1

PROJECT REPORT

ON

MICROCONTROLLER BASED HUMANOID ARM

Submitted in partial fulfilment of the requirements

for the award of the degree Of

BACHELOR OF TECHNOLOGY In

MECHANICAL ENGINEERING By

MUTHAMIZH SELVAN. A (1020940099)

NITHIN KUMAR. D (1020940106)

SRIRAM. R (1020940168)

Under the guidance of

Mr E. THAMBIRAN, M.E

(Asst. Professor (Sr.G), School of Mechanical Engineering)

FACULTY OF ENGINEERING AND TECHNOLOGY

SRM UNIVERSITY (Under section 3 of UGC Act, 1956)

Ramapuram Campus - Part, Vadapalani

Chennai - 600 026

APRIL-2013

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BONAFIDE CERTIFICATE

Certified that the project report entitled “MICROCONTROLLER BASED

HUMANOID ARM” Submitted by “MUTHAMIZH SELVAN. A (1020940099),

NITHIN KUMAR. D(1020940106), SRIRAM. R (1020940168)” is a record of

project work done by them under my supervision towards the partial fulfilment of the

requirements for the award of the degree of Bachelor of Technology in Mechanical

engineering in SRM University, Chennai during the year 2012-2013. This project has

not formed the basis for the award of any degree, diploma, associate ship or

fellowship.

Mr E. THAMBIRAN Prof.C.K.LAKSHMYNARAYANAN

PROJECT GUIDE HOD

MECHANICAL ENGINEERING MECHANICAL ENGINEERING

Internal Examiner External Examiner

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DECLARATION

I do hereby declare that the project report entitled “MICROCONTROLLER BASED

HUMANOID ARM” is a record of original work carried out by MUTHAMIZH

SELVAN. A (1020940099), NITHIN KUMAR. D (1020940106), SRIRAM. R

(1020940168) under the supervision of Mr E. THAMBIRAN, Asst. Professor,

department of Mechanical Engineering, SRM

UNIVERSITY, RAMAPURAM PART – VADAPALANI. This project has not been

submitted earlier in part or full for the award of any degree, diploma, associate ship or

fellowship.

MUTHAMIZH SELVAN. A

NITHIN KUMAR. D

DATE: SRIRAM. R

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ACKNOWLEGDEMENT

This final year project was the result of the thought process combined with hard work of

not just us, but a group of other people. This thesis would be incomplete without

expressing our heartfelt gratitude to them.

First and foremost we want to thank god or enabling us to complete our project in the

required time. We are extremely grateful to our beloved Dr.R.PACHAMUTHU

(Chancellor, SRM University) for providing us with the quality infrastructure and lab

facilities.

We choose this moment to thank our Dean Dr.N.VASUDEVAN, B.E., M.TECH., PhD

for the support he has rendered throughout OUR educational experience in SRM

University City campus.

We are grateful to our Head of the department Prof.C.K. LAKSHMI NARAYANAN,

B.Sc.Engg., M.E,(Head Of The Department) for his invaluable guidance, motivation,

timely and insightful technical discussions. We are immensely grateful for his constant

encouragement, smooth approach throughout our project and make this work possible.

We wish to express our heartfelt thanks to our guide Asst.Prof .E. THAMBIRAN M.E,

for guiding us in this endeavour throughout the project. We are deeply indebted to him for

his unconditional support and thorough guidance.

Our Sincere thanks to Asst.Prof.E. SANKAR, M.E, (Project Coordinator) who shared

his valuable information that helped in the successful completion of this project.

We also express our sincere thanks to Mr SANTHOSH Diploma in A.M.I.E, technical

assistant, Automation laboratories helping and rendering his valuable help to us in our

research.

We are very grateful to Mr PRAKASH (Simple Labs) and Mr BASKAR (Mercy

Electronics) for dealership of all the required components for this project at a reasonable

price and also for his whole hearted support during the entire project.

We also take this opportunity to thank all our colleagues and other teaching faculty, whose

valuable suggestion and motivation, without which we could never have completed this

work.

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ABSTRACT

This Paper gives a clear-cut idea about design, manufacturing, theory and application of

Humanoid Robotic Hand. The task was to develop a prototype of a Wireless operated -

Humanoid hand, This Five-Fingered Humanoid hand has the capability of replicating

complex actions of an actual human hand operated from distance of up to 300-400 ft in

the line of sight outdoor and 100ft indoors.

The focus of this thesis within the project lied on to improve the function and wireless

application of the robotic hand. From Mechanical point of view and interest in addition

to the control system, a Conceptual design & 3D-Model should be developed and NX-

CAM code for milling the prototype has to be generated.

Simultaneously a developing the control interface of the hand glove using Flexible

sensor and Arduino Uno was also made. To reduce the cost of the hand, working model

was made as simple as possible. To keep the manufacturing costs down is also an

important issue developing the new Prototype. Several different concepts where analysed

before the final Prototype was built. To designing and rendering the hand Solid Works

was used. CAM codes were generated using NX-CAM. This project revolves around

applications from subjects such as Mechatronics, Fluid Power Control and Engineering

Design etc…. from our undergraduate study.

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TABLE OF CONTENT

CHAPTER TITLE PAGE No.

