Robotic Arm Final Main Report

ROBOTIC ARM 2014
1. PROJECT IDEA GENERATION
As we all group members are not only passionate about the robotics but also we
know the importance of it. After knowing the current scenarios of robotic market
we found that. High production rate with minimum wastage and greater control
over the quality of production are now a days very valuable for any industry to
compute in todays competitive word. An automation is one of the key way to
achieve this which also reduce the dependency of production on the workers.
But the major problem arise with the automation is its high capital cost and its
complexity. Also we are largely dependent on imported robots which made it
difficult for SSI to implement automation.
Hence we decided to do effort and use our engineering knowledge for the
development of a robot which must be having low cost, simple in construction with
greater accuracy.
D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.
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ROBOTIC ARM
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SCHEAMATIC REPRENSANTATION OF PROJECT CONCEPT
Figure 1 :scheamatic reprensantation of project concept
In our project we made a embedded system based ROBOTIC ARM with

conveyor system interfacing . This arrangement is totally mounted on ply
board .for minimization of handling time we introduce this typical
arrangement for moving the job from conveyor to the machining center and
to the another conveyor.
Firstly we initialized robotic arm then its moving towards conveyor
and pick the job . and place on the machining center , after machining again
pick the job and place on another conveyor. This arrangement is very helpful
for to reduce material handling cost as well increase productivity.
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2. ABSTRACT
Robotics is the science and technology of robots, their design, manufacture, and
application. Robotics requires a working knowledge of electronics, mechanics, and
software and a person working in the field has become known as a roboticist.
Robots are being employed in a wide assortment of applications in recent days. Today
most of the applications are in manufacturing to move materials, parts and tools of various
types. Future applications will include non-manufacturing tasks, such as construction
work, exploration of space, and medical care. At some time in distant future, a household
robot may become a mass produced item.
The objective of this paper is to provide some information in this fascinating field. The
main purpose is to describe some of the research and development that is presently taking
place and to estimate some of the future advances in robotic technology.
We anticipate that robots of the future will be richly endowed with better sensor
capabilities, which would permit the robot to be more aware of its environment, to
communicate with human operators more readily, and to make use of higher level of
intelligence.
Robotics is a technology that can be harnessed only for the benefit of humankind. But like
other technologies, there are potential dangers involved, and safe guards must be instituted
to prevent its harmful usage. It is suggested that developing a robot with a conscience may
be helpful in this regard.
The future technology of robotics and the potential applications in industrial and medical
fields, which this technology will bring, the difficulty in the application of robotics is the
subject of discussion of this paper.
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3. INTRODUCTION
1. Now days , there is lot of completion in the market . So there is need of
developing a new method of process for effective manufacturing . That
process or methods should fulfill the requirement about accuracy
productivity and also reduce the material handling cost etc.
2. It is necessary to reduce total machining time . there are various ways by
which the total machining time can be effectively minimized. There are
various time consuming step or sub process , which can be minimized by
various methods. In mass production the time criteria is very important.
Within small time limit , single unit jog has to be completed . for minimizing
the job completion time, the handling of job should be minimum. So that
the labor time considerably saved.
3. In our project we made a embedded system based ROBOTIC ARM with
conveyor system interfacing . This arrangement is totally mounted on ply
board .for minimization of handling time we introduce this typical
arrangement for moving the job from conveyor to the machining center and
to the another conveyor.
Firstly we initialized robotic arm then its moving towards conveyor
and pick the job . and place on the machining center , after machining again
pick the job and place on another conveyor. This arrangement is very helpful
for to reduce material handling cost as well increase productivity.
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4. DESIGN
4.1 Mechanical
4.1.1 About Robotic Arm
Cartesian robot / Gantry robot: Used for pick and place work, application of sealant,
assembly operations, handling machine tools and arc welding. It's a robot whose arm has
three prismatic joints, whose axes are coincident with a Cartesian coordinator.
Cylindrical robot: Used for assembly operations, handling at machine tools, spot
welding, and handling at diecasting machines. It's a robot whose axes form a cylindrical
coordinate system.
Spherical robot / Polar robot (such as the Unimate): Used for handling at machine
tools, spot welding, diecasting, fettling machines, gas welding and arc welding. It's a
robot whose axes form a polar coordinate system.
SCARA robot: Used for pick and place work, application of sealant, assembly
operations and handling machine tools. This robot features two parallel rotary joints to
provide compliance in a plane.
Articulated robot: Used for assembly operations, diecasting, fettling machines, gas
welding, arc welding and spray painting. It's a robot whose arm has at least three rotary
joints.
Parallel robot: One use is a mobile platform handling cockpit flight simulators. It's a
robot whose arms have concurrent prismatic or rotary joints.
Anthropomorphic robot: Similar to the robotic hand Luke Skywalker receives at the
end of The Empire Strikes Back. It is shaped in a way that resembles a human hand, i.e.
with independent fingers and thumbs.
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4.1.2 Design of Gripper Links :
The object to be lifted is: - Metal Plates Weight of the object: - 50-80gm
The link has two parts, Part1 and Part2.
The Arm manipulator has length as follows:- Part1 = 250mm Part2 = 50mm
Therefore, the ratio of the length of the two links is Link1: Link2: 5:
Figure 2 : Show of wrist & End-effectors.
Description: A spur gear meshing with a worm gear.

9 V stepper motor.
Two end effectors out of which one is fixed and another is movable.
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The object to be lifted is: - Metal Plates
Weight of the object: - 50-80gm
The link has two parts, Part1 and Part2.
The Arm manipulator has length as follows:Part1 = 25 cm Part2 = 5 cm

Therefore, the ratio of the length of the two links is Link1: Link2: 5: 1
4.1.3 Spur Gear Design and selection

Objectives
Apply principles learned in Chapter 11 to actual design and selection of spur
gear systems.
Calculate forces on teeth of spur gears, including impact forces associated with
velocity and clearances.
Determine allowable force on gear teeth, including the factors necessary due to
angle of involute of tooth shape and materials selected for gears.
Design actual gear systems, including specifying materials, manufacturing
accuracy, and other factors necessary for complete spur gear design.
Understand and determine necessary surface hardness of gears to minimize or
prevent surface wear.
Understand how lubrication can cushion the impact on gearing systems and cool
them.
Select standard gears available from stocking manufacturers or distributors.
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Figure 3 : View of spur gear arrangement 1
Figure 4: View of spur gear arrangement 2
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Description:Forces on spur gear teeth

Power, P; or
Torque, T = Ft r and
r = Dp /2
Combining the above we can write
P = T n / pt D
F=2T/n
T = 63,000 P
20-tooth , 8 pitch , 1-inch-wide , 20 pinion transmits 5 hp at 1725 rpm to a 60-tooth gear.

We Determine driving force, separating force, and maximum force that would act on mounting
shafts.
P = Tn / 63,000
T =63,000P / n
T =(63,000)5 / 1725
= 183 in-lb
Find pitch circle:
Dp = Np / Pd
Dp =20 teeth / 8 teeth/in diameter
= 2.5 in
Find transmitted force:
Ft =2T / Dp
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Ft =183 in-lb / 2.5 in
= 146 lb
Find separating force:
Fn = Ft tan
Fn = 146 lb / tan 20
Fn = 53 lb
Find maximum force:
Fr = Ft / cos
Fr =146 lb /cos 20
Fr = 155 lb
No of teeth on pinion=20
No of teeth on gear=60
Gear ratio= 60/20 =3/1
Diameter of gear and pinion= 60mm and 40 mm respectively.
Pressure angle= 20
Module=1.75 mm
Pitch line velocity = DpNp/60
=(*0.015*20)/60
=0.015 m/s
4.1.4 DESIGN THE ROBOTIC ARM

The best idea is to put into drawing. The drawing is important for documentation
purposes and to simplify the fabrication. The design modified from time to time for
improvement purpose. For Designing We use Solid Works Softwares like ProE .
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Required dimensions of all work pieces (acrylic sheet) were achieved by switch
board cutting Machine.
Required dimensions of all M.S.work pieces were achieved by lathe machine and
welded by welding machine.
Use required dimensions of nut bolts , screw.
Force Calculation of Joints :
This will provide a fundamental understanding of moment arm calculations for

statics and dynamics.
The point of doing force calculations is for motor selection. We must make sure
that the motor chosen can not only support the weight of the robot arm, but also
what the robot arm will carry.
Choose these parameters: weight of each linkage weight of each joint weight of
object to lift length of each linkage
Figure 5 : View of loads /moments on joints.
This particular design has just two DOF that requires lifting, and the center of mass of
each linkage is assumed to be acting at half of the length.
Torque about Joint 1 M1 = L1/2 * W1 + L1 * W4 + (L1 + L2/2) * W2 + (L1 + L3) * W3
.
Torque about Joint 2 M2 = L2/2 * W2 + L3 * W3
For each DOF we add the math gets more complicated, and the joint weights get heavier.
We also see that shorter arm lengths allow for smaller torque requirements
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4.1.5 Design of Base Shaft
Figure6 : View of Shaft and bearing arrangement
Length of shaft: - In mm
Torque (T):- In N-m
Tangential force on gear = 2T/D (D: - Diameter of gear)
Twisting moment (Te) =N-m
Normal load acting on tooth on gear: - Ft/cos20 = In N .
Maximum bending moment (M) = WL/4 = In N-m.
Power and Torque Transmitted
Voltage:- V
Current:- A
Speed:- rpm
Power transmitted: - VI P= In watt.
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4.1.6 CALCULATIONS :
Torque = (P60)/2N
= In N-m
Force Calculation of Joints

o This will provide a fundamental understanding of moment arm calculations for
statics and dynamics.
o The point of doing force calculations is for motor selection. We must make sure
that the motor chosen can not only support the weight of the robot arm, but also
what the robot arm will carry.
o Choose these parameters: weight of each linkage weight of each joint weight of
object to lift length of each linkage
o This particular design has just two DOF that requires lifting, and the center of
mass of each linkage is assumed to be acting at half of the length.
o Torque about Joint 1 M1 = L1/2 * W1 + L1 * W4 + (L1 + L2/2) * W2 + (L1 +
L3) * W3 .
o Torque about Joint 2 M2 = L2/2 * W2 + L3 * W3
Degree of freedom :
Figure 7 : View of degree of freedom
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4.2 ELECTRIC CIRCUIT DESIGN

