window Motor
The Rod Screw Attached With Power Window Motor Gripper Attached With Power Window Motor
Gripper Part Attached With Rotation Part Right View
Front View Robot Controller
Flowchart Of Operation Robot Voltage Regulator Circuit
33 34 34 35 35 36 36 37 37 37 41 42
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LIST OF TABLE
NO TITLE PAGE
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1 CHAPTER I
INTRODUCTION
1.1 Introduction
Nowadays, robot is not something foreign in industries technology. Robot is usually using in industries technology especially in heavy industries. Robot is popular by replacing human to do some work which is dangerous to do by human, for example is chemical work, Electro Static Discharge (ESD) working area, lift heavy thing and many more. So, when using the robot we can do everything without any obstacle. The chemical work will bring unhealthy environment and threaten our operator when handle the chemical work. It gives some trouble when they have to lift for mixed up the chemical in the mixture for produce product. Its look simple work, but the work is danger for human. In other case, it will bring bad feedback for human body. The above case bring uncomfortable and danger situation on the working area. The up side down robot gripper is design for liquid pour application. The special criteria for this robot compare with others gripper robot is this robot can rotate the wrist and pour liquid. The other gripper robot only can move up side down and grip thing. The function of this robot is lift up and pour the liquid. Besides that, the up side down robot gripper also can move forward and backward. Through this robot, hopefully the liquid pour application will be improve to make working area more safety for our workers and make our heavy lift work become easy.
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2 1.2 Problem Statement
Robot is usually using in industries technology especially in heavy industries. And it is also popular by replacing human to do some work which is dangerous to do by human, for example is chemical work, Electro Static Discharge (ESD) working area, lift heavy thing and many more. In real life, the gripper robot is used for liquid pour application. From the previous gripper robot, the robot wrist cannot rotate and the liquid cannot pour. To solve this problem, the up side down robot gripper is design. The special criteria for this robot compare with others are this robot can rotate the wrist 180 degree to pour the liquid. The another robot gripper only can move up side down and grip thing. With this improvement, the liquid pour application will be improve and make our heavy lift work become easy and also to complete the task for Robocon to score point easily.
1.3 Objective
The objective of this project is :
To improve the liquid pour application in the industrial sector.
To make our heavy lift work become easy.
To complete the task for ROBOCON to score point easily.
To design new robot for lift thing application.
To study and design the PIC16F877programming for software and hardware for microcontroller.
To gain experience in system design, hardware and software design, electrical and mechanical drawing, wiring, troubleshooting and documentation.
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3 1.4 Scope of Project
The scope of this project is divided by two parts, the hardware and the software. The hardware involves designing the mechanical part and electrical part for up side down robot gripper. The mechanical part involves the chassis, and the electrical part involves in microcontroller and driver circuit. The software involves designing and writing the program for the robot to move forward, backward, left, right, up, down and grip.
1.5 Methodology
1) Collecting information i. PIC function ii. Operation method
iii. Understand Software C- language
2) Circuit development i. PIC basic circuit ii. Driver motor circuit
3) Design and develop the robot model i. Design the gripper
ii. Develop the hardware part of robot iii. Combine the motor with robot model
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4 4) Software development
i. Do flowchart for operation of robot ii. Design the program using C- language
5) Combine the software and robot model i. Burn the program in the PIC16f877A IC ii. Wiring the robot
iii. Connect the driver circuit with motor
6) Testing
i. Testing and define the problem when combine the software and hardware.