NUMBER

1 INTRODUCTION 8

1.1 ABOUT OUR PROJECT 8

1.2 ROBOTICS 9

1.3 BIO INSPIRED TECHNOLOGY 9

1.4 STUDY ON HUMAN HAND 10

1.5 HUMANOID HAND 10

1.6 APPLICATION OF HUMANOID HAND 13

2 MECHANICAL DESIGN 15

2.1 SOLIDWORKS 16

2.2 PART MODELING 16

2.3 ASSEMBLY MODELING 17

2.4 RENDERING 19

2.5 DRAWING AND DETAILING 19

3 ANALYSIS 21

4 COMPUTER AIDED MANUFACTURING 26

5 MICROCONTROLLER BOARD AND

WIRELESS COMPONENTS 34

5.1 ARDUINO UNO 34

5.2 WIRELESS CAPABILITIES 36

6 ACTUATOR AND SENSOR USED 38

6.1 SERVO MOTOR 38

6.2 FLEX SENSOR 39

7 COMPONENTS PURCHASE QANTITY 41

7

8 EXPERIMENTS CONDUCTED 42

9 PROGRAMMING THE ARDUINO 43

9.1 SENDING ARDUINO CODE 43

9.2 RECEVING ARDUINO CODE 44

10 FINAL ASSEMBLY 46

10.1 CONTROL GLOVE 46

10.2 HUMANOID HAND ASSEMBLY 47

11 WORKING 48

12 RESULTS AND DISCUSSIONS 50

13 CONCLUSION 51

14 BIBLIOGRAPHY 52

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1. INTRODUCTION

In this chapter, the sole purpose of this project and theory behind this project will be

described. It will also be mentioned why it is important to develop Humanoid hand and

what was important to achieve within this project.

1.1 ABOUT OUR PROJECT

The task was to develop a prototype of a Wireless operated -Humanoid hand, This Five-

Fingered Humanoid hand has the capability of replicating complex actions of an actual

human hand. The focus of this thesis within the project lied on to improve the function and

wireless application of the robotic hand. In addition to that a Conceptual design & 3D-

Model should be developed and NX-CAM code for milling the prototype has to be

generated. Simultaneously a developing the control interface of the hand glove using

Flexible sensor and Arduino Uno was also made. To reduce the cost of the hand, working

model was made as simple as possible. To keep the manufacturing costs down is also an

important issue developing the new Prototype. Several different concepts where analyzed

before the final Prototype was built. To designing and rendering the hand Solid Works was

used. CAM codes were generated using NX-CAM. This project revolves around

applications from subjects such as Mechatronics, Fluid Power Control and Engineering

Design etc…. from our undergraduate study.

WIRELESS

TECHNOLOGY

MECHATRONICS

ENGINEERING DESIGN

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1.2 ROBOTICS

Robotics is the branch of technology that deals with the design, construction,

operation, and application of robots. The study of robots involves various aspects of

Mechanical Engineering, Electrical Engineering and control Theory. Robotics deals

with automated machines that can take the place of humans in dangerous

environments or manufacturing processes, or resemble humans in appearance,

behaviour, and cognition. These definitions are also not enough or not very close to

defining Robotics, as it’s a vast, rapidly growing and multidisciplinary field.

Many robots do jobs that are hazardous to people such as defusing bombs, exploring

shipwrecks, and mines. They are also employed in jobs which are too dirty or dull to be

suitable for humans. Robots are widely

used in manufacturing, assembly,

packing and packaging, transport, earth

and space exploration, surgery,

weaponry, laboratory research, safety,

and the mass production of consumer

and industrial goods. Japan and

Germany are the leading nations in the

field of robotics, which has substantially

helped those countries to become

Industrial super powers of this field.

Robots are mainly used in

manufacturing firm especially

Automobile manufacturing plants. Japan

and Germany are leaders in Advanced

Robotic research and development; this

has substantially paid of them by making

contributing to manufacturing sector.

Now Japan and Germany are two

Industrial super powers of the world. Figure 1.1

1.3 BIO INSPIRED TECHNOLOGY

Biologically inspired technology is a power full tool for advanced research in Mechanical

Engineering especially in the field of robotic locomotion and object handling. Bio-inspired

robotics is about studying biological systems, and look for the mechanisms that may solve

a problem in the engineering field. The designer should then try to simplify and enhance

that mechanism for the specific task of interest. It is about observing the nature and

learning from it, later the principles or the mechanism devised is applied to the real world

engineering systems. More specifically, this field is about making robots that are inspired

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by the biological systems. As a product designer and developer we can refine our product

for better looks and performance maximum 15-20 iterations, but nature has course of

thousands of years evolution and infinite number of iterations.

Figure 1.2

1.4 STUDY ON HUMAN HAND Developed under many years of evolution the human hand has made us to what we are today.

The human hand is composed by 27 different bones and the opposing thumb is characteristic

For the human. The opposing thumb enables the precision grasp between the long finger and

The thumb which enables us to write or to perform precision work. Further the hand has 20

DOF and the most muscles are placed in the forearm and transmit their developed force via

tendons to the fingers. The bigger muscles in the hand are the thenar muscle on the thumb

side and the Hypothenar muscle on the side of the little finger.

1.5 HUMANOID HAND

In our project we have the inspiration from the Human hand, a microcontroller based

humanoid arm with wireless capabilities. Our design and mechanism are very much

similar to an actual human arm. The very word Humanoid means human like , A humanoid

is something that has an appearance resembling a human being.

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1.5.1. TWO TYPES OF HUMANOID HANDS

MODULAR HAND They are autonomous units with all the components required to function that includes

actuator, sensor etc ...They are more of an end effector that connects to the robot's arm

kinematics to execute their functions An overall complex design is required , still in

research and development level. Slightly lower gripping is achieved that the integrated

hand , and slightly bigger in size compared to human hand.

Modular Hand Examples- Stanford Hand, Barret Hand, DLR Hand, SRM Hand…

2. INTEGRATED HAND

End effector is integrated to the robotic Arm kinematics. Larger actuators can be used to

generate greater gripping force as they are placed away from the hand housing. One

disadvantage is force transfer from actuator to finger is difficult due to distance involved.