4.2.1 PCB DESIGN FOR CIRCUIT ROBOARM
Figure 8 : pcb design for circuit roboarm
4.2.2 PCB DESIGN FOR ROBOTIC TRACK
Figure 9 : pcb design for robotic track

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4.2.3 BLOCK DIAGRAM OF P89V51RD2 :
Figure 10 : Block Diagram Of P89v51rd2
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4.2.3 PIN DIAGRAM OF P89V51RD2 :
Figure 11 : pin diagram of p89v51rd2
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4.2.4 General Description
The P89V51RB2/RC2/RD2 are 80C51 microcontrollers with 16/32/64 kB flash and 1024 B of
data RAM.
A key feature of the P89V51RB2/RC2/RD2 is its X2 mode option. The design engineer can
choose to run the application with the conventional 80C51 clock rate (12 clocks per machine
cycle) or select the X2 mode (six clocks per machine cycle) to achieve twice the throughput at
the same clock frequency. Another way to benefit from this feature is to keep the same
performance by reducing the clock frequency by half, thus dramatically reducing the EMI.
The flash program memory supports both parallel programming and in serial ISP. Parallel
programming mode offers gang-programming at high speed, reducing programming costs and
time to market. ISP allows a device to be reprogrammed in the end product under software
control. The capability to field/update the application firmware makes a wide range of
applications possible.
The P89V51RB2/RC2/RD2 is also capable of IAP, allowing the flash program memory to be
reconfigured even while the application is running.
Features
80C51 CPU
5 V operating voltage from 0 MHz to 40 MHz
16/32/64 kB of on-chip flash user code memory with ISP and IAP
Supports 12-clock (default) or 6-clock mode selection via software or ISP
SPI and enhanced UART
PCA with PWM and capture/compare functions
Four 8-bit I/O ports with three high-current port 1 pins (16 mA each)
Three 16-bit timers/counters
Programmable watchdog timer
Eight interrupt sources with four priority levels
Second DPTR register
Low EMI mode (ALE inhibit)
TTL- and CMOS-compatible logic levels
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4.2.5 P89V51RD2 pin description
Symbol Pin Type Description
DIP40 TQFP44 PLCC44 - P0.0 to P0.739-32 37-30 43-36 I/O
Port 0: Port 0 is an 8-bit open drain bi-directional I/O port. Port 0 pins that have 1s written to
them float, and in this state can be used as high-impedance inputs. Port 0 is also the multiplexed
low-order address and data bus during accesses to external code and data memory. In this
application, it uses strong internal pull-ups when transitioning to 1s. Port 0 also receives the
code bytes during the external host mode programming, and outputs the code bytes during the
external host mode verification. External pull-ups are required during program verification or as
a general purpose I/O port.
P1.0 to P1.7 -1-8 40-44, 1-3 2-9 I/O with internal pull-up
Port 1: Port 1 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 1 pins are pulled
high by the internal pull-ups when 1s are written to them and can be used as inputs in this state.
As inputs, Port 1 pins that are externally pulled LOW will source current (IIL) because of the
internal pull-ups. P1.5, P1.6, P1.7 have high current drive of 16 mA. Port 1 also receives the loworder address bytes during the external host mode programming and verification.
P1.0 1 40 2 I/O T2: External count input to Timer/Counter 2 or Clock-out from Timer/Counter 2
P1.1 2 41 3 I T2EX: Timer/Counter 2 capture/reload trigger and direction control
P1.2 3 42 4 I ECI: External clock input. This signal is the external clock input for the PCA.
P1.3 4 43 5 I/O CEX0: Capture/compare external I/O for PCA Module 0.
Each capture/compare module connects to a Port 1 pinfor external I/O. When not used by the
PCA, this pin can handle standard I/O.
P1.4 5 44 6 I/O SS: Slave port select input for SPI
CEX1: Capture/compare external I/O for PCA Module 1
P1.5 6 1 7 I/O MOSI: Master Output Slave Input for SPI
P1.6 7 2 8 I/O MISO: Master Input Slave Output for SPI
P1.7 8 3 9 I/O SCK: Master Output Slave Input for SPI
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P2.0 to P2.7 21-28 18-25 24-31 I/O with internal pull-up

Port 2: Port 2 is an 8-bit bi-directional I/O port with internal pull-ups. Port 2 pins are pulled
HIGH by the
internal pull-ups when 1s are written to them and can be used as inputs in this state. As inputs,
Port 2 pins that are externally pulled LOW will source current (IIL)because of the internal pullups. Port 2 sends the
high-order address byte during fetches from external program memory and during accesses to
external Data Memory that use 16-bit address (MOVX@DPTR). In this application, it uses
strong internal pull-ups when transitioning to 1s. Port 2 also receives some control signals and
a partial of high-order address bits during the external host mode programming and verification.
P3.0 to P3.7
10-17 5, 7-13 11, 13-19 I/O with internal pull-up
Port 3: Port 3 is an 8-bit bidirectional I/O port with internal pull-ups. Port 3 pins are pulled
HIGH by the internal pull-ups when 1s are written to them and can be used as inputs in this
state. As inputs, Port 3 pins that are externally pulled LOW will source current (IIL) because of
the internal pull-ups. Port 3 also receives some control signals and a partial of high-order address
bits during the external host mode programming and verification.
P3.0 10 5 11 I RXD: serial input port
P3.1 11 7 13 O TXD: serial output port
P3.2 12 8 14 I INT0: external interrupt 0 input
P3.3 13 9 15 I INT1: external interrupt 1 input
P3.4 14 10 16 I T0: external count input to Timer/Counter 0
P3.5 15 11 17 I T1: external count input to Timer/Counter 1
P3.6 16 12 18 O WR: external data memory write strobe
P3.7 17 13 19 O RD: external data memory read strobe
PSEN 29 26 32 I/O Program Store Enable: PSEN is the read strobe for external program
memory. When the device is executing from internal program memory, PSEN is inactive
(HIGH). When the device is executing code from external program memory, PSEN is activated
twice each machine cycle, except that two PSEN activations are skipped during each access to
external data memory. A forced HIGH-to-LOW input transition on the PSEN pin while the RST
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input is continually held HIGH for more than 10 machine cycles will cause the device to enter
external host mode programming.
RST 9 4 10 I Reset: While the oscillator is running, a HIGH logic state on this pin for two
machine cycles will reset the device. If the PSEN pin is driven by a HIGH-to-LOW input
transition while the RST input pin is held HIGH, the device will enter the external host mode,
otherwise the device will enter the normal operation mode.
EA 31 29 35 I External Access Enable: EA must be connected to VSS in order to enable the
device to fetch code from the external program memory. EA must be strapped to VDD for
internal program execution. However, Security lock level 4 will disable EA, and program
execution is only possible from internal program memory. The EA pin can tolerate a high
voltage of 12 V.
ALE/PROG30 27 33 I/O
Address Latch Enable: ALE is the output signal for latching the low byte of the address during
an access to external memory. This pin is also the programming pulse input (PROG) for flash
programming. Normally the ALE is emitted at a constant rate of 1 6 the crystal frequency and
can be used for external timing and clocking. One ALE pulse is skipped during each access to
external data memory. However, if AO is set to 1, ALE is disabled.
NC - 6, 17, 28,391, 12, 23,34
I/O No Connect
XTAL1 19 15 21 I Crystal 1: Input to the inverting oscillator amplifier and input to the internal
clock generator circuits.
XTAL2 18 14 20 O Crystal 2: Output from the inverting oscillator amplifier.
VDD 40 38 44 I Power supply
VSS 20 16 22 I Ground
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4.2.6 Peripheral Simulation
1. For NXP (founded by Philips) P89V51RD2 6 or 12 Clocks Per Machine Cycle

(X2)
Simulation support for this peripheral or feature is comprised of:
Accurate simulation of special on-chip features.

