AN AUTOMATIC TRAFFIC CONES DISPENSER AND COLLECTOR
SYSTEM
SITI NOOR AISHAH BINTI MOHAMAD ARIFFIN
A project report submitted in partial
fulfilment of the requirement for the award of the
Degree of Master of Electrical Engineering
Faculty of Electrical and Electronic Engineering
Universiti Tun Hussein Onn Malaysia
JULY 2014
v
ABSTRACT
This project report is about to develop an automatic system for dispense
and collect the traffic cones by using manipulator which is robot arm. The
development of the robot arm which is five degree of freedom is the most
important part in this project in order to make this system become an automatic
system. A microcontroller PIC18F46K22 is used as the brain part of the robot
arm and C programming had been used to programme the microcontroller. For
the five joint parts of the robot arm, three different types of motor had been used
which are cube servo, dc motor and servo motor to represent five degree of
freedom of the robot arm. The sensor that had been used in this project is
potentiometer which is used for measurement to measure the position needs for
this robot arm. The size of traffic cones used is reduced to the smaller size which
is compatible with the size of the robot arm in this project.
.
vi
ABSTRAK
Laporan projek ini adalah berkaitan dengan pembangunan sistem automatik
untuk mengagihkan dan mengumpulkan kon lalu lintas dengan menggunakan
sistem yang lain iaitu lengan robot. Pembangunan lengan robot yang mempunyai
lima darjah kebebasan adalah bahagian yang paling penting dalam projek ini
untuk membuat sistem ini menjadi satu sistem automatik. Sejenis
mikropengawal PIC18F46K22 telah digunakan sebagai bahagian utama untuk
mengawal lengan robot dan pengaturcaraan C telah digunakan sebagai bahasa
bagi program untuk pengawal mikro. Bagi lima bahagian lengan robot yang
dihubungkan, tiga jenis motor telah digunakan iaitu servo kiub, dc motor dan
motor servo untuk mewakili lima darjah kebebasan lengan robot. Pengesan yang
telah digunakan dalam projek ini adalah potentiometer yang digunakan sebagai
pengukur untuk mengukur kedudukan lengan robot ini. Saiz kon lalu lintas telah
dikurangkan kepada saiz yang lebih kecil sesuai dengan saiz lengan robot yang
digunakan dalam projek ini.
.
vii
CONTENTS
CHAPTER TITLE PAGE
TITLE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF SYMBOLS AND ABBREVIATIONS xv
LIST OF APPENDICES xvii
CHAPTER 1 INTRODUCTION
1.1 Introduction
1.2 Project Background
1
2
1.3 Problem statement 3
1.4 Objectives 4
1.5 Scopes of Project 4
1.6 Thesis Organization 4
viii
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 6
2.2 Computer Controlled Robotic Arm 6
2.3 Loading-Unloading Path Optimization of
the AS/RS 7
2.4 Robot Arm Force Control through System
Linearization by Nonlinear Feedback 8
2.5 Fast pick and Place at Robot Singularities 9
2.6 Humanoid Robot System Design Based on
DC Reduction Servo Motor 10
2.7 Enhanced Position Sensing Device for
Mobile Robot Applications Using an
Optical Sensor 10
CHAPTER 3 METHODOLOGY
3.1 Introduction 12
3.2 Project Methodology 12
3.3 Hardware Overview 15
3.4 Developing Hardware and Software 17
3.4.1 Articulate/Revolute type of Robot
arm 17
3.4.2 Microcontroller 22
3.4.3 Actuator 24
3.4.3.1 Cube Servo 24
3.4.3.2 DC Motor 25
3.4.3.3 Servo motor 29
3.4.4 Potentiometer 30
3.4.5 End-effector (Gripper) 32
3.4.6 MPLAB X IDE 33
3.5 Hardware and Software Setup 34
3.6 Mathematical Modeling 36
3.6.1 Robot Arm Control System 36
ix
CHAPTER 4 RESULT AND ANALYSIS
4.1 Introduction 42
4.2 Result and Discussion 42
4.2.1 Basic Robot Arm Movement 42
4.2.2 Position Setting Program of Robot
Arm 48
4.2.3 Automatic Setting of Robot Arm
Movement 53
4.2.4 Position feedback of the Motor
System 61
CHAPTER5 CONCLUSION AND RECOMMENDATION
5.1 Conclusion 63
5.2 Recommendation 64
REFERENCES 65
APPENDICES A-B
x
LIST OF TABLES
TABLE NO TITLE PAGE
2.2 Position Error Reduction by Force Feedback 9
3.15 Specification of PIC18F46K22 23
3.34 Parameter of DC Motor 37
4.40 Proper position setting of the robot arm 59
xi
LIST OF FIGURES
FIGURE NO TITLE PAGE
2.1 Control circuit of robotic arm 7
2.3 Robot arm manipulator and straight path 9
2.4 The relation between the angle and the
pulse width
10
2.5 Position sensing device 11
3.1 Block diagram of this overall control
