IEEETRANSACTIONSONINDUSTRIALINFORMATICS,VOL.1,NO.

1,APIRAL2017

SMART PHONE CONTROLLEDFORK LIFT ROBOT

Chandraganth.S, Ezhilarasan.C, Kamalakannan.S and Mr.Suresh.S Senior Member, IEEE

Abstract The authors report in heavy tool industries, lifting heavy tools only by the man intervention is not sufficient. In that
case we will be using the mechanical vehicles like fork lift. To overcome this problem, we are introducing the automation based
system SMART PHONE CONTROLLED FORK LIFT ROBOT. Here we are able to operate the drive without the direct
contact of vehicle. To achieve this we are using ATMEGA328p which acts as a mediator to transmit and control the robot with
the help of SMART PHONES. It makes the work easier and saves the time. We have traditional fork lift vehicle which operates
with the fuel. Its fuel cost is high and it release toxic gases like carbon-di-oxide, carbon monoxide etc., which causes the
environmental pollution. The aim is to improve forklift dispatching and reduce the costs associated with the delays of
loading/unloading delivery trucks. To that end, an integrated system including both hardware and software is constructed. This
makes the work easier, energy efficient, saves the time and also it is pollution free as we are using battery as a DC power source
which can be re-energized.

INTRODUCTION

In earlier forklifts are rated for loads at a specified maximum weight and a specified forward centre of gravity This
information is located on a nameplate provided by the manufacturer, and loads must not exceed these specifications. In many
jurisdictions it is illegal to alter or remove the nameplate without the permission of the forklift manufacturer. An important
aspect of forklift operation is that it must have rear-wheel steering. While this increases maneuverability in tight cornering
situations, it differs from a drivers traditional experience with other wheeled vehicles. While steering, as there is no caster
action, it is unnecessary to apply steering force to maintain a constant rate of turn. In traditional fork lift vehicle which
operates with the fuel. Its fuel cost is high and it release toxic gases like carbon-di-oxide, carbon monoxide etc., which causes
the environmental pollution. To overcome this problem, we are introducing the automation based system their by we can able
control the forklift by using the mobile phones. Here we are able to operate the drive without the direct contact of vehicle. This
reduce energy consumption and thus make system efficient. pollution due to usage of battery. In early forklifts are either with
levers directly manipulating the hydraulic valves, or by electrically controlled actuators, using smaller "finger" levers for
control. The latter allows forklift designers more freedom in ergonomical design. Forklift trucks are available in many
variations and load capacities. In a typical warehouse setting most forklifts have load capacities between one and five tons.
Larger machines, up to 50 tons lift capacity, are used for lifting heavier loads, including loaded shipping containers. In addition
to a control to raise and lower the forks (also known as blades or tines), the operator can tilt the mast to compensate for a
load's tendency to angle the blades toward the ground and risk slipping off the forks. Tilt also provides a limited ability to
operate on non-level ground. This can be overcome by using arduino board their by we can control the upward and downward
motion by simply injecting coading to the arduino board.

DETAILED STUDY

Forklift is an small industrial vehicle which has been used in every industries for moving the products or load form one place
to another. In early forklifts are either with levers directly manipulating the hydraulic valves, or by electrically controlled
actuators, using smaller "finger" levers for control. The latter allows forklift designers more freedom in ergonomical design.
Forklift trucks are available in many variations and load capacities. In a typical warehouse setting most forklifts have load
capacities between one and five tons. This project had already been existed with lot of disadvantages,the traditional fork lift
vehicle which operates with the fuel. Its fuel cost is high and it release toxic gases like carbon-di-oxide, carbon monoxide etc.,
which causes the environmental pollution, this system takes more time to transfer the product form one place to another place
which reduces the work speed of the industry,by considering all these drawbacks of the existing system we had been
implemented the system which has similar working operation same as that of existing one but this can be controlled by using
smart phones rather than that of using the petrol or diesel engines which could cause some kind of pollutions.
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PROPOSED ARCHITECTURE

ARDUINO UNO R3

This is the Arduino Uno R3. In addition to all the features of the previous board, the Uno now uses an ATmega16U2 instead of
the 8U2 found on the Uno (or the FTDI found on previous generations). This allows for faster transfer rates and more memory.
No drivers needed for Linux or Mac (inf file for Windows is needed and included in the Arduino IDE), and the ability to have
the Uno show up as a keyboard, mouse, joystick, etc.The Uno R3 also adds SDA and SCL pins next to the AREF. In addition,
there are two new pins placed near the RESET pin. One is the IOREF that allow the shields to adapt to the voltage provided
from the board. The other is a not connected and is reserved for future purposes. The Uno R3 works with all existing shields
but can adapt to new shields which use these additional pins.

The Arduino Uno is a microcontroller board based on the ATmega328. Arduino is an open-source, prototyping platform and its
simplicity makes it ideal for hobbyists to use as well as professionals. The Arduino Uno has 14 digital input/output pins (of
which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz crystal oscillator, a USB connection, a power jack, an ICSP
header, and a reset button. It contains everything needed to support the microcontroller; simply connect it to a computer with
a USB cable or power it with a AC-to-DC adapter or battery to get started.