VTREGs (Virtual Target Registers) which support I/O with the peripheral.
These simulation capabilities are described below.
6/12 Clocks per Machine Cycle

This device can run in either 6 or 12 clocks per machine cycle. Enabling 6 clocks per cycle mode
allows equivalent processing speed at half the clock frequency. This clock double feature
doubles only the internal system clock and the clock used to access internal flash memory, so
access to external memory and external peripherals could be affected when it is enabled.
X2 VTREG
Data Type: unsigned char
XTAL VTREG
Data Type: unsigned long
The XTAL VTREG contains the frequency of the oscillator (in Hertz) used to drive the
microcontroller. The value is automatically set from the value specified in Project Options Options for Target. However, you may change the value of XTAL using the command window.
For example:
XTAL=12000000
You may also output the current value of XTAL using the following:
XTAL
XTAL may be used in calculations to synchronize external scripts with the simulated
microcontroller
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2. For NXP (founded by Philips) P89V51RD2 Interrupts 9S/4L (Including
External)
Dialog boxes which display and allow you to change peripheral configuration.
Interrupt System Dialog
The Interrupt System dialog (available from the Peripherals menu) displays the status of all
simulated MCU interrupts. The interrupt source, vector address, mode, request, priority, and
enabled status are displayed. You may use this dialog to manually change the interrupt
configuration. Select the desired interrupt and click on the desired check box to immediately
effect the change. You may even trigger an interrupt by clicking on its request bit. You may
trigger an external interrupt by toggling the appropriate port pin. External interrupt 0 is triggered
by either a changing edge or level on I/O PORT 3.2. You can change the state of the pin by
writing to the PORT3 VTREG. The following assignments may be entered in the command
window to toggle PORT 3.2.
PORT3 ^= 0x04
PORT3 ^= 0x04
// Toggle PORT 3.2

// Toggle PORT 3.2
These commands toggle the state of PORT 3.2 and then toggle it back
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3. For NXP (founded by Philips) P89V51RD2 PCA Timer with modules
Programmable Counter Array Dialog
For NXP (founded by Philips) P89V51RD2 Port 1

Parallel Port 1 Dialog

This dialog displays the SFR and pins of Port 1.
P1: This is the P1 SFR. The HEX value and value of each
bit is displayed and may be changed from this dialog.
Pins: These are the states of the pins on the simulated
MCU. When used as outputs, these have the same value as
the P1 SFR. When used as inputs (P1.x is 1) you may set the level of the input pin to high
(1) or low (0).
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The PORT1 VTREG may be used (from the Command Window or from a user or signal
function) to affect the input values of the simulated pins of Port 1.
PORTx VTREG
The PORTx VTREGs represent the I/O pins of the simulated MCU for Port 0, Port 1, and so on.
PORT0 represents Port 0, PORT1 represents Port 1, etc. You may read PORTx to determine the
state of the output pins of that port. For example, in the command window, you may type,
PORT0
to obtain value corresponding to the set pins of Port 0. You may also change the input values of
port pins by changing the value of the VTREG. For example,
PORT1=0xF0
sets the upper four port pins of Port 1 to a value of 1 and the lower 4 port pins to a value of 0.
You may use the bitwise operators AND(&), OR(|) and XOR(^) to change individual bits of the
PORTx VTREGs. For example:
PORT1 |= 0x01;
PORT3 &= ~0x02;
PORT1 ^= 0x80;
/* Set P1.0 Pin */

/* Clr P3.1 Pin */
/* Toggle P1.7 Pin */
4. For NXP (founded by Philips) P89V51RD2 Port 2

Pins: These are the states of the pins on the simulated
MCU. When used as outputs, these have the same value as
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the P2 SFR. When used as inputs (P2.x is 1) you may set the level of the input pin to high
(1) or low (0).
PORTx VTREG
PORT0
PORT1=0xF0
PORT1 |= 0x01;
PORT3 &= ~0x02;
PORT1 ^= 0x80;
/* Set P1.0 Pin */

/* Clr P3.1 Pin */
5. For NXP (founded by Philips) P89V51RD2 Port 3


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Pins: These are the states of the pins on the simulated MCU. When used as outputs, these
have the same value as the P3 SFR. When used as inputs (P3.x is 1) you may set the level
of the input pin to high (1) or low (0).
PORTx VTREG
PORT0
PORT1=0xF0
PORT1 |= 0x01;
PORT3 &= ~0x02;
PORT1 ^= 0x80;
/* Set P1.0 Pin */

/* Clr P3.1 Pin */
6. For NXP (founded by Philips) P89V51RD2 Power Saving Modes (Idle and Power
Down)
Example code which helps you get started quickly.
Idle Mode Example Program

The Keil Debugger fully simulates the effects of Idle Mode. When your target program initiates
Idle Mode program execution stops until the next interrupt is triggered. The following example
code shows how to enter Idle Mode.
while (1)
{
// Repeat Forever
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PCON |= 0x01;
count++;
}
// Enter IDLE Mode

// Interrupt Wakes-up MCU
Power Down Mode Example Program

The Keil Debugger fully simulates the effects of Power Down Mode. When your target program
initiates Power Down Mode program execution stops until the next external interrupt is triggered
or until the MCU is reset. The following example code shows how to enter Power Down Mode.
while (1)
{
PCON |= 0x02;
count++;
}
// Repeat Forever
// Enter Power Down Mode
// External Interrupt or Reset Wakes-up MCU
7. For NXP (founded by Philips) P89V51RD2 Serial UART (Enhanced Interface)

Serial Channel Dialog

SIN VTREG
Data Type: unsigned int
The SIN VTREG represents the serial input of the simulated

microcontroller. Values you assign to SIN are input to the serial
channel. You may assign input using the command window. For
example,
SIN='A'
causes the simulated microcontroller serial input to receive the

ASCII character A. If you want to use the SIN VRTEG to
simulate reception of multiple characters, you must be sure to
delay for atleast one character time between successive
assignments to SIN. This may be done using a signal function.
For example:
signal void send_cat (void) {
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swatch(0.01);
SIN='C';
swatch(0.01);
SIN='A';
swatch(0.01);
SIN='T';
}
/* Wait 1/100 seconds */

/* Send a C */
You may use the SIN VTREG to input more than 8 bits of data. For example,
SIN=0x0123
inputs a 9-bit value. This is useful if you use 9-bit serial I/O. In addition to the SIN VRTEG, the
serial window allows you to input serial characters by simply typing. Serial characters that are
transmitted byt the simulated microcontroller appear in the serial window.
SOUT VTREG
The SOUT VTREG represents the serial output from the simulated microcontroller. Whenever
the simulated serial port transmits a character, the value transmitted is automatically assigned to
SOUT (which is read-only). You may read the value of SOUT to determine the character
transmitted by your simulated program. For example,
SOUT
outputs the value of the last character transmitted. You may use the SOUT VTREG in a script to
process transmitted data. For example,
signal void sout_sig (void) {
while (1)
{
wwatch(SOUT);
/* wait for something in SOUT */
printf ("Transmitted a %2.2X\n", (unsigned) SOUT);
}
}
STIME VTREG
The STIME VTREG allows you to control the timing of the simulated serial port.
A value of 1 (which is the default) indicates that the serial port timing is identical to the
target hardware. Use this value when you want to see the effects of baud rate on the serial
port I/O.
A value of 0 indicates that all serial input and output occur instantaneously. Use this
value when you don't care about any baud rate effects or when you want serial output to
be fast.
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For example:
STIME = 0
STIME = 1
/* Set Serial Port for FAST timing */

/* Set Serial Port for accurate timing */
8. SPI (Serial Peripheral Interface)

SPI Dialog
SPI_IN VTREG
The SPI_IN VTREG contains a byte which is received

via the MCU SPI (Serial Peripheral Interface) port on the
next SPI transfer. You may use this VTREG in a
simulation script. For example:
signal void spi_func (void) {
while (1) {
wwatch (SPI_OUT);
printf ("SPI_OUT: %2.2X\n", (unsigned)
SPI_OUT);
SPI_IN = SPI_OUT + 1;
}
}
This signal function returns the SPI byte send plus 1 on

the next SPI transfer.
SPI_OUT VTREG
The SPI_OUT VTREG contains a byte output via the MCU SPI (Serial Peripheral Interface)
port. When your simulated program sends a byte via SPI, the SPI_OUT VTREG is set with the
value output. You may monitor this VTREG in a simulation script. For example:
signal void spi_watcher (void) {
while (1) {
wwatch (SPI_OUT);
printf ("SPI_OUT: %2.2X\n", (unsigned) SPI_OUT);
}
}
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9. Timer 0
Timer/Counter 0 Dialog
The Keil Debugger simulates all aspects of Timer/Counter 0. The
configuration is reflected in the Timer/Counter 0 Dialog that you
may open from the Peripherals Menu. You may use the controls
in the dialog to override the settings configured by your target
program. This allows you to learn how the timer/counter works
by interactively changing the configuration settings.
Mode
Mode settings select the size and auto-reload functions,

and set either Timer or Counter operation.
TCON (Timer Control Register) holds the run/stop and
overflow flag for Timers 0 and 1.
TMOD (Timer Mode Register) holds the mode, gate
cotrol and counter/timer select bits.
TH0 (Timer 0 - High Byte) contains the upper 8-bits of the Timer 0 value.
TL0 (Timer 0 - Low Byte) contains the lower 8-bits of the Timer 0 value.
T0 Pin is the Timer/Counter 0 pin for external input (P3.4/T0).
TF0 (Timer 0 Overflow Flag) is set when when Timer 0 overflows.
Control
Status (Timer/Counter Status) displays the current status of the Timer/Counter.