system
13
3.2 The overall flowchart for the methodology 14
3.3 Overall hardware overview for traffic
cones dispenser and collector system
15
3.4 The distance between traffic cones next to
each other
15
3.5 The control system for traffic cones
dispenser and collector system
16
3.6 Mini traffic cone 16
3.7 The spherical-shaped work envelope for
Articulate Robot
17
3.8 5 DOF for Articulate Robot Arm 18
3.9 Dimension of 5 DOF Robot Arm 18
3.10 Schematic diagram of the robot arm 19
3.11 PCB design component layout of the robot
arm
20
3.12 PCB layout of the robot arm for etching
process
20
xii
3.13 Robot arm development 21
3.14 40 Pins PIC18F46K22 microcontroller 22
3.16 Cube Servo 24
3.17 DC Motor 26
3.18 Closed loop control of DC Motor 26
3.19 MD10C type of motor driver 27
3.20 Duration of Pulse Width Signal 28
3.21 RC Servo Motor 29
3.22 SC08A type of motor driver 30
3.23 Potentiometer 31
3.24 Potentiometer construction 32
3.25 Gripper of the robot arm 32
3.26 MPLAB X IDE software 33
3.27 Hardware and software setup 34
3.28 Joysticks and PCD8544 LCD display as a
supporter hardware
35
3.29 Motor Driver MD10C for DC motor 35
3.30 Motor Driver SC08A for servo motor 35
3.31 Overall control system of the robot arm 36
3.32 DC motor circuit theory model 37
3.33 DC motor transfer function 37
3.35 System block diagram representing one dc
motor coupled with the mechanical load
39
3.36 Block diagram of the system 39
4.1 Arm 1 for base rotation (cube servo) 43
4.2 Minimum position for Arm 1 ‘0000’ 43
4.3 Maximum position for Arm 1 ‘0543’ 44
4.4 Arm 2 for up and down rotation (DC
motor)
44
4.5 Minimum position for Arm 2 ‘0160’ 44
4.6 Maximum position for Arm 2 ‘0500’ 45
4.7 PWM of the DC Motor recorded 45
xiii
4.8 Arm 3 for up and down rotation (cube
servo)
45
4.9 Minimum and maximum position of Arm
3
46
4.10 Arm 4 for gripper rotation (Servo motor) 46
4.11 Minimum position for Arm 4 ‘0543’ 46
4.12 Maximum position for Arm 4 ‘1087’ 47
4.13 Arm 5 for end-effector 47
4.14 Minimum position for Arm 5 ‘0000’ 47
4.15 Maximum position for Arm 5 ‘8000’ 48
4.16 Position setting stored in memory 48
4.17 Position setting program for Arm 1 49
4.18 Memory stored of position setting
program for Arm 1
49
4.19 Position setting program for Arm 2 DC
motor
49
4.20 Memory stored of position setting
program for Arm 2
50
4.21 Position setting program for Arm 3 50
4.22 Memory stored of position setting
program for Arm 3
50
4.23 Position setting program of servo motor
for Arm 4
51
4.24 Memory stored of position setting
program gripper rotation for Arm 4
51
4.25 Position setting program of gripper for
Arm 5
51
4.26
Memory stored of position setting
program for gripper of Arm 5
52
4.27 Memory stored for delay setting program 52
4.28 Menu setup 53
4.29 Delay is set to 50 ms 53
xiv
4.30 First step setting 54
4.31 The gripper had grip the traffic cone in
second step
54
4.32 Arm 2 lift up one of the traffic cones and
PWM of the motor had been showed in
this third step setting
55
4.33 Robot Arm had move to to place the
traffic cones
55
4.34 Fifth step setting 56
4.35 Robot arm move back to the initial
position to dispense another traffic cone
56
4.36 Robot arm grip another traffic cone 57
4.37 Robot arm rotate to to place another
traffic cone
57
4.38 Robot arm dispense another traffic cone
with 23 cm distance from another traffic
cone
58
4.39 Robot arm collect back the traffic cone
back into the storage
58
4.41 Position feedback for ARM 1 61
4.42 Position feedback for ARM 2 62
4.43 Position feedback for ARM 3 62
xv
LIST OF SYMBOLS AND ABBREVIATIONS
SYMBOL DESCRIPTION
cm - Centimetre
V - Voltage
rpm - Revolutions per Minute
ms - Miliseconds
emf - Electromotive Force
AS/RS - Automatic Storage/Retrieval System
EPROM - Erasable Programmable Read Only Memory
EEPROM - Electrically Erasable Programmable Read Only Memory
PIC - Programmable Integrated Circuit
IC - Integrated Circuit
DC - Direct Current
PWM - Pulse Width Modulation
DOF - Degree of Freedom
LCD - Liquid Crystal Display
PCB - Printed Circuit Board
RAM - Random Access Memory
CW - Clockwise
CCW - Counter Clockwise
xvi
RC - Radio Control
IDE - Integrated Development Environment
D-H - Danevit-Hartenberg
A - Ampere
Hz - Hertz
xvii
LIST OF APPENDICES
APPENDICES TITLE