Example: Airics Arm from Feisto and Robonaut from NASA.

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SRM HAND – MODULAR HAND

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1.6 APPLICATIONS OF HUMANOID HAND

1.6.1. NUCLEAR FACILITIES:

Safe operation, avoidance of direct radiation on workers with the use of wireless operated

humanoid arms. Radiation exposure is a long standing problem in nuclear research and

reactor facilities. Exposure to harmful nuclear radiation causes several health related

hazards that includes lethal cancer. Hence an Operator or a scientist will definitely has to

seek the help of wireless-operated humanoid hand for the safe distance handling of

radioactive materials. During times of emergency robots will be of great use in Nuclear

facilities were people will be forbidden to enter, robots without robotic hand will be

useless.

1.6.2. BOMB DETECTION AND DEFUSING:

The major application of this project id Bomb detection and defusing, an highly trained

person can only defuse a bomb, though special Anti-Bomb suits are developed many a

time loss of life is encountered because the bomb can only be defused at closer distance by

physical contact. During war time in the war zones powerful Explosives are placed in

many places leading to loss of several lives. When our Humanoid Hand is connected to a

Robotic Arm mounted on a RC vehicle, it can be wirelessly operated by our specialist with

video camera installed on RC vehicle. The risk will be greatly reduced and our Bomb-

defusing specialist can operate at safer zone and defuse the bomb. Hence this project will

be highly regarded in Defence research circle like DRDO, DARPA..

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1.6.3. SURGICAL ROBOT:

Telemedicine is highly regarded technology of 21st century; Humanoid hand will find its

application in surgical robotics research for its ability of replicating Complex tasks of

human hand. Here doctors can operate the robotic arm and humanoid hand via internet to

perform emergency procedure that can save precious life.

1.6.4. PROSTETIC HAND:

Better designed artificial hands for those who lost their hands in accidents and war will be

a gift to mankind from Engineers. Our Humanoid hand is designed close to human hand

hence it can be extended for use in prosthetics.

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2. MECHANICAL DESIGN

AIM

The aim is to design a Five-Fingered Humanoid hand using Solidworks software.

Specification is taken from actual human hand because this is a Biologically inspired

technology- project and innovative in nature. The design specification must be

practical considering the shape and the assembly properties of the hand

TASK SPECIFICATION

• The hand shall be able to grasp objects of smaller diameter, irrespective of height.

That means the hand has to perform grasp.

• The hand shall be able to replicate the Gestures of Human hand operating the sensor

Glove

• The hand shall also be able to operate with Servo motor placed at distance of

100mm-300mm from the figure tip.

• The hand shall be able to press a button.

DESIGN SPECIFICATIONS

• The Hand shall house all actuators, control board and cables.

• The dimensions and the shape of the palm (hand) shall be close to a human hand..

• The hand shall also be able to operate with Servo motor placed at distance of

100mm-300mm from the figure tip.

• The hand shall be easier to assemble.

• The Hand must be attractive in looks to the customers with good aesthetic features.

PERFORMANCE SPECIFICATIONS

• The mass of the hand shall be less than 500 g.

• The hand and full wireless control setup shall cost less than Rs.18,000 to prototype.

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2.1 SOLIDWORKS

SolidWorks is a 3D mechanical CAD (computer-aided design) program that runs on

Microsoft Windows and is being developed by Dassault Systems SolidWorks

Corporation

MODELING METHODOLOGY

SolidWorks is a Para solid-based solid modeller, and utilizes a parametric feature-

based approach to create models and assemblies.

Parameters refer to constraints whose values determine the shape or geometry of the

model or assembly. Parameters can be either numeric parameters, such as line lengths

or circle diameters, or geometric parameters, such as tangent, parallel, concentric,

horizontal or vertical, etc. Numeric parameters can be associated with each other

through the use of relations, which allow them to capture design intent.

In an assembly, the analog to sketch relations are mates. Just as sketch relations define

conditions such as tangency, parallelism, and concentricity with respect to sketch

geometry, assembly mates define equivalent relations with respect to the individual

parts or components, allowing the easy construction of assemblies. SolidWorks also

includes additional advanced mating features such as gear and cam follower mates,

which allow modelled gear assemblies to accurately reproduce the rotational

movement of an actual gear train.

The drawings can be created either from parts or assemblies. Views are automatically

generated from the solid model, and notes, dimensions and tolerances can then be

easily added to the drawing as needed. The drawing module includes most paper sizes

and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

2.2 PART MODELING:

This module produces parts easily and rapidly by creating features such as

extrudes, revolves, thin features, lofts, sweeps, advanced shelling, feature patterns and

holes.

The 3D part is basic building block of the SOLIDWORKS mechanical

designing software. In solidworks the part can be designed by sketching its component

shapes and defining their size, shape and inter relationships. By successfully creating

their shapes, called features, the part can be constructed.

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STEPS INVOLVED IN MODELLING PROCESS

• Plan the part

• Create the base feature

• Create the remaining feature

• Analyse the part

• Modify the features as necessary

FINGER AND END CAP

Fingers are designed to act like spring once released from bend position they must

return to their original extended shape. The lines from the Servo motor horn is directly

tied through the centre hole in the End cap.

2.3 ASSEMBLY MODELING:

Assembly design gives a user the ability to design with user controlled

associability. SolidWorks builds these individual parts and the sub-assemblies into

assembly in a hierarchical manner. This is based on the relationships defined by the

constraints.

SolidWorks assembly design reference parts directly and maintains

relationships when creating new parts. In the assembly module, physical simulation

and mechanical interaction between the parts can be performed and potential design

flaws can be avoided.

In Assembly Servo motors mounting position can also be determined by placing

them on the hand chassis, before actually mounting them.