TR0 (Timer 0 Run Control) is set to turn Timer 0 on, and reset to turn it off.
GATE (Gating Control) is set to enable a timer/counter while the INT0 flag is high and
run control (TR0) is set.
INT0# External Interrupt 0 Input / Timer 0 Gate Control Input pin.
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10. Timer 1
Timer/Counter 1 Dialog
The Keil Debugger simulates all aspects of Timer/Counter 1. The
configuration is reflected in the Timer/Counter 1 Dialog that you
may open from the Peripherals Menu. You may use the controls
in the dialog to override the settings configured by your target
program. This allows you to learn how the timer/counter works
by interactively changing the configuration settings.
Mode
Mode settings select the size and auto-reload functions,

and set either Timer or Counter operation.
TCON (Timer Control Register) holds the run/stop and
overflow flag for Timers 0 and 1.
TMOD (Timer Mode Register) holds the mode, gate
cotrol and counter/timer select bits.
TH1 (Timer 1 - High Byte) contains the upper 8-bits of the Timer 1 value.
TL1 (Timer 1 - Low Byte) contains the lower 8-bits of the Timer 1 value.
T1 Pin is the Timer/Counter 1 pin for external input (P3.5/T1).
TF1 (Timer 1 Overflow Flag) is set when when Timer 1 overflows.
Control
Status (Timer/Counter Status) displays the current status of the Timer/Counter.

GATE (Gating Control) is set to enable a timer/counter while the INT1 flag is high and
run control (TR1) is set.
INT1# External Interrupt 1 Input / Timer 1 Gate Control Input pin.
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11. Timer 2 (Extended Timer 2)
TIMER 2 Dialog
The Keil Debugger simulates all aspects of Timer/Counter 2.
The configuration is reflected in the Timer/Counter 2 Dialog
that you may open from the Peripherals Menu. You may use
the controls in the dialog to override the settings configured
by your target program. This allows you to learn how the
timer/counter works by interactively changing the
configuration settings.
Mode settings select the size and auto-reload

functions, and select either Timer or Counter
operation for Timer 2.
T2CON (Timer Control Register) holds the run/stop
and overflow flag for Timer 2.
T2MOD (Timer 2 Mode Register) holds the down
count enable (DCEN) setting.
T2 (Timer/Counter 2) holds the value of Timer/Counter 2.
RCAP2 (Reload/Capture Timer 2) holds the 16-bit reload/capture register value.
C/T2# (Counter/Timer Select) is set to configure Timer 2 as an external event counter, or
reset to configure it as a timer.
CP/RL2# (Capture/Reload Select) is set for capture mode, and reset for reload mode.
When either RCLK = 1 or TCLK = 1, this bit is ignored.
EXEN2 (Timer 2 External Enable) is set to capture or reload based on pin T2EX (P1.1).
This bit is only meaningful if Timer 2 is being used to clock the serial port.
TCLK (Transmit Clock Enable) is set to use Timer 2 overflow pulses for the transmit
clock.
RCLK (Receive Clock Enable) is set to use Timer 2 overflow pulses for the receive
clock.
T2OE (Timer 2 Output Enable) is set to enable clock output on the T2 pin(P1.0).
DCEN (Down Count Enable) is set to use Timer 2 as an up/down counter. The level of
T2EX determines up or down counting.
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I/O
T2EX (Timer 2 Capture/Reload Trigger) is an external input (P1.1/AN1/T2EX) for

up/down counting or triggering a timer 2 reload.
T2 Pin is an external input pin for counter 2(P1.0/T2).
IRQ
TF2 (Timer 2 Overflow Flag) is set when a Timer 2 overflow occurs.

EXF2 (Timer 2 External Flag) is set when an external event on T2EX causes a capture or
reload of Timer 2.
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4.2.7 ARM Compilation Tools
The ARM Compiler toolchain, previously known as ARM RealView Compilation tools include:
The ARM C/C++ Compiler (armcc)

Microlib
The ARM Macro Assembler (armasm)
The ARM Linker (armLink)
ARM Utilities (Librarian and FromELF)
These development tools for the ARM family of microcontrollers allow you to write ARM
applications in C or C++ that, once compiled, have the efficiency and speed of assembly
language.
The ARM Compiler toolchain translates C/C++ source files into relocatable object modules
which contain full symbolic information for debugging with the Vision Debugger or an incircuit emulator. In addition to the object file, the compiler generates a listing file which may
optionally include symbol table and cross-reference information.
Continuous Improvement
The ARM Compilation is industry recognized as the highest performance ARM technologytargeted compiler. Developed and tuned to deliver the highest code density, the ARM Compiler
produces the smallest code size which leads to significant product cost savings. The compiler
generates optimized code for the 32-bit ARM, the 16-bit Thumb, and the mixed 32/16-bit
Thumb2 instruction sets while supporting ISO Standard C and C++.
The ARM Compiler has been consistently refined and improved both in code density and
performance and with new features such as MicroLib.
ARM C/C++ Compiler (armcc)
Features and Benefits
ARM and Thumb generation modes.

You can mix ARM and Thumb code in the same source file. ARM mode allows for faster
code operation making it ideal for interrupt handlers. Thumb mode provides the smallest
code size.
Industry leading code size optimizations.

Enables you achieve memory cost savings by generating the smallest compiled code size.
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ROBOTIC ARM 2014
Industry leading code performance optimizations.

Reduces power consumption by enabling increased throughput without clock speed
increases.
Function Attributes for Hardware Support.

The ARM C compiler provides function attributes that give you access to ARM hardware
features. For example:
o __irq allows you to create interrupt service routines in C.
o __swi(id) allows you to invoke a software interrupt handler.
Embedded Assembler.
You may insert assembler code into C function definitions. This capability is necessary
for fast DSP and other signal-processing algorithms. The ARM compiler supports full
program optimization even when embedded assembler is used.
Function In-lining.
You may speed-up execution of frequently called functions by using function inlining.
Inline functions are expanded inline without the overhead associated with function call,
parameter passing, and return.
Parameter Passing in CPU Registers.

The ARM Compiler automatically uses CPU registers to pass most function arguments. It
can even pass and return small C structs in registers.
Reentrant Run-time Library.

Most library routines are reentrant (refer to the library reference in the Compiler User's
Guide) and may be invoked from the main program thread and from interrupts. There is
no need to include special protection schemes for library calls.
IEEE-754 Compliant Single and Double Precision Floating-point.

High accuracy floating-point support.
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ROBOTIC ARM 2014

4.2.8 Programming :
Flash Magic is a tool which used to program hex code in micro-controller. it is a freeware tool. It
only supports the micro-controller of Philips and NXP. We type and then burn a hex code into
those controller which supports ISP (in system programming) feature. To check whether our
micro-controller supports ISP or not take look at its datasheet. So if our device supports ISP then
we can easily burn a hex code into our device.
Flash magic supports several chips like ARM Cortex M0, M3, M4, ARM7 and 8051.
The procedure to program code memory is very easy and needs only five steps to configure Flash
magic for better operation. Flash magic use Serial or Ethernet protocol to program the flash of
device.
#include"roboarm.h"
void init(void)
{
P0=0x00;
P0=0xFF;
delay_ms(1000);
P0=0x00;
delay_ms(1000);
P0=0xFF;
delay_ms(1000);
P0=0x00;
if (gr_s1!=0)
{
gr_m3=1;
grip=1;
do{mr();}while(gr_s1!=0);
delay_ms(50);
gr_m3=0;
grip=0;
hold();
delay_ms(1000);
}
if ((wr_s2!=0))
{
wr_m2=1;
elbow=1;
do{mf();}while(wr_s2!=0);
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ROBOTIC ARM 2014

delay_ms(50);
wr_m2=0;
elbow=0;
hold();
delay_ms(1000);
}
if (arm_s2!=0)
{
arm_m1=1;
arm=1;
do{mr();}while(arm_s2!=0);
delay_ms(500);
arm_m1=0;
arm=0;
hold();
delay_ms(1000);
}
delay_ms(1000);
rotation1();
delay_ms(2000);
}
void arm_fw(void)
{
if (arm_s1!=0)
{
arm_m1=1;
arm=1;
mf();
delay_ms(5000);
do{mf();}while(arm_s1!=0);
delay_ms(500);
hold();
arm_m1=0;
arm=0;
delay_ms(2000);
}
wr_m2=1;
elbow=1;
mr();
delay_ms(4000);
hold();
wr_m2=0;
elbow=0;
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}
void arm_fw1(void)
{
wr_m2=1;
elbow=1;
mr();
delay_ms(4000);
hold();
wr_m2=0;
elbow=0;
if (arm_s1!=0)
{
arm_m1=1;
arm=1;
mf();
delay_ms(5000);
do{mf();}while(arm_s1!=0);
delay_ms(500);
hold();
arm_m1=0;
arm=0;
delay_ms(1000);
}
}
void arm_rev(void)
{
if (arm_s2!=0)
{
arm_m1=1;
arm=1;
do{mr();}while(arm_s2!=0);
delay_ms(500);
arm_m1=0;
arm=0;
hold();
delay_ms(500);
}
if ((wr_s2!=0))
{
wr_m2=1;
elbow=1;
do{mf();}while(wr_s2!=0);
delay_ms(50);
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ROBOTIC ARM 2014