7) Provide final report
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5 The development project flowchart
Figure1.1: Flowchart of development project
START
COLLECTING
INFORMATION
CIRCUIT
DEVELOPMENT
DESIGN AND
DEVELOP THE
ROBOT MODEL
SOFTWARE
DEVELOPEMENT
COMBINE
SOFTWARE AND
ROBOT MODEL
TESTING
PROVIDE FINAL
REPORT
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6 CHAPTER II
LITERATURE REVIEW
2.0 Introduction
The term robot comes from the Czech word robota [1], generally translated as
"forced labor"[2]. This describes the majority of robots fairly well. Most robots in the world are designed for heavy, repetitive manufacturing work. Robot is usually using in heavy industries. Robot also popular by replacing human to do some work which is dangerous and difficult to do by human, for example is chemical work, Electro Static Discharge (ESD) working area, lift heavy thing and many more. The most common manufacturing robot is the robotic arm. A typical robotic arm is made up of seven metal segments, joined by six joints. The computer controls the robot by rotating individual step motors connected to each joint (some larger arms use hydraulics or pneumatics).The robot uses motion sensors to make sure it moves just the right amount. The up side down robot gripper is same like arm robot, but the differential is this robot can move forward, backward, left, right and the wrist can rotate 180 degree. The up side down robot gripper is controlled by using microcontroller PIC16F877. The PIC16F877 microcontroller will control the motor and gripper movement.
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7 2.1 Gripper Robot Background
Robots which must work in the real world require some way to manipulate objects; pick up, modify, destroy or otherwise have an effect. Thus the 'hands' of a robot are often referred to as end effectors, while the arm is referred to as a
manipulator [3]. Most robot arms have replaceable effectors, each allowing them to perform some small range of tasks. Some have a fixed manipulator which cannot be replaced, while a few have one very general purpose manipulator, for example a humanoid hand.
Grippers: A common effectors is the gripper. Usually it consists of just two fingers which can open and close to pick up and let go of a range of small objects.
Vacuum Grippers: Pick and place robots for electronic components and for large objects like car windscreens, will often use very simple vacuum grippers. These are very simple, but can hold very large loads, and pick up any object with a smooth surface to suck on to.
General purpose effectors: Some advanced robots are beginning to use fully humanoid hands, like the Shadow Hand (right), or the Chunk hand. These highly dexterous manipulators, with as many as 20 degrees of freedom and hundreds of tactile sensors can be difficult to control. The computer must consider a great deal of information, and decide on the best way to manipulate an object from many possibilities.
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8 2.2 The Similarities Case Study
2.2.1 SCARA robot
The SCARA acronym [4] stands for Selective Compliant Assembly Robot Arm or Selective Compliant Articulated Robot Arm. In general, traditional SCARAs are 4-axis robot arms, i.e., they can move to any X-Y-Z coordinate within their work envelope. There is a fourth axis of motion which is the wrist rotate (Theta-Z). The
„X‟, „Y‟ and the „Theta-Z‟ movements are obtained with three parallel-axis rotary joints. The vertical motion is usually an independent linear axis at the wrist or in the base. SCARA robots are used in assembly operations where the final move to insert the part is a single vertical move. Component insertion into printed circuit boards is an example. This is often called "vertical assembly". They are very common in pick-and-place, assembly, and packaging applications. The electronic printed circuit board industry, in particular, use large numbers of SCARAs for placing semiconductor ICs and other components on the circuit boards of computers and related equipment.
The second attribute of the SCARA is the jointed two-link arm layout similar to our human arms, hence the often-used term, Articulated. This feature allows the
arm to extend into confined areas and then retract or “fold up” out of the way. This is
advantageous for transferring parts from one cell to another or for loading/ unloading process stations that are enclosed. SCARAs are generally faster and cleaner than comparable Cartesian systems. Their single pedestal mount requires a small footprint and provides an easy, unhindered form of mounting. On the other hand, SCARAs can be more expensive than comparable Cartesian systems and the controlling software requires inverse kinematics for linear interpolated moves. This software typically comes with the SCARA though and is usually transparent to the end-user.
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9 2.2.2 Canada Arm
The “Canada hand” resembles a headless torso fitted with two extremely agile, 11 fit long arms and several smaller appendages [5]. The 12 ft long “torso” pivots at the “waist”. The “torso” has a grapple fixture at one end that can be grasped by the larger Space Station Arm, Canadarm2 so that the SPDM can be positioned at the various Orbital Replacement Unit (ORU) worksites along the Space Station trusses. The other end of the “torso” has a grasp fixture virtually identical to that of Canadarm2, so that the SPDM can be stored on Space Station grapple fixtures or can be used as an extension to the larger arm.