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PALM ASSEMBLED WITH FIVE FINGERS

Palm is designed in such a way that base of the

Fingers are accommodated rigidly in their

respective slots by fitting method. In

Solidworks assembly is done using mating

options, there are various mating like

circumferential mate, planar mate, parallel and

several other.

HUMANOID HAND WITH SERVOS

MOUNTED TO CHASSIS

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2.4 RENDERING

Rendering is the final product with finishing touch generated by Solidworks rendering

tool. The Hand design is complete with realistic render produced.

2.5 DRAWING AND DETAILING:

2D drawings module develops complete production ready engineering

drawings without drawing the sketches, makes the revision quickly and accurately,

and generates bill of materials and balloons automatically, easily controlling and

alignment of balloons.

• Modelling Dimensions: Model dimensions are created as the part feature is

created and then it is inserted into various drawing views. Change in dimension in the

model updates the drawings and changing an inserted dimension a drawing changes of

the model.

• Reference Dimensions: Dimensions cans be added in the drawing document,

but these are reference dimensions and are driven; the values of the reference

dimensions cannot be edited to change the model. However, the values of reference

dimension change when the model dimensions change.

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HAND ASSEMBLY DRAWING

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3. ANALYSIS

Once the 3D Modelling and Drafting is over the product has to be tested using

analysis software like ANSYS , NASTRAN etc.. We used ANSYS Workbench to

analyse our design.

ANSYS WORKBENCH

ANSYS Workbench, developed by ANSYS Inc., USA, is a Computer Aided Finite

Element Modeling and Finite Element Analysis tool. In the Graphical User Interface

(GUI) of ANSYS Workbench, the user can generate 3-dimensional (3D) and FEA

models, perform analysis, and generate results of analysis. We can perform a variety

of tasks ranging from Design Assessment to Finite Element Analysis to complete

Product Optimization Analysis by using ANSYS Workbench. ANSYS also enables

you to combine the stand-alone analysis system into a project and to manage the

project workflow.

The following is the list of analyses that can be performed by using ANSYS

Workbench:

1. Design Assessment

This analysis system is used to perform a combined solution for static and

transient structural analyses. It also performs post-processing through a script using

additional data associated with the geometry.

2. Explicit Dynamics

This analysis system is used to identify the dynamic response of a component

under stress wave propagation, or time-dependent loads or impacts. It is also used for

modal mechanical phenomena that are highly non-linear.

3. Fluid Flow (CFX)

This system allows users to carry out flow analysis of compressible and

incompressible fluids. It is also used to analyze heat transfer in fluids.

4. Fluid Flow (FLUENT )

Like Fluid Flow (CFX), Fluid Flow (Fluent) system is also used to carry out

fluid flow analysis of compressible and incompressible fluids and their heat transfer

analysis.

5. Harmonic Response

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Harmonic response is the response of a system under a sustained cyclic load.

Harmonic Response analysis system is used to analyze a system working under

periodic or sinusoidal loads. This analysis helps in determining whether a particular

structure will be able to withstand resonance, fatigue, and other effects of forced

vibration.

6. IC Engine

This analysis system helps determine the performance of the whole system of

an IC engine. It takes into consideration the various fluid properties, moving

components, and electric and electronic components inside an engine.

7. Linear Buckling

This analysis system is used to evaluate the buckling strength of a system under

external loads.

8. Magnetostatic

This analysis system is used to analyze the magnetic field developed due to the

presence of a temporary or permanent magnet.

9. Modal

Modal analysis is the study of dynamic properties of a model, subjected to

vibrations. Modal analysis system in ANSYS Workbench helps in determining the

frequencies and mode shapes of a model.

10. Random Vibration

This analysis is carried out to determine the reaction of a structure or a

component to changing frequencies of vibrations. Many components experience

vibrations which are random in nature. This analysis system is used to determine the

responses of structures that are exposed to such varying or random vibrations.

11. Response Spectrum

Response Spectrum analysis system is similar to Random Vibration analysis

system and is used after a transient analysis is done.

12. Rigid Dynamics

Rigid Dynamics analysis system is used to determine the response of a rigid

body or a mechanism consisting of rigid bodies. Response of a robot mechanism is an

example of rigid body analysis.

13. Static Structural

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The Static Structural analysis system is used to determine the response of a

structure subjected to static loading conditions. The loads in this case are assumed to

produce no or negligible time based loading characteristics. Using this type of

analysis, displacement, stresses, and deformations of structures under static loading

conditions can be determined.

14. Steady-State Thermal

Steady-state thermal analysis system is used to determine the temperature,

thermal gradient, heat flow rates and heat fluxes under the influence of thermal

loading which remains constant with time and are static in nature.

15. Transient Structural

Transient Structural analysis system is used to determine responses of

structures under the action of time dependent variables. Using this analysis, time-

varying displacement, stresses and strains can be determined.

16. Transient Thermal

Transient Thermal analysis system is used to determine the temperature and

other thermal variables of a structure that vary over time.

STATIC STRUCTURAL ANALYSIS: Static structure analysis is used to analyse

our design. Following steps are performed to obtain results.

STEP1: The Palm solid model is imported and fixed

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STEP 2: Force magnitude and direction is specified

STEP 3: Mesh is generated.

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STEP 4: Result obtained.

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4. COMPUTER AIDED MANUFACTURING

Computer Aided Manufacturing is the use of computer software and hardware in

transforming the computer aided design models into manufacturing instructions for

numerical controlled machine tools. Computer Aided Manufacturing refers to

automation process, which accurately converts product design and drawings into code

format which is read by the machine to manufacture the designed product.

CAM software converts 3D models generated in CAD into set of basic

operating instructions written in G-code. The G-code is a programming language that

can be understood by numerical controlled machine tools – essentially industrial

robots. The G-code provides instructions to the machine tool to manufacture a large

number of items with perfect precision and faith to CAD design.