wr_m2=0;
elbow=0;
hold();
delay_ms(500);
}
}
void griper (void)
{
if(gr_s2!=0)
{
gr_m3=1;
grip=1;
do{mf();}while(gr_s2!=0);
delay_ms(100);
hold();
gr_m3=0;
grip=0;
delay_ms(1000);
}
}
void griper_r (void)
{
if (gr_s1!=0)
{
gr_m3=1;
grip=1;
do{mr();}while(gr_s1!=0);
delay_ms(50);
gr_m3=0;
grip=0;
hold();
delay_ms(500);
}
}
void done(void)
{
do{}while(job!=0);
}
void rotation1(void)
{
// if(pos_s1!=0)
// {
rotat_m4=1;
rotat=1;
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ROBOTIC ARM 2014

mf();
//do{mf();}while(pos_s1!=0);
delay_ms(3000);
hold();
rotat_m4=0;
rotat=0;
delay_ms(1000);
// }
}
{
rotat_m4=1;
rotat=1;
mr();
delay_ms(3000);
// do{mf();}while(pos_s2!=0);
hold();
rotat_m4=0;
rotat=0;
delay_ms(2000);
}
{
rotat_m4=1;
rotat=1;
mr();
delay_ms(3000);
hold();
rotat_m4=0;
rotat=0;
delay_ms(2000);
}
{
rotat_m4=1;
rotat=1;
mf();
delay_ms(6500);
hold();
rotat_m4=0;
rotat=0;
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ROBOTIC ARM 2014

delay_ms(2000);
}
void job_ff(void)
{
if(pos_s1!=0)
{
feed_m5=1;
conver=1;
do{mf();delay_ms(500);}while(feed_s1!=0);
feed_m5=0;
conver=0;
hold();
delay_ms(2000);
}
}
void main() {
P0 = 0x00;
P1 = 0x00;
P2 = 0xFF;
P3 = 0xE0;
init();
while (1)
{
// Turn OFF diodes on PORT0

arm_fw();
griper();
arm_rev();
rotation2();
arm_fw1();
griper_r();
arm_rev();
done ();
arm_fw();
griper();
arm_rev();
rotation3();
arm_fw1();
griper_r();
arm_rev();
rotation4();
}
}
void mf()
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{mc1=1;mc2=0;}
void mr()
{mc1=0;mc2=1;}
void free()
{mc1=0;mc2=0;}
void hold()
{mc1=1;mc2=1;}
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ROBOTIC ARM 2014

5. SELECTION OF COMPONENTS
5.1 SELECTION OF MOTOR
Figure 12 : DC Geared motor
Force and torque

The fundamental purpose of the vast majority of the world's electric motors is to
electromagnetically induce relative movement in an air gap between a stator and rotor to produce
useful torque or linear force.
According Lorentz force law the force of a winding conductor can be given simply by:
or more generally, to handle conductors with any geometry:
The most general approaches to calculating the forces in motors use tensors.
Power
Where rpm is shaft speed and T is torque, a motor's mechanical power output Pem is given by,
in British units with T expressed in foot-pounds,
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ROBOTIC ARM 2014

(horsepower), and,
in SI units with shaft speed expressed in radians per second, and T expressed in newton-meters,
(watts).
For a linear motor, with force F and velocity v expressed in newtons and meters per second,
(watts).
In an asynchronous or induction motor, the relationship between motor speed and air gap power
is, neglecting skin effect, given by the following:
, where
Rr - rotor resistance
Ir2 - square of current induced in the rotor
s - motor slip; ie, difference between synchronous speed and slip speed, which provides
the relative movement needed for current induction in the rotor.
Back emf
Main article: Electromotive force
Since the armature windings of a direct-current motor are moving through a magnetic field, they
have a voltage induced in them. This voltage tends to oppose the motor supply voltage and so is
called "back electromotive force (emf)". The voltage is proportional to the running speed of the
motor. The back emf of the motor, plus the voltage drop across the winding internal resistance
and brushes, must equal the voltage at the brushes. This provides the fundamental mechanism of
speed regulation in a DC motor. If the mechanical load increases, the motor slows down; a lower
back emf results, and more current is drawn from the supply. This increased current provides the
additional torque to balance the new load.
In AC machines, it is sometimes useful to consider a back emf source within the machine; this is
of particular concern for close speed regulation of induction motors on VFDs, for example.
Losses
Motor losses are mainly due to resistive losses in windings, core losses and mechanical losses in
bearings, and aerodynamic losses, particularly where cooling fans are present, also occur.
Losses also occur in commutation, mechanical commutators spark, and electronic commutators
and also dissipate heat.
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Efficiency
To calculate a motor's efficiency, the mechanical output power is divided by the electrical input
power:
,
where is energy conversion efficiency,
output power:
is electrical input power, and
is mechanical
where is input voltage, is input current, is output torque, and is output angular velocity.
It is possible to derive analytically the point of maximum efficiency. It is typically at less than
1/2 the stall torque.
Various regulatory authorities in many countries have introduced and implemented legislation to
encourage the manufacture and use of higher efficiency electric motors. There is existing and
forthcoming legislation regarding the future mandatory use of premium-efficiency inductiontype motors in defined equipment. For more information, see: Premium efficiency and Copper in
energy efficient motors.
Goodness factor
Main article: Goodness factor
proposed a metric to determine the 'goodness' of an electric motor:
Where:
is the goodness factor (factors above 1 are likely to be efficient)
are the cross sections of the magnetic and electric circuit
are the lengths of the magnetic and electric circuits
is the permeability of the core
is the angular frequency the motor is driven at
From this, he showed that the most efficient motors are likely to have relatively large magnetic
poles. However, the equation only directly relates to non PM motors.
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5.2 SELECTION OF LIMIT SWITCHES
Figure 13 : Limit switch

INTRODUCTION
A limit switch is an electromechanical device that consists of an actuator mechanically

linked to a set of contacts.
When an object comes into contact with the actuator, the device operates the contacts to
make or break an electrical connection.
It can determine the presence or absence of an object. It was first used to define the limit
of travel of an object; hence the name "Limit Switch."
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BASIC COMPONENTS
Actuator: The portion of the switch that comes in contact with the object being sensed.
Head: It houses the mechanism that translates actuator movement into contact
movement. When the actuator is moved as intended, the mechanism operates the switch
contacts.
Contact Block: It houses the electrical contact elements of the switch. It typically
contains either two or four contact pairs.
An O-ring provides the seal between the operating head and the switch cover while a
custom-cut gasket guards the switch body against entry of oil, dust, water, and coolants.
Design benefits of the plug-in housing:
Installation without removal of the cover
No moving parts located in base
Reduced downtime because head and body can be replaced quickly without
disturbing wiring in base.
Figure 14 : Working of Limit switch

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ROBOTIC ARM 2014
A side rotary actuator is a shaft protruding from the side of a limit switch head that
operates the switch contacts when rotated.
It can move in a clockwise and/or a counterclockwise direction and is designed for either
uni- or bi-directional operation of the contacts.
A lever arm is typically affixed to the shaft, allowing passing objects to activate the
switch by pushing on the lever.
MAINTAINED VS. MOMENTARY CONTACTS
The contacts of a limit switch change state when a predetermined force or torque
is applied to the actuator.
A spring return (momentary) switch returns its contacts to their original position
when the operating force is removed.
The contacts of a maintained switch remain in the actuated position until force or
torque is applied in the opposite direction.
MECHANICAL ADVANTAGES OF LIMIT SWITCHES
Ease of use
Simple visible operation
Durable housing
Well sealed for reliable operation
High resistance to different ambient conditions found in industry
High repeatability
Positive opening operation of contacts (some models)
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ELECTRICAL ADVANTAGES OF LIMIT SWITCHES
Suitable for switching higher power loads than other sensor technologies (5A at 24V DC
or 10A at 120V AC typical vs. less than 1A for proximities or photoelectrics)
Immunity to electrical noise interference
Immunity to radio frequency interference (walkie-talkies)
No leakage current
Minimal voltage drops
Simple Normally Open and/or Normally Closed operation.
TYPICAL APPLICATIONS
Conveyor systems
Transfer machines
Automatic turret lathes
Milling and boring machines
Radial drills
High speed production equipment
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ROBOTIC ARM 2014