The two SPDM arms each have seven, specially offset joints giving a greater freedom of movement in a smaller package than previous systems. At the end of each of these arms is a system called the Orbital Replacement Unit/Tool Change out Mechanism (OTCM). It has built-in grasping jaws, a retractable socket drive, a monochrome TV camera, lights, and an umbilical connector that can provide power and data, and receive video, to/from a payload. The lower “torso” of Dexture has a pair of Orientale color TV cameras with lights, an ORU platform, and tool holders.
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10 2.2.3 Articulated Robot
An articulated robot is a robot with rotary joints (e.g. a legged robot) [6]. Articulated robots can range from simple two-jointed structures to systems with 10 or more interacting joints. They are powered by a variety of means, including electric motors. Some types of robots, such as robotic arms, can be articulated or non-articulated
Figure 2.3 : Articulated Robot
2.2.4 Vision Arm
The SRI VA5 Vision Arm™ has six or seven degrees of freedom, depending on wrist choice, plus the manipulator or gripper action, and is designed for a carry-weight of up to 5 lbs with the arm fully extended. The arm has a reach of just under five (5) feet to the gripper point and can be fitted with a video-camera for remote viewing and control. An early add-on option for the arm will be an image-sensor (black and white camera) which attaches to the gripper in such a way that an experimental image system can distinguish objects and autonomously guide the grasping (and releasing) of items.
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11 As more experience is generated and archived in development and experimentation with the image system, the more capable the VisionArm™ system will become in performing autonomous and/or unattended activity. Further specifications for the arm and control electronics are included in the tables below.
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12 CHAPTER III
METHODOLOGY AND RESEARCH
3.1 General Methodology
To develop the up side down robot gripper, there are some method that all objective of this project successfully archive. The main sub is literature review, hardware development and software development. The flowchart below demonstrate the approach used in completing the project. The methodology of this project is divided by 3 stage.
Stage 1: Understand the objective target, scope of project and problem statement. Do literature review for initial theory execution.
Stage 2: PIC circuit development and software development.
Stage 3: Hardware development, Combination hardware, software and troubleshooting.
First of all, we must understand the objective target, scope, and problem statement of the project. After understand, we must do a lot of literature review for initial theory execution. We also decide what kind of microcontroller and motor will use in this project. After settle the stage 1, we can proceed to stage 2. In the stage 2, we have two part which is PIC circuit development and software development. This part is most important. If PIC circuit and software development finish, we can
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13 continue to next stage. If not finish, we need to repeat the process again. In the stage 3, need to develop the hardware. Design and construct the chassis of up side down robot gripper. If finish, we can go to next step, if not we need to repeat the process again. After settle hardware development, the hardware and software will combine and troubleshooting. This stage is the final stage to make sure the project is
successfully function or not. This stage also the difficult stage because we need to combine the hardware and software. After troubleshooting, if no problem occur, the combination is pass and the robot can function. If no, we need to check the error. We will check back the software and hardware design until we get the result we want.
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8 2.2 The Similarities Case Study
2.2.1 SCARA robot
The SCARA acronym [4] stands for Selective Compliant Assembly Robot Arm or Selective Compliant Articulated Robot Arm. In general, traditional SCARAs are 4-axis robot arms, i.e., they can move to any X-Y-Z coordinate within their work envelope. There is a fourth axis of motion which is the wrist rotate (Theta-Z). The „X‟, „Y‟ and the „Theta-Z‟ movements are obtained with three parallel-axis rotary joints. The vertical motion is usually an independent linear axis at the wrist or in the base. SCARA robots are used in assembly operations where the final move to insert the part is a single vertical move. Component insertion into printed circuit boards is an example. This is often called "vertical assembly". They are very common in pick-and-place, assembly, and packaging applications. The electronic printed circuit board industry, in particular, use large numbers of SCARAs for placing semiconductor ICs and other components on the circuit boards of computers and related equipment.