NX CAM

NX CAM provides a wide range of machine tool programming capabilities in a single

integrated solution enabling one to take advantage of the latest machine tool

technologies and manufacturing processes.

BENEFITS OF USING NX CAM:

1. Maximizing productivity and efficiency

2. Total design to manufacture connectivity

3. First time quality through simulation

4. Efficiency through leading technology

5. An all-inclusive solution for machining

BROAD SUPPORT OF MACHINE TOOLS AND OPERATIONS

1. MILLING

2 and 3 axis machining

5 axis machining

Drilling

Feature based machining

High speed machining

Engraving

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2. TURNING

Turning

Merging lathes

Milling and turning combination

3. OTHER

Electrical discharge machining

A full set of applications

4. DESIGN/ASSEMBLY

Fixture design

Part and assembly modelling and editing

Geometry translators

5. AUTOMATION TOOLS

Process templates

Tool libraries

Feeds and speeds data

6. VERIFICATION AND SIMULATIONS

Tool Path Verification

Machine tool modelling and kinematics

Machine tool simulation

7. OUTPUT

Postprocessor building and editing

Shop documentation output

Data management

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GRAPICAL OVERVIEW OF NX-CAM

Steps involved :

1. Import the solid model

2. Create the milling tool

3. Define work piece and block.

4. Insert operation and define operation parameters

5. Generate the cut pattern

6. Visualize milling in 3D

7. Post process and code generation

NX-CAM

NC programming and machining database

3D modelling of machine tools

Machine tool kinematics definition

Machine tool simulation

Post processing

Post processor creation and editing

3D modeling of tools and fixtures

Tool path verification

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NX-CAM CODES GENERATED FOR CNC-MACHINE

=========================================================

N0010 G40 G17 G90 G70

N0020 G91 G28 Z0.0

N0030 T00 M06

N0040 G0 G90 X.4211 Y-1.8504 S0 M03

N0050 G43 Z1.1024 H00

N0060 Z.315

N0070 G1 X1.3027 Z.0787 F9.8 M08

N0080 X-1.2785

N0090 Z.1969

N0100 G0 Z1.1024

N0110 X1.3027

N0120 Z.1969

N0130 G1 Z.0787

N0140 X1.3301 Y-1.7917

N0150 X-1.2886

N0160 Z.1969

N0170 G0 Z1.1024

N0180 X1.3301

N0190 Z.1969

N0200 G1 Z.0787

N0210 X1.3575 Y-1.7329

N0220 X-1.2987

N0230 Z.1969

N0240 G0 Z1.1024

30

N0250 X1.3575

N0260 Z.1969

N0270 G1 Z.0787

N0280 X1.3849 Y-1.6742

N0290 X-1.3088

N0300 Z.1969

N0310 G0 Z1.1024

N0320 X1.3849

N0330 Z.1969

N0340 G1 Z.0787

N0350 X1.4123 Y-1.6154

N0360 X-1.319

N0370 Z.1969

N0380 G0 Z1.1024

N0390 X1.4123

N0400 Z.1969

N0410 G1 Z.0787

N0420 X1.4397 Y-1.5567

N0430 X-1.3291

N0440 Z.1969

N0450 G0 Z1.1024

N0460 X1.4397

N0470 Z.1969

N0480 G1 Z.0787

N0490 X1.4671 Y-1.4979

N0500 X-1.3392

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N0510 Z.1969

N0520 G0 Z1.1024

N0530 X1.4671

N0540 Z.1969

N0550 G1 Z.0787

N0560 X1.4945 Y-1.4392

N0570 X-1.3494

N0580 Z.1969

N0590 G0 Z1.1024

N0600 X1.4945

N0610 Z.1969

N0620 G1 Z.0787

N0630 X1.5218 Y-1.3805

N0640 X-1.3595

N0650 Z.1969

N0650 Z.1969

N0660 G0 Z1.1024

N0670 X1.5218

N0680 Z.1969

N0690 G1 Z.0787

N0700 X1.5492 Y-1.3217

N0710 X-1.3696

N0720 Z.1969

N0730 G0 Z1.1024

N0740 X1.5492

N0750 Z.1969

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N0760 G1 Z.0787

N0770 X1.5766 Y-1.263

N0780 X-1.3797

N0790 Z.1969

N0800 G0 Z1.1024

N0810 X1.5766

N0820 Z.1969

N0830 G1 Z.0787

N0840 X1.604 Y-1.2042

N0850 X-1.3899

N0860 Z.1969

N0870 G0 Z1.1024

N0880 X1.604

N0890 Z.1969

N0900 G1 Z.0787

N0910 X1.6314 Y-1.1455

N0920 X-1.4

N0930 Z.1969

N0940 G0 Z1.1024

N0950 X1.6314

N0960 Z.1969

N0970 G1 Z.0787

N0980 X1.6588 Y-1.0867

N0990 X-1.4101

N1000 Z.1969

N1010 G0 Z1.1024

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N1020 X1.6588

N1030 Z.1969

N1040 G1 Z.0787

N1050 X1.6862 Y-1.028

N1060 X-1.4203

.

.

.

.

N1350 G0 Z1.1024

N1360 X1.6535 Y1.9488

N1370 Z.7087

N1380 G1 Z.5906

N1390 X1.6142

N1400 X-1.6142

N1410 X-1.6535

N1420 Z.7087

N1430 G0 Z1.1024

N1440 M02 (Code end line)

%

**The code was very lengthy, hence it was cut shorted.

34

5. MICROCONTROLLER BOARD AND WIRELESS COMPONENTS

5.1 ARDUINO UNO (MICROCONTROLLER BOARD)

The Arduino Uno is a microcontroller board based on the ATmega328 .It has 14

digital input/output pins ,6 Analog inputs, a 16 MHz ceramic resonator, 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.