5.3 SELECTION OF LEAD SCREW
Figure 15 : Lead screw
5.4 TERMINOLOGY
The glossary of terms and basic formulas presented below will aid designers in evaluating
system requirements. Critical system parameters , efficiency, maximum load and critical speed
are easily evaluated.
Lead Screw Assembly: A screw and nut device used for the purpose of transmitting motion
or power as opposed to fastening.
Backlash: Free axial movement between screw and nut.
Column Strength: Maximum compressive load that can be applied to a shaft without taking
a permanent set.
Critical Speed: Operating speed of spinning shaft that develops severe vibrations during
rotation. This is a function of length, diameter and end supports.
Drag Torque: The torque necessary to drive the lead screw assembly alone.
Efficiency: Ratio of work output to work input; varies with lead, thread angle and coefficient
of friction .
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Lead: Distance traveled by the nut in one revolution (equal to the screw pitch x the number of
starts).
Lead Angle: The angle made by the helix of the thread at the screw pitch line with plane
perpendicular to the screw axis.
Major Diameter: The diameter of a cylinder formed by the crests of the thread.
Minor Diameter: The root diameter
.
Pitch: The distance as measured parallel to the thread axis between corresponding points on
adjacent thread forms, generally equal to the lead divided by the number of starts.
Self Locking: When it is impossible for a thrust load on a nut to create a torque on its screw,
the screw and nut are said to be selflocking. A self-locking screw will not convert thrust to
torque. Generally, Acme screws are self-locking while most high lead and ball screw are non
self-locking. A non self-locking screw will require a mechanical brake or some other locking
means to a sustain a load.
Stroke: The axial distance traveled by the nut in either direction.
Thread per inch: The reciprocal of the pitch is the number of threadsper inch.
The application engineering information in this section should enable the designer to fully
evaluate the lead screws offered in this catalog.
CRITICAL SPEED / ANGULAR VELOCITY
When a shaft is spinning, as in the case of an operating Lead screw, it will experience excessive
vibration at a speed approximating its natural frequency of vibration. This speed is called the
Critical Speed and good design practice dictates that speed should be limited to 85% of a
shafts first order critical speed. Critical speed is a function of shaft diameter, end support
configuration and unsupported length. These speeds are shown in graphic form for various shaft
diameters, lengths and supports.
COLUMN STRENGTH / COMPRESSION LOAD
Under compressive loading a sufficiently slender shaft will fail by elastic instability at a load
well below the shafts elastic limit or rated load. A graph is provided to show the maximum safe
column load for various diameters, lengths and supports. Shaft slenderness ratios exceeding 200
are not recommended and the curves are dotted for these ratios. Column strength limitations do
not apply to shafts under tension loads.
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5.5 CALCULATIONS
TORQUE, ROTARY TO LINEAR
(Torque needed to move load)
Torque (in. lbs.) = Load (lbs.) x Lead (inches)
2 x efficiency
TORQUE, LINEAR TO ROTARY (Backdriving Torque)
Torque to hold load = Load x Lead x Efficiency
2
If greater than 1 may backdrive*
FORWARD DRIVING EFFICIENCY (See screw data)
EF = (tan ) [(cos n - f tan ) / (cos n tan + f )]
BACKWARD DRIVING EFFICIENCY
EB = (1/tan ) [(cos n tan - f ) / (cos n + f tan ) ]
= Load x Lead x Efficiency
2
f = Coefficient of friction
EB = Back drive efficiency
EF = Forward drive efficiency
= Thread lead angle
n = Thread angle in normal plane. (29 for ACME Thread,
30 for Metric Trapezoidal, 40 for Precision PS Series.)
SCREW RPM
RPM = Velocity (in/ min)
Lead (in/ rev)
COLUMN LOAD STRENGTH (Based on Eulers Formula)
Pcr = 14.03 x 106Fcd4
L2
Pcr = maximum load (lbs.)
Fc = end support factor (see page 3-3)
= .25 one end fixed, other free
= 1.00 both ends supported
= 2.00 one end fixed, other supported
= 4.00 both ends fixed
d = root diameter of screw (inches)
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L = maximum distance between nut & load carryingbearing (inches)
When possible, design for tension loads to eliminate the buckling factor and reduce the required
screw size.
CRITICAL SCREW SHAFT SPEED (Maximum rotational speed of a screw)
Cs = F x 4.76 x 106 x d / L2
Cs = Critical speed (RPM)
d = root diameter of screw (inches)
L = Length between supports (inches)
F = end support factor (see page 3-3)
.36 one end fixed, other free
1.00 simple supports both ends
1.47 one end fixed, one simple
2.23 both ends fixed
Critical shaft speed should be reduced to 85% to allow for otherfactors such as alignment and
straightness.
Lead Screw Formulas and Sample Calculations Linear Speed (ipm)
=
1 Linear Speed= steps/second / steps/revolution
where: p = lead screw pitch in threads per inch Axial Force (lb)
2 Force = 2*3.14/16 x T x p x eff.
16 where: T = torque (oz in)
p = lead screw pitch in threads per inch eff.
efficiency expressed as a decimal: 90% = 0.90
Ball screws are generally 85% to 95% efficient.
Acme lead screw efficiency is generally 35% to 45%, but can be as high as 85%. A.
Calculating the torque required to accelerate a mass moving horizontally and driven by a ball
bearing lead screw and nut.
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ROBOTIC ARM 2014
The total torque the motor must provide includes the torque required to:
a. accelerate the weight
b. accelerate the lead screw
c. accelerate the motor rotor
d. overcome the frictional force
To calculate the rotational equivalent of weight w:
I(eq)
I(eq) = w x 1/ p2
2 where: w = weight (lb)
p = pitch (threads per inch)
= equivalent polar inertia (lb in2)
to calculate lead screw inertia (steel screw)

I (screw) = D4 x length x .028
Example: Weight = 1000 lb

Velocity = 0.15 feet per second Time to Reach
Velocity = 0.1 seconds Ball Screw
Diameter = 1.5"
Ball Screw Length = 48"
Ball Screw Pitch = 5 threads per inch Motor Rotor Inertia = 2.5 lb in2
Friction Force to Slide Weight = 6
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5.6 Major Electronic Components
Sr.
NO
1
2
3
4
5
6
7
8
9
10
11
Component
Function
9 V Step down
transform
5 V Step down
transform
Diodes
Capacitors
7812 and 7805
Motor driver
ULN2803
Controller
P89V51RD2
12 V Really
Transistor BC547
Pull-up resistors
A103J
PCB board 12cm
20cm
Reset switch
Controlled Power supply for motor

Controlled Power supply for microcontroller
Bridge ckt, for signal conditioning and rectification
For noise reduction and as a filter ckt.
for control and drive motors
As a switch to for motors
In reset ckt. As a switch
To protect controller from damage.
For mounting and connecting all components of ckt.
To reset the controller when needed
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ROBOTIC ARM 2014

6. DRAWING
6.1 Drawing Of Base
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7. CONSTRUCTION
7.1 CONSTRUCTION OF ROBOTIC ARM ASSEMBLY.
As our project is having no. of subassemblies. Hence we constructed our

project step by step. During the construction we divided our project in
three construction phases for the sake of convenience of construction.
The major phases of construction are as follows:
1. Base frame
2. Acrylic body structure of arm
3. Conveyors
7.2 Base frame:
As the whole weight of arm along with the payload is directly comes
over the base. And also the balancing is largely depends on the base
frame. Hence the base frame must be very rigid and strong. So that it
does not deflected the arm and keeps the accuracy of arm.
For the construction of base frame. The raw material M.S angles
(20mm20mm) are used. These angles are cut as per the drawing with
the help of cutting saw. The cut parts of the angle plate are joined with
the help of arc welding process as the arc welding gives the joint as
strong as base metal hence we used arc welding for joining and
fabrication of angle plate. The plate is joined in such a way that it
resembles to a supporting table. After welding operation the grinding is
done for the finishing the joints.
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ROBOTIC ARM 2014

7.3 Acrylic body of arm:
The arm must be having light weight with enough strength so that the
body of arm is made up of acrylic material. These acrylic body
construction contains the accurate cutting of acrylic sheets and drilling
on acrylic sheet with accuracy as per the design details.
The cutting of the acrylic sheet is done with the help of power hack-saw.
As it gives the accuracy and fine cuts. The drilling is done with portable
drilling machine.
7.4
Conveyors:
The conveyors are the separate unit in our project which are used to
show the application of robotic arm. The conveyor consist Rollers, Belt,
Motor support and base as a major components.
For this the base of conveyor is cut with the help of power heck-saw.
Then the rollers are made with the help of using standard PVC pipes of
diameter 8 mm. in this joining and pasting is done with the help of
adhesive chemical flex quick. The conveyor belt needs cutting and
stitching operation. The cutting is done with the help of simple scissor and
stitching is done on stitching machine.
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8. WORKING
The working of this ROBOTIC ARM is a combination of rotary motion of base and bowing
motion of elbow. There are several parts working together for simultaneous motion and
operations to be carried out on a ROBOTIC ARM.
As per the experience, in terms of quality and quantity of the phenomena to be found in
automation industry the sensors and motors are mostly used for automation. We had use 4
sensors i.e. limit switch, and 6 motors i.e. dc geared motor for required operation that we have to
carry.
As the name implies pick and place robotic arm the main task is to pick and place components
sfrom one place to another place without human interface. For that purpose we had use several
sensors and motors. The model is made in acrylic material so it is light in weight and has a great
strength to pick the component as the system required. It works on mainly microcontroller circuit
i.e. p89v51rd2. The controller is programmed in C and assembly and the program is compile in
microcontroller with the help of flash magic software. The controller is reprogrammable so we
can reprogram the system. As change in cycle time or operation the program is changeable and it
makes whole system versatile and user friendly.
To show the application of robotic arm we are constructed prototype model for bottling plant.
The working of arm is simple. The bottle from conveyor 1 comes to the predefined position.
Then arm moves from initial position to the position of bottle. Then gripper holds the bottle and
arm moves to machining center and release the bottle. Then the operation of bottle filling is
done. Then push button is pushed as defined in program manually. And again it holds the bottle
in gripper and moves to conveyor 2. Conveyor 2 runs and bottle moves to dispatch. This process
repeats continuously.
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8.1 Project overall working
Figure 19 : project overall working
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ROBOTIC ARM 2014