The second attribute of the SCARA is the jointed two-link arm layout similar to our human arms, hence the often-used term, Articulated. This feature allows the arm to extend into confined areas and then retract or “fold up” out of the way. This is advantageous for transferring parts from one cell to another or for loading/ unloading process stations that are enclosed. SCARAs are generally faster and cleaner than comparable Cartesian systems. Their single pedestal mount requires a small footprint and provides an easy, unhindered form of mounting. On the other hand, SCARAs can be more expensive than comparable Cartesian systems and the controlling software requires inverse kinematics for linear interpolated moves. This software typically comes with the SCARA though and is usually transparent to the end-user.
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9 2.2.2 Canada Arm
The “Canada hand” resembles a headless torso fitted with two extremely agile, 11 fit long arms and several smaller appendages [5]. The 12 ft long “torso” pivots at the “waist”. The “torso” has a grapple fixture at one end that can be grasped by the larger Space Station Arm, Canadarm2 so that the SPDM can be positioned at the various Orbital Replacement Unit (ORU) worksites along the Space Station trusses. The other end of the “torso” has a grasp fixture virtually identical to that of Canadarm2, so that the SPDM can be stored on Space Station grapple fixtures or can be used as an extension to the larger arm.
The two SPDM arms each have seven, specially offset joints giving a greater freedom of movement in a smaller package than previous systems. At the end of each of these arms is a system called the Orbital Replacement Unit/Tool Change out Mechanism (OTCM). It has built-in grasping jaws, a retractable socket drive, a monochrome TV camera, lights, and an umbilical connector that can provide power and data, and receive video, to/from a payload. The lower “torso” of Dexture has a pair of Orientale color TV cameras with lights, an ORU platform, and tool holders.
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10 2.2.3 Articulated Robot
An articulated robot is a robot with rotary joints (e.g. a legged robot) [6]. Articulated robots can range from simple two-jointed structures to systems with 10 or more interacting joints. They are powered by a variety of means, including electric motors. Some types of robots, such as robotic arms, can be articulated or non-articulated
Figure 2.3 : Articulated Robot
2.2.4 Vision Arm
The SRI VA5 Vision Arm™ has six or seven degrees of freedom, depending on wrist choice, plus the manipulator or gripper action, and is designed for a carry-weight of up to 5 lbs with the arm fully extended. The arm has a reach of just under five (5) feet to the gripper point and can be fitted with a video-camera for remote viewing and control. An early add-on option for the arm will be an image-sensor (black and white camera) which attaches to the gripper in such a way that an experimental image system can distinguish objects and autonomously guide the grasping (and releasing) of items.
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11 As more experience is generated and archived in development and experimentation with the image system, the more capable the VisionArm™ system will become in performing autonomous and/or unattended activity. Further specifications for the arm and control electronics are included in the tables below.
(5)
12 CHAPTER III
METHODOLOGY AND RESEARCH
3.1 General Methodology
To develop the up side down robot gripper, there are some method that all objective of this project successfully archive. The main sub is literature review, hardware development and software development. The flowchart below demonstrate the approach used in completing the project. The methodology of this project is divided by 3 stage.
Stage 1: Understand the objective target, scope of project and problem statement. Do literature review for initial theory execution.
Stage 2: PIC circuit development and software development.
Stage 3: Hardware development, Combination hardware, software and troubleshooting.
First of all, we must understand the objective target, scope, and problem statement of the project. After understand, we must do a lot of literature review for initial theory execution. We also decide what kind of microcontroller and motor will use in this project. After settle the stage 1, we can proceed to stage 2. In the stage 2, we have two part which is PIC circuit development and software development. This part is most important. If PIC circuit and software development finish, we can
(6)
13 continue to next stage. If not finish, we need to repeat the process again. In the stage 3, need to develop the hardware. Design and construct the chassis of up side down robot gripper. If finish, we can go to next step, if not we need to repeat the process again. After settle hardware development, the hardware and software will combine and troubleshooting. This stage is the final stage to make sure the project is
successfully function or not. This stage also the difficult stage because we need to combine the hardware and software. After troubleshooting, if no problem occur, the combination is pass and the robot can function. If no, we need to check the error. We will check back the software and hardware design until we get the result we want.