Reasonably price and reliable quality were the deciding factors for choosing this

microcontroller board for our project. Added advantage of using an Arduino is that it

is Open-source hardware and supporting software provided. Working with Arduino

can be fun and easy, at the same time one can learn a lot about electronics and

robotics. Especially when Mechanical Engineering students and other disciplinary

students getting started with electronics can explore the amazing world of robotics

control with Arduino Uno.

DETAILS- ARDUINO UNO

Microcontroller ATmega328

Operating Voltage 5V

Input Voltage (recommended) 7-12V

Input Voltage (limits) 6-20V

Digital I/O Pins 14 (of which 6 provide PWM output)

Analog Input Pins 6

DC Current per I/O Pin 40 Ma

DC Current for 3.3V Pin 50 Ma

Flash Memory 32 KB (ATmega328) of which 0.5 KB used by boot loader

SRAM 2 KB (ATmega328)

EEPROM 1 KB (ATmega328)

Clock Speed 16 MHz

35

AT MEGA-328

(MICROCONTROLLER)

The ATmega328 is a single chip

micro-controller created by Atmel

and belonging to the megaAVR

series. In our case it comes along

with Arduino Uno board which

makes our work easy.

SERVO MOTOR SHIELD

The Simple Labs' Servo Shield is

a custom designed Shield to drive Servo Motors. The Shield Can drive up to 10 servo

motors at a time. It was originally designed for our Quadbot Robot Kit (8 Servos) +

Mini Pan and Tilt Kit (2 Servos). In addition to this, the servo shield has suitable pin

outs to be able to connect the Compound Eye IR Sensor.It has a screw terminal for

external supply to be connected to power the servos. We can use 6V battery to Power

these up.

The servo shield has Servo control pins on Arduino Digital Pins D2, D3, D4, D5, D6,

D9, D10, D11, D12 & D13. Refer to the TOP Legend on the board "D + - " for the

Orientation of the Servo Connector Connection. We used five outputs from this motor

shield, maximum ten servo motors can be operated using this servo shield. We were

very fortunate to find this board as it made our control system very compact and neat.

The pins are designed in such a way it mounts directly into the Arduino Uno-Wireless

setup shield.

36

5.2 WIRELESS CAPABILITIES

Our project the Humanoid Hand or the Robotic Hand has the capability of replicating

figure flex and gestures of Human Hand with the help of Control Glove. We later

included the wireless control in this setup , It would greatly enhance the project in its

application area. Wireless control of our Robotic Hand helped us break into the world

of communication and expand our horizon to Military ,Defence Bomb defusing and

Nuclear Facility applications. Working with wireless can be hard and frustrating,

especially when you are a Mechanical student. We have found an easier and cost

effective solution for these problems. Just buy the following components in pair , we

will need one as a sender(master) and other as receiver(Slave).

5.2.1 XBEE SERIES-2 MODULE

The XBee XB24-Z7WIT-004 Series 2 improves on the power output and data

protocol. XBee Series 2 modules allow a very reliable and simple communication

between microcontrollers, computers, systems, really anything with a serial port!

Point to point and multi-point networks are supported. We just need to create

communication between two Arduino Uno Boards. The Series 2 requires considerable

setup and configuration but there are tons of tutorials out there in Internet. To create a

network pair we must configure using X-CTU Software. One must be configured as

Co-ordinator and other must be Router device. Indoor/Urban range up to 133 ft.

(40m) , Outdoor RF line-of-sight rang up to 400 ft. (120m)

5.2.2 ITEAD XBEE SHIELD

XBee Shield is an enhanced Zigbee XBee Series modules breakout board for Arduino,

it can directly plug in with Arduino Uno Board. It Protects the XBee modules from

damage due to higher voltage and has a 3.3 V regulator for this purpose. The XBee

Shield simplifies the task of interfacing an XBee with your Arduino. This board mates

directly with an Arduino Pro or USB board, and equips it with wireless

communication capabilities using the popular XBee module. This unit works with all

XBee modules including the Series 2 (and 2.5), standard and Pro version. There was

no need of soldering in wireless system, they are easy to assemble, just place the

wireless shield on Arduino make sure the pins are correctly matched and gently press,

same applies for Servo motor shield and XBee module.

37

38

6. ACTUATOR AND SENSOR USED

6.1 SERVOMOTOR:

Servomotor is a mechanical actuator that gives highly precise angular motion using

closed loop position feedback. Servomotors are used in applications such as robotics,

CNC machinery or automated manufacturing.

MODELS PURCHASED

V 3006 Servomotor It is a heavy duty plastic geared economy hobby servo motors for general purposes. Specification: Operating Voltage: 4.8-6.0V Stall Torque: 6 kg-cm at 4.8V, 7.1 Kg-cm at 6V Operating Speed: 0.18 sec/ 60° at 4.8V, 0.16 sec/ 60° at 6V at no load Weight: 40g Size: 41.3*20.3*38.7 Connector wire length: 30cm

TowerPro SG5010 TowerPro SG5010 is a high quality but really low-cost servo for all your mechatronic

needs. It comes with a 3-pin power and control cable, even a dozen of hardware as

shown.

Features: 3 pole ferrite, all nylon gear, Top ball bearing.