MOTOR DRIVE (LC293D)

L293D is a typical Motor driver or Motor Driver IC which allows DC motor to drive on either direction. L293D is a 16-pin IC
which can control a set of two DC motors simultaneously in any direction. It means that you can control two DC motor with a
single L293D IC. Dual H-bridge Motor Driver integrated circuit (IC).The l293d can drive small and quiet big motors as well,
check the Voltage Specification at the end of this page for more info.You can Buy L293D IC in any electronic shop very easily
and it costs around 70 Rupees (INR) or around 1 $ Dollar (approx Cost) or even lesser cost. You can find the necessary pin
diagram, working, a circuit diagram, Logic description and Project as you read through. It works on the concept of H-bridge.
H-bridge is a circuit which allows the voltage to be flown in either direction. As you know voltage need to change its direction
for being able to rotate the motor in clockwise or anticlockwise direction, Hence H-bridge IC are ideal for driving a DC motor.

In a single L293D chip there are two h-Bridge circuit inside the IC which can rotate two dc motor independently. Due its size it
is very much used in robotic application for controlling DC motors. Given below is the pin diagram of a L293D motor
controller.There are two Enable pins on l293d. Pin 1 and pin 9, for being able to drive the motor, the pin 1 and 9 need to be
high. For driving the motor with left H-bridge you need to enable pin 1 to high. And for right H-Bridge you need to make the
pin 9 to high. If anyone of the either pin1 or pin9 goes low then the motor in the corresponding section will suspend working.
Its like a switch. The L293D is a 16 pin IC, with eight pins, on each side, dedicated to the controlling of a motor. There are 2
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INPUT pins, 2 OUTPUT pins and 1 ENABLE pin for each motor. L293D consist of two H-bridge. H-bridge is the simplest
circuit for controlling a low current rated motor.
The Theory for working of a H-bridge is given below. H-bridge is given this name because it can be modelled as four switches
on the corners of H.

The basic diagram of H-bridge is given below

In the given diagram, the arrow on the left points to the higher potential side of the input voltage of the circuit. Now if the
switches S1 & S4 are kept in a closed position while the switches S2 & S3 are kept in a open position meaning that the circuit
gets shorted across the switches S1 & S4. This creates a path for the current to flow, starting from the V input to switch S1 to
the motor, then to switch S4 and then the exiting from the circuit. This flow of the current would make the motor turn in one
direction. The direction of motion of the motor can be clockwise or anti-clockwise, this is because the rotation of the motor
depends upon the connection of the terminals of the motor with the switches.For simplicity, lets assume that in this condition
the motor rotates in a clockwise direction.Now, when S3 and S2 are closed then and S1 and S4 are kept open then the current
flows from the other direction

and the motor will now definitely rotates in counter-clockwise direction When S1 and S3 are closed
and S2 and S4 are open then the STALL condition will occur.

L293D Pin Diagram :

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L293D Logic Table.

Let us consider a Motor connected on left side output pins (pin 3,6). For rotating the motor in clockwise direction the input
pins has to be provided with Logic 1 and Logic 0.

Pin 2 = Logic 1 and Pin 7 = Logic 0 | Clockwise Direction

Pin 2 = Logic 0 and Pin 7 = Logic 1 | Anticlockwise Direction
Pin 2 = Logic 0 and Pin 7 = Logic 0 | Idle [No rotation] [Hi-Impedance state]
Pin 2 = Logic 1 and Pin 7 = Logic 1 | Idle [No rotation]

In a very similar way the motor can also operate across input pin 15,10 for motor on the right hand side.

Circuit Diagram For L293D motor driver IC controller.

Voltage Specification
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VCC is the voltage that it needs for its own internal operation 5v; L293D will not use this voltage for driving the motor. For
driving the motors it has a separate provision to provide motor supply VSS (V supply). L293d will use this to drive the motor.
It means if you want to operate a motor at 9V then you need to provide a Supply of 9V across VSS Motor supply.

The maximum voltage for VSS motor supply is 36V. It can supply a max current of 600mA per channel.Since it can drive
motors Up to 36v hence you can drive pretty big motors with this l293d.

VCC pin 16 is the voltage for its own internal Operation. The maximum voltage ranges from 5v and upto 36v.

BLUETOOTH MODULE

The Bluetooth module HC-05 is a MASTER/SLAVE module. By default the factory setting is SLAVE. he Role of the module
(Master or Slave) can be configured only by AT COMMANDS. The slave modules cannot initiate a connection to another
Bluetooth device, but can accept connections. Master module can initiate a connection to other devices. The user can use it
simply for a serial port replacement to establish connection between MCU and GPS, PC to your embedded project, etc.

HC05 module is an easy to use Bluetooth SPP (Serial Port Protocol) module,designed for transparent wireless serial
connection setup.The HC-05 Bluetooth Module can be used in a Master or Slave configuration, making it a great solution for
wireless communication.This serial port bluetooth module is fully qualified Bluetooth V2.0+EDR (Enhanced Data Rate) 3Mbps
Modulation with complete 2.4GHz radio transceiver and baseband. It uses CSR Bluecore 04External single chip Rluetooth
system with CMOS technology and with AFH (Adaptive Frequency Hopping Feature).