8.2 Block diagram of Circuit
Figure 20 : Block Diag. Of Circuit
8.3 Signal conditioning:

The output signal from the sensor has generally to be processed in some way to make it suitable
for the next stage of the operation. The signal may be, for example too small and have to be
amplified, contain interference which has to be removed, be non-linear and required
linearization, be analogue and have to be made digital, be digital and have to be made analogue,
be a resistance change and have to be made current change, be a voltage change and have to be
made into suitable size current change, etc. all this changes can be referred as signal
conditioning.
Interfacing with microcontroller:
Input and output devices are connected to a microcontroller system through ports. The term
interface is used for the item that is used to make connections between devices and a port. Thus
there could be inputs from sensor, switches and key boards and output to display and actuators.
The simple interface could be a piece of wire. However interface often consist of signal
conditioning and protection, the protection being to prevent damage to the microcontroller
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ROBOTIC ARM 2014

system for example inputs needing to be protected against excessive voltage or signals or wrong
polarity.
microcontroller required inputs which are digital, thus a conversion of analog to digital signal is
necessary if the output from sensor is analogue .signal conditioning might also be needed with
digital signal to improve their quality. Thus the interface may include number of elements.
There is also output from microcontroller, perhaps to operate an actuator. A suitable interface is
also required here. The actuator might require analog signal and so the digital signal output from
the microcontroller need to convert to an analogue signal. There can also be a need for protection
to stop any signal becoming inputted back through the output port to damage the microcontroller.
Signal conditioning process:
Protection to prevent damage to the next element, e.g. a microcontroller as a result of

high current or voltage. Thus there can be series current-limiting resistors, fuses to break
if the current is too high, polarity and voltage limitation circuits. Hence in our ckt we
used four pull-up resistors A103J and fuse which protect the controller from being
damage
Eliminating or reducing noise. For example, filters might be used to eliminate mains
noise from a signal. For this Capacitors 7812 used
Signal manipulation, example. Making it a linear function of some variable. The signals
from some sensors e.g. a flow meter are nonlinear and thus a signal conditioner might be
used so that the signal fed on to the next element is linear.
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ROBOTIC ARM 2014
Figure 21: Power Supply And Rectification
Getting the signal into the right type of signal. This can mean making the signal into a
D.C voltage or current. Thus for example, the resistance change of a strain gauge has to
be converted in to a voltage change. This can be done by the use of Wheatstone bridge
and using the out of balance voltage. It can mean making the signal digital or analogue.
This is done by Bridge ckt, amplifiers and analogue to digital convertor.
Getting the level of the signal right. For example the signal from a thermocouple might
be just a few millivolts. If the signal is to be fed into an analogue to digital converter for
inputting to a microcontroller then it need to be made much larger, volts rather than
millivolts. For this Operational amplifiers and capacitors are used are used.
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ROBOTIC ARM 2014

9. PROCESS SHEET
9.1 PROCESS SHEET FOR BASE
PART NO. : 1
MATERIAL : M.S.
BASE : 1
FLOW PROCESS CHART
NO
OPERATION
DESCRIPTION
Inspection of Langle bar.
Take 1 inch X
2400 mm.
Grinding
Welding
MACHINE TOOLS
USED
Circular
Circular
Hack Saw
Hack Saw
Blade
GAUGE
Bench
Grinder
Welding
Machine
Mannual
Insp.
Mannual
Insp.
Grinding
wheel
Welding
rod
Vernier
TIME IN
MINUTES
20
15
30
Total Time = 65min
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9.2 PROCESS SHEET FOR ARM BODY
PART NO. : 2
MATERIAL : Acrylic Sheet
ARM BODY: Various part
FLOW PROCESS CHART
NO
1
2
OPERATION
MACHINE TOOLS
DESCRIPTION USED
Base Plate
Hack Saw
Saw
Hack Saw
Saw
Round Base
Plate
Shoulder
Hack Saw
Saw
Elbow
Hack Saw
Saw
Motor Supporter
Hack Saw
Saw
counter Weight
sopporter
Hack Saw
Saw
GAUGE
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
TIME IN
MINUTES
10
10
10
10
20
10
Total Time = 70min
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ROBOTIC ARM 2014

9.3 PROCESS SHEET FOR CONVEYOR
PART NO. : 3
MATERIAL : Various
Conveyor : 2
FLOW PROCESS CHART
NO
1
2
OPERATION
MACHINE TOOLS
DESCRIPTION USED
Conveyor Base
Hack Saw
Saw
Hack Saw
Saw
Conveyor
Supporter
Conveyor Roller
Hack Saw
Saw
Stitching Belt
Stitching
GAUGE
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
TIME IN
MINUTES
20
20
50
10
Total Time = 100min
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9.4 PROCESS SHEET FOR WOODEN BASE
PART NO. : 4
MATERIAL : Plywood + Foam sheet
FLOW PROCESS CHART
NO
MACHINE TOOLS
USED
Hack Saw
Saw
OPERATION
DESCRIPTION
Cutting Plywood
Board
Pasting foam
sheet
Painting
Pasting sticker
1
2
GAUGE
Mannual
Insp.
Mannual
Insp.
Mannual
Insp.
TIME IN
MINUTES
20
20
20
40
Total Time = 100min
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ROBOTIC ARM 2014

10.MATERIAL LIST
MATERIAL LIST
PART NO.
NAME OF PART
MATERIAL
QTY.
L angle bar 1 inch X

2400 mm
Bearing 2530
Acrylic sheet -12sq ft
X 3mm
Lead screw
Motor
plate
Inges
Nut bolt
Gripper
Counter weight
Alluminium sheet
Motor coupling
Sliding wheel
Plywood board 15 sq.
ft X 8mm
Conveyor roller
Conveyor support
Washers dia 20 X
3mm
Screw inch
Screw 1 inch
Screw 2 inch
Electrical circuit
Push button
M.S
Std
Acrylic
10
1
M.S
M.S
Al alloy
M.S
Std
C.I
Al
Al
Std
Wood
2
6
2
4
12
1
3
8
8
4
1
Foam sheet
Foam sheet
M.S
4
8
38
M.S
M.S
M.S
-
50
100
30
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
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11.COST ESTIMATION
11.1 APROXIMATE COST

SR. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
PART NAME
COST
Acrylic Sheet
Motor
Electric Component
Electric Circuit Assembly
Foam Sheet
Lead Screw
coupling
M.S. L-Bar
Bearing
Conveyor
Painting
Asthestics
Other STD Part
1000
3000
11500
4000
1500
300
100
500
250
1000
500
500
1500
Total
25,650
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11.2 MATERIAL LIST
TABLE NO : A
SR NO.
NAME OF
PART
1.
L angle bar
2.
3.
4.
Bearing 2530
Acrylic sheet
Lead screw
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
plate
Inges
Nut bolt
Counter weight
Alluminium sheet
Motor coupling
Roller bearing
Plywood board
Conveyor roller
Conveyor support
Washers
Screw inch
Screw 1 inch
Screw 2 inch
SIZE /
Per (mm)
QUANTITY
Cost in RS /-
1 inch X 2400
mm
Bearing 2530
12sq ft X 3mm
Dia 8mm X 1
mtr
1 inch
100mm X 3 mm
Dia 20 mm
15 sq. ft X 8mm
dia 20 X 3mm
inch
1 inch
2 inch
1000
5
1
1
200
1080
460
2
4
15
3
8
3
4
50
60
150
400
20
60
80
600
120
40
72
37.5
150
60
38
50
100
30
Total
4639.5
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ROBOTIC ARM 2014

11.3 MATERIAL LIST - ACCESSORIES
TABLE NO : B
SR NO.
PARTICULARS
QTY.
COST IN RS. /-
1
2
3
4
5
6
Electronic Componant
Wire
Paint
2-way switch
Gripper
Motor
1
4
2
1
6
11500
500
200
40
950
2750
Total
15,940
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ROBOTIC ARM 2014

11.4 MATERIAL LIST
TABLE NO : C
M/C USED /
PROCESS
TOTAL TIME
IN min
RATE / HOUR
COST IN RS. /-
Electric Circuit
Assembly
Drilling
Welding
Conveyor Assembly
480
375
3000
80
120
240
225
250
250
300
500
1000
Total
4800
Total Cost = Table A + Table B + Table C .