Operating

Voltage:

4.8V~6.0V

Operating

speed:,

0.16sec/60deg

(6.0V)

Stall torque:

6.5kg*cm

(6.0V)

Dimension:

41 x 20 x

38mm

Weight: 41g

Connector wire

length: 30cm

39

6.2 FLEX SENSOR

Description: A simple flex sensor 4.5" in length. As the sensor is flexed, the

resistance across the sensor increases. Patented technology by Spectra Symbol - they

claim these sensors were used in the original Nintendo Power Glove which was used

as control glove for gaming.. The resistance of the flex sensor changes when the metal

pads are on the outside of the bend (text on inside of bend).Connector is 0.1" spaced

and bread board friendly. It can bend and flex physically with motion device.

Possible Uses

• Robotics

• Gaming (Virtual Motion)

• Medical Devices

• Computer Peripherals

• Musical Instruments

Mechanical Specifications:

• Life Cycle: >1 million

• Height: 0.43mm (0.017")

• Temperature Range: -35°C to +80°C

40

6.2.1 CONNECTING FLEX SENSOR WITH ARDUINO UNO

Flex sensor has two terminals one is for 5v and other must be connected to Analog pin

resistor (10K or 22K) which acts as a voltage divider, then grounded. In order to

connect five Flex sensor to Arduino a separate PCB board has to be made. This board

is mounted on the Control Glove, ready for acton.

41

7. COMPONENTS PURCHASE-QANTITY

Major components like Servo motors, Arduino Uno( microcontroller ),Custom

designed plastic cut parts, Robotic- Frame, Flexible sensors, Wireless shield, Xbee

series-2 Hand Gloves purchased are listed along with the quantity of purchase in the

following Table.1.1

Purchase of components ( Table 1.1 )

S.No Components Quantity

1 Servo motor 5

2 Flexi sensor 4.5 5

3 Arduino Uno 2

4 Wireless shield 2

5 Servo Motor shield 1

6 Xbee series-2 2

7 Hand Glove 1

8 Robotic chassis 2

9 Rechargeable 6V battery 1

42

8. EXPERIMENTS CONDUCTED

For the successful operation of the wirelessly controlled Humanoid Hand the

following series experiments must be performed. This experiment leads to better

understanding of the mechatronic systems, microcontrollers, sensors etc. Doing a

project like this could be hectic, we need to assure the quality and working condition

of all the electronics components all the time, hence doing this following experiments

in regular interval gives good results and confident boost. These experiments require

some additional components but very cheap like LEDS, push buttons, and some

patience.

The following experiments are listed out in the Table 1.2

ExNo Title of the Experiment parameters Date Status

1. Servo control sweep Speed &

Position

07.03.2013 Completed

2. Servo control knob Angle 09.03.2013 Completed

3. Wireless Blink Signal

strength

17.03.2013 Completed

4. Observing Flexi Sensor Reading Deflection,

Angle &

voltage output

27.03.2013 Completed

5. Assembly & Final working All 06.04.2013 Completed

43

9. PROGRAMMING THE ARDUINO

It is a major and final step in this project, the codes written is compiled and uploaded

to the ATmega in the Arduino Uno by the use of Arduino IDE software. Arduino IDE

can be downloaded for free of cost from Arduino.cc website. The microcontroller is

reprogrammable, at a time it can only accommodate a single programme.

Screen shot of Aduino 1.0.1 software with basic LED blink code

SENDING ARDUINO (CONTROL GLOVE) – CODE

int Finger1 = 0; int Finger2 = 2; int Finger3 = 3; int Finger4 = 4; int Finger5 = 5; void setup() { Serial.begin(9600);

44

} void loop() { int FingerV1 = analogRead(Finger1); int FingerV2 = analogRead(Finger2); int FingerV3 = analogRead(Finger3); int FingerV4 = analogRead(Finger4); int FingerV5 = analogRead(Finger5); if (FingerV1 < 470) FingerV1 = 470; else if (FingerV1 > 545) FingerV1 = 545; if (FingerV2 < 370) FingerV2 = 370; else if (FingerV2 > 475) FingerV2 = 475; if (FingerV3 < 350) FingerV3 = 350; else if (FingerV3 > 505) FingerV3 = 505; if (FingerV4 < 370) FingerV4 = 370; else if (FingerV4 > 520) FingerV4 = 520; if (FingerV5 < 420) FingerV5 = 420; else if (FingerV5 > 530) FingerV5 = 530; int servoVal1 = map(FingerV1,545, 470, 9, 1); int servoVal2 = map(FingerV2,475, 370, 9, 1); int servoVal3 = map(FingerV3,505, 350, 9, 1); int servoVal4 = map(FingerV4,520, 370, 9, 1); int servoVal5 = map(FingerV5,530, 420, 9, 1); Serial.print(servoVal1); Serial.print(servoVal2); Serial.print(servoVal3); Serial.print(servoVal4); Serial.print(servoVal5); delay(100); }

RECEVING ARDUINO (HUMANOID HAND) -CODE #include <Servo.h> Servo myservo1; Servo myservo2; Servo myservo3; Servo myservo4;

45

Servo myservo5; void setup() { Serial.begin(9600); myservo1.attach(2); myservo2.attach(3); myservo3.attach(4); myservo4.attach(5); myservo5.attach(6); } void loop() { if (Serial.available() >= 5) { int servoAng1 = Serial.read() - '0'; int servoAng2 = Serial.read() - '0'; int servoAng3 = Serial.read() - '0'; int servoAng4 = Serial.read() - '0'; int servoAng5 = Serial.read() - '0'; int Angle1 = map(servoAng1, 9, 1, 179, 0); Angle1 = constrain(Angle1, 179, 0); int Angle2 = map(servoAng2, 9, 1, 179, 0); Angle2 = constrain(Angle2, 179, 0); int Angle3 = map(servoAng3, 9, 1, 179, 0); Angle3 = constrain(Angle3, 179, 0); int Angle4 = map(servoAng4, 9, 1, 179, 0); Angle4 = constrain(Angle4, 179, 0); int Angle5 = map(servoAng5, 9, 1, 179, 0); Angle5 = constrain(Angle5, 179, 0); myservo1.write(Angle1); myservo2.write(Angle2); myservo3.write(Angle3); myservo4.write(Angle4); myservo5.write(Angle5); Serial.flush(); } }

We had written like number of codes for this project, First few didn’t work well, thank god this pair worked for us. We were not specialist in programming, just learned it from tutorials in Arduino support sites.