PIN DIAGRAM:

PIN DESCRIPTION:

The HC-05 Bluetooth Module has 6pins. They are as follows:

ENABLE:
When enable is pulled LOW, the module is disabled which means the module will not turn on and it fails to
communicate.When enable is left open or connected to 3.3V, the module is enabled i.e the module remains
on and communication also takes place.
Vcc:
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Supply Voltage 3.3V to 5V

GND:
Ground pin
TXD & RXD:
These two pins acts as an UART interface for communication
STATE:
It acts as a status indicator.When the module is not connected to / paired with any other
bluetoothdevice,signal goes Low.At this low state,the led flashes continuously which denotes that the module is not
paired with other device.When this module is connected to/paired with any other bluetoothdevice,the signal
goes High.At this high state,the led blinks with a constant delay say for example 2s delay which indicates that the
module is paired.
BUTTON SWITCH:
This is used to switch the module into AT command mode.To enable AT command mode,press the button
switch for a second.With the help of AT commands,the user can change the parameters of this module but only when
the module is not paired with any other BT device.If the module is connected to any other bluetooth device, it starts to
communicate with that device and fails to work in AT command mode.

PROGRAM FOR HC-05 BLUETOOTH MODULE:

The program given below is the HC-05 bluetooth module program.This process is quite different from others since we are
going to use android mobile to control and communicate with arduino.Here the bluetooth module acts as an interface between
our mobile and Arduinoboard.Before getting into the execution process,follow the given procedure:

First of all,the user should install an application called Bluetooth SPP PRO from the playstore which is a free
application.

After installation,pair the bluetooth module to your mobile as like connecting one device to other using bluetooth.The
default pairing code is 1234.

Upload the given program to the Arduino Uno board.After uploading the code,unplug the USB from the arduino.

Now use external power adapter to power the Uno board.

The Bluetooth SPP PRO has three types of communication mode.Here Byte stream mode is used to communicate. So select that
mode and give the input as 1,as soon as the input has given the led will turn on and for 0 led will turn off.

DC MOTOR

Geared DC motors can be defined as an extension of DC motor which already had its Insight details demystified here. A geared
DC Motor has a gear assembly attached to the motor. The speed of motor is counted in terms of rotations of the shaft per
minute and is termed as RPM .The gear assembly helps in increasing the torque and reducing the speed. Using the correct
combination of gears in a gear motor, its speed can be reduced to any desirable figure. This concept where gears reduce the
speed of the vehicle but increase its torque is known as gear reduction. This Insight will explore all the minor and major details
that make the gear head and hence the working of geared DC motor.

SMART PHONES

A smartphone is a mobile phone (also known as cell phones or cell mobiles) with an advanced mobile operating system that
combines features of a personal computer operating system with other features useful for mobile or handheld use. [1][2]
[3]
Smartphones, which are usually pocket-sized, typically combine the features of a mobile phone, such as the abilities to place
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and receive voice calls and create and receive text messages, with those of other popular digital mobile devices like personal
digital assistants (PDAs), such as an event calendar, media player, video games, GPS navigation, digital camera and digital
video camera. Smartphones can access the Internet and can run a variety of third-party software components ("apps"
from Google Play Store, Apple App Store etc). They typically have a color display with a graphical user interface that covers
more than 76% of the front surface. The display is almost always a touchscreen and sometimes additionally a touch-enabled
keyboard like the Priv/Passport BlackBerrys, which enables the user to use a virtual keyboard to type words and numbers and
press onscreen icons to activate "app" features.

APPLICATION

At the end of this article, you will realize how wonderful can be a 17-year old wireless technology and how easy is to control a
robot using a simple application and an Android device. Every technology has its limits, and the Bluetooth technology is
perhaps the best way to control the robot remotely as long as it is in the range of the Android device. The wireless
communication is between two systems. One is the device that runs the Android OS, while the second system is the robot with a
Bluetooth module attached. On the Android device, the control system is simple and uses an application to control the
Bluetooth service on Serial Port Profile (SPP) connection. The application has to be able to send data over Bluetooth module
according to the sensors, touch screen, and the application features. On the robot side, you have to add a Bluetooth module
connected to the robot controller. The Bluetooth module is a little device designed to transmit data between peripheral devices.
In other words, this little device is able to synchronize the I/O data between the robot and the Android device.

CONCLUSION

This paper reports on an approach for integrating the fuel cost, prevents the release of toxic gases like carbon mono oxide,
carbon di oxide,etc. which leads to the environmental pollution. Our proposed system is an semi automatic system, which is
only due to the man intervention which was the only similarity between the existing system and proposed system. By
connecting or fixing the wireless sensors and also with some changes in the program which has been uploaded to arduino board
our system will completely work as an automatic system which could be an future enhancement for our project.By taking our
project as an existing one upcoming students can also work in the same system by considering all the drawbacks they can able
to do the improvised version of our project.

REFERENCE

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