= 4,639.5 + 15,940 + 4,800
= 25,379.5
= 25,500 Rs. Approx.
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ROBOTIC ARM 2014

12.ADVANTAGES AND DISADVANTAGES
12.1 ADVANTAGES
Quality:
Industrial automated robots have the capacity to dramatically improve product quality.
Applications are performed with precision and high repeatability every time. This level of
consistency can be hard to achieve any other way.
Production:
With robots, throughput speeds increase, which directly impacts production. Because an
automated robot has the ability to work at a constant speed without pausing for breaks, sleep,
vacations, it has the potential to produce more than a human worker.
Safety:
Robots increase workplace safety. Workers are moved to supervisory roles where they no longer
have to perform dangerous applications in hazardous settings.
Savings:
Improved worker safety leads to financial savings. There are fewer healthcare and insurance
concerns for employers. Automated robots also offer untiring performance which saves valuable
time. Their movements are always exact, minimizing material waste.
1. Figure 22 : advantages and disadvantages

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ROBOTIC ARM 2014

12.2 DISADVANTAGES
Expense:
The initial investment to integrated automated robotics into your business is significant,
especially when business owners are limiting their purchases to new robotic equipment. The cost
of robotic automation should be calculated in light of a business' greater financial budget.
Regular maintenance needs can have a financial toll as well.
ROI:
Incorporating industrial robots does not guarantee results. Without planning, companies can have
difficulty achieving their goals.
Expertise:
Employees will require training program and interact with the new robotic equipment.
This normally takes time and financial output.
Safety:
Robots may protect workers from some hazards, but in the meantime, their very presence can
create other safety problems. These new dangers must be taken into consideration.
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ROBOTIC ARM 2014

13.APPLICATIONS
The most developed robot in practical use today is the robotic arm and it is seen in applications
throughout the world. We use robotic arms to carry out dangerous work such as when dealing
with hazardous materials. We use robotic arms to carry out work in outer space where man
cannot survive and we use robotic arms to do work in the medical field such as conducting
experiments without exposing the research. Some of the most advanced robotic arms have such
amenities as a rotating base, pivoting shoulder, pivoting elbow, rotating wrist and gripper
fingers. All of these amenities allow the robotic arm to do work that closely resembles what a
man can do only without the risk
13.1 Welding Robot Applications

Arc Welding
Electron Beam
Flux Cored Welding
Laser Welding
Mig Welding
Plasma Cutting
Plasma Welding
Resistance Welding
Spot Welding
Tig Welding
Welding Automation
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ROBOTIC ARM 2014
13.2 Material Handling Robot Applications
Dispensing
Injection Molding
Machine Loading
Machine Tending
Material Handling
Order Picking
Packaging
Palletizing
Part Transfer
Pick and Place
Press Tending
Vision
13.3 Other Robot Applications

Assembly
Bonding / Sealing
Cleanroom
Coating
Cutting
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ROBOTIC ARM 2014

Deburring
Drilling
Fiberglass Cutting
Foundry
Grinding
Material Removal
Milling
Painting Automation
Polishing
Routing
Spindling
Thermal Spray
Waterjet
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ROBOTIC ARM 2014

14.CONCLUSION
Robotics is a technology with a future, and is a technology for the future. If present trends
continue, and if some of the laboratory research currently underway is ultimately converted into
practicable technology, robots of future will be mobile units with one or more arms, multiple
sensor capabilities and the computational and data processing power of todays mainframe
computers. They will be able to respond to human voice command. They will be able to receive
general instructions and will translate those instructions using artificial intelligence into a specific
set of actions required to carry them out. In short, future robots will have many of the attributes of
human beings.
Getting from the present to the future will require much work in mechanical engineering, computer
science, electrical engineering, industrial engineering, materials technology, manufacturing
systems engineering, and the social sciences. A combination of economic and technical factors will
determine how the future applications will be introduced. Although there is significant
development in the science of robots, still its usage is limited due to high cost of production, less
availability of resources. If we can overcome these limitations, more benefits can be gained from
robotics.
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14.1 FUTURE SCOPE
We can theorize a likely profile of the future robot based on the various research activities
that are currently being performed. The features and capabilities of the future robot will
include the following (it is unlikely that all future robots will possess all of the features
listed).
Intelligence: The future robot will be an intelligent robot, capable of making decisions
about the task it performs based on high-level programming commands and feed back
data from its environment.
Sensor capabilities: the robot will have a wide array of sensor capabilities including
vision, tactile sensing, and others. Progress is being made in the field of feedback and
tactile sensors, which allow a robot to sense their actions and adjust their behavior
accordingly. This is vital to enable robots to perform complex physical tasks that require
some active control in response to the situation. Robotic manipulators can be very precise,
but only when a task can be fully described.
Tele presence: it will possess a presence capability, the ability to communicate
information about its environment (which may be unsafe for humans) back to a remote
safe location where humans will be able to make judgments and decisions about actions
that should be taken by the robots.
Mechanical design: the basic design of the robot manipulator will be mechanically more
efficient, more reliable, and with improved power and actuation systems compared to
present day robots. Some robots will have multiple arms with advanced control systems
to coordinate the actions of the arms working together. The design of robot is also likely
to be modularized, so that robots for different purposes can be constructed out of
components that are fairly standard.
Mobility and navigation: future robots will be mobile, able to move under their own
power and navigation systems.
Universal gripper: robot gripper design will be more sophisticated, and universal hands
capable of multiple tasks will be available.
Systems integration and networking: robots of the future will be user friendly and
capable of being interfaced and networked with other systems in the factory to achieve a
very high level of integration.
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15. REFERENCES
[1] Saeed B Niku, Introduction to roboticsanalysis,systems,applications,Pearson Education.Page
no:- 30-68.
[2] Mikell P Groover, Industrial roboticstechnology,programming and applications,Mc Graw
Hill. Page no:-110-180
[3] S.R.Deb,Robotics technology and Flexible automation by,Mc Graw Hill. Page no:-32-75
[4] R.K Mittal and I.J.Nagrath,Robotics & control by Tata McGrar Hills. Page no:-66-90
[5] Ha duk M., Bal V.: Measurement deviation movement of robot Kuka from define
tra ectory with laser senzor ., IV medizn rodn konferencia , Mechanika z .67, Modulowe
technologie i konstrukc e w budowie maszyn , zesz v 2006, Polsko, str. 261-264(3).
[6] C. Blume and W. Jakob Programming Languages for Industrial Robots, :Springer-Verlag
(3)
[7] I.Cox and N.Gehani "Exception handling in robotics", IEEE Computer.
[8] Fundamentals of Sensing Rockwell Automation / Allen Bradley
[9] Hameyer, Kay (2001). "Electrical Machine I: Basics, Design, Function, Operation". RWTH
Aachen University Institute of Electrical Machines. Retrieved 11 January 2013.
[10] Manufacturing Technology By P N Rao - http://ebookdig.biz/ebook/q/pdf/manufacturingtechnology-by-p-n-rao.html
[11] Design of Robotic Arm Using Delay Based ... ASMEproceedings.asmedigitalcollection.asme.org/pdfaccess.ashx?ResourceID...by DASAB
Pandey - 2008 - Related articles
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ROBOTIC ARM 2014

1. PROJECT IDEA GENERATION

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Figure 1 :scheamatic reprensantation of project concept

In our project we made a embedded system based ROBOTIC ARM with

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Figure 2 : Show of wrist & End-effectors.

Description: A spur gear meshing with a worm gear.

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

The object to be lifted is: - Metal Plates

Weight of the object: - 50-80gm

The link has two parts, Part1 and Part2.

The Arm manipulator has length as follows:Part1 = 25 cm Part2 = 5 cm

4.1.3 Spur Gear Design and selection

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Figure 3 : View of spur gear arrangement 1

Figure 4: View of spur gear arrangement 2

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Description:Forces on spur gear teeth

20-tooth , 8 pitch , 1-inch-wide , 20 pinion transmits 5 hp at 1725 rpm to a 60-tooth gear.

ROBOTIC ARM 2014

4.1.4 DESIGN THE ROBOTIC ARM

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Force Calculation of Joints :

This will provide a fundamental understanding of moment arm calculations for

Figure 5 : View of loads /moments on joints.

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Figure6 : View of Shaft and bearing arrangement

Power and Torque Transmitted

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Force Calculation of Joints

Figure 7 : View of degree of freedom

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

4.2 ELECTRIC CIRCUIT DESIGN

Figure 8 : pcb design for circuit roboarm

4.2.2 PCB DESIGN FOR ROBOTIC TRACK

Figure 9 : pcb design for robotic track

ROBOTIC ARM 2014

Figure 10 : Block Diagram Of P89v51rd2

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

Figure 11 : pin diagram of p89v51rd2

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

D. Y. PATIL COLLEGE OF ENGINEERING & TECHNOLOGY KOLHAPUR.

ROBOTIC ARM 2014

ROBOTIC ARM 2014