46

10. FINAL ASSEMBLY

In order to obtain fully functioning model final assembly must be made, power supply

from USB or battery must be connected. Both Arduinos must be programmed and

shields must be mounted.

10.1 CONTROL GLOVE

The control glove is ready to be worn only when all five Flex sensors are sewed to the

glove and connected with the PCB and Arduino Uno. Flex sensor is very sensitive at

the base hence nice padding must be given so that when flexi is bent the base is not

damaged or disturbed. In our Glove the Arduino is also stitched neat and tidy way.

The Arduino can be powered by battery or USB based on the need.

47

10.2 HUMANOID

HAND ASSEMBLY

Servo motors are

rigidly mounted using

nuts and bolts on to the

robotic chassis, All the

fingers with end caps

with fishing tackles

tied to it internally are

mounted or attached to

the palm. The palm in

turn is attached to the

Servo chassis. All the electronics components are mounted to the Hand using proper

spacers.

48

11. WORKING

Operator wears the Control Glove (practically anyone can wear the glove, its elastic

and comfortable). The control glove and Humanoid Hand setup are placed within the

working range of wireless communication of XBee series-2. Final assembly is

complete.

Servomotors are connected to the Servomotor shield powered by 6V Rechargeable or

four ordinary 6v batteries. Arduinos are powered up either by USB or battery.

When the communication begins all the fingers come to the fully extended state, when

a finger is bent the flex sensor senses the bend and the angle is obtained and processed

by the Arduino.

According to the programme we written the obtained angle value is transmitted via

XBee module (Sending) to other XBee module (Receiving).

Subsequently the Receiving Arduino processes the signal and corresponding

Servomotor is actuates and the same figure is flexed exactly to the angle of finger

bend.

All five fingers can be flexed at the same time, and the corresponding Humanoid hand

finger will respond immediately.

By the above mentioned steps , Humanoid hand will be able to replicate any gestures

of the operator from distance of upto 300-400ft in line of sight.

Flex sensor senses the angle of finger

bend

Value obtained is processed by

Arduino Uno on Control Glove

Value is sent wirelessly by XBee

module

Value is received by XBee module

on the Humanoid Hand

The received value is processed by

Arduino Uno

Servomotor is actuated and

rotates the precise angle of fingure

49

PICTURES OF THE WORKING MODEL

HUMANOID HAND SHOWING GERSTURES

50

12. RESULT AND DISCUSSION:

Thus a Wirelessly controlled Humanoid hand is designed and fabricated and testing is

done under supervision of our Project guide..

The Design can be improved to produce variety of movements that include wrist

movement and opposing thumb.

Two microcontrollers are successfully made to communicate with each other using

Wireless system.

Using computer we can monitor the sensor values of the glove to iterate and improve

the sensor value give in the code.

This Humanoid Hand being modular type can be integrated with any Robotic

Kinematic Arm. As it has all the actuators and power supply housed in it.

This programme (codes) can be modified and changed for higher resolution and

accurate bend of fingers.

Material property and manufacturability has to be improved.

In order to use the fullest potential of our motor the fishing tackle used to connect

Servomotor horn must be replaced by alternative line which can withstand higher load

and friction.

It will be great if this Mechatronic system is made closed loop feedback system,

presently our project is a open loop system.

51

13. CONCLUSION

The hand prototype is working fine but some improvements could be made. Also the

Design of the hand can be improved by including a stronger material and higher

mechanisms and additional motions.

The Ultimate goal to develop a functioning prototype and a wireless control glove

which was fulfilled, the Humanoid hand can replicate the complex gestures of an

actual Human hand. It can perform grasps using the palm and can grasp objects in a

better way. Also the assembly properties and cable routing is well planned.

As it’s a Bio- inspired technology the Humanoid hand has dimensions close to the

human ones and looks humanlike. The process is made wireless using XBee, Which is

used to send and receive signals.

A Five finger robot hand could be developed at a total project cost of Rs.18,000.

This project can be further developed in many aspects and futuristic ideas can be

implemented. The resolution, mechanism, degree of freedom (D.O.F), precision can

be improved considerably. Hence the system will be more flexible and can be used in

Advanced functions like Nuclear facility, Bomb defusing and defence research.

52

14. BIBLIOGRAPHY:

LITRATURE

“THEORY OF MACHINES”.. R.S.KHURMI..

“ENGINEERING DESIGN”.. R.S.KHURMI..

“MICROPROCESSOR, ARCHITECTURE, PROMMING AND APPLICATIONS”..

RAMESH S.GAONKAR, PENRAM INTERNATIONAL

“MECHATRONICS”.. W.BOLTON.. PEARSON EDUCATION.

“ARDUINO - A QUICK START GUIDE QUICK START GUIDE”..MAIK

SCHMIDT..THE PRAGMATIC BOOKSHELF

“ARDUINO COOKBOOK 2011”..JEREMY BLEM..OREILLY

“ARDUINO_ROBOTIC_EBOOKAMZ”..JOSH ADAMS..TECHNOLOGY IN

ACTION

WEBSITES :

www.Arduino.com

www.iteadstudio.com

www.simplelabs.com

www.sparkfun.com

www.makershed.com

www.element14.com

www.digi.com