APPENDIX A Gantt Chart for Master’s Project
APPENDIX B1 Robot Arm Program
APPENDIX B2 Position Simulation of the Robot Arm
1
CHAPTER 1
INTRODUCTION
In this first chapter it will focus on brief introduction of the project to be carried
out. The important overview or description in introduction including the project
background, problem statement, objective of the project, project scopes and thesis
organization are well emphasized in this chapter.
1.1 Introduction
In modern technology society the issues of safety is very important in a
daily life. The safety here refers on the prevention someone from having serious
injury when the person is doing the construction process on the road. The process
of placing traffic cones to close a lane on a highway involves a worker placing or
dispenses the cones from a work platform and collects the cones back altogether
into the storage. Usually this scenario occurs on the highway where the truck moves
forward in the closed lane along the highway while the worker on the work
platform will dispense and collect the cones. But, with this situation the workers
would be exposed in danger situation while doing dispensing and collecting the
traffic cones along the highway.
Loading or unloading the load like traffic cones can be done from the
storage by using suitable manipulator that will be working automatically in order to
dispense and collect the traffic cones outside or inside the storage. By using this
2
manipulator, it can reduce human risk encountered from danger situation while
dispenses and collects the traffic cones in the busiest highway. The manipulator
plays a very predominant role in manufacturing technology due to their advantages
such as simplicity, large load capacity, high stiffness, quick dynamic response and
high accuracy. The conventional machining equipment due to machine complex
shape of objects is not sufficient [1].
With the development of technologies, the manipulators such as robots are
used in a wide variety of material transfer applications. A robot is a re-
programmable multifunctional manipulator designed to move material, parts, tools
or specialized devices through variable programmed motions for performance of a
variety tasks. These tasks either replace or enhance human work, such as in
manufacturing, construction or manipulation of heavy or hazardous materials. The
robots also have the ability to work for an extended time.
Pick and place robot is one of the categories of the robot arm. The robot arm
system is widely used in variety of material transfer applications such as in
production, processing, product transportation, domestic services and other fields. It
is because it has some advantages such as high efficiency, precise repeated
movements and has good carrying capacity [2].
1.2 Project Background
This project is about modelling a robot arm manipulator and control system
of the robotic arm using microcontroller as the controller based system. The cube
servo, dc motor and servo motor are used to represent the link or joints of the robot.
The project is focusing on robot arm system that can operate for dispense and
collect the traffic cones. For this case, the end effectors or gripper is very important
to grab the traffic cones. It is because the different shape of the material is being
used, the end effectors of the robot had to be changed as well to suit the material
handling. The function of the gripper is to grasp object, usually the work part and
hold it during the work cycle [3]. The storage is used to store the stacking traffic
3
cones before loading and unloading traffic cones process on the road take place by
pick and place robot arm system.
1.3 Problem Statement
In real world, the distance for construction progress at the highway usually
takes about half of kilometer or more. It is a very long distance to put the traffic
cones along the highway so it needs a lot of traffic cones line up along during the
constructions process. Usually the traffic cones have almost the same difference
distance next to each other which is about 5 meters long distance next to each
cones. A lot of manpower involves in placing the traffic cones along the highway
for example the one who drive the truck, one person who dispense and collect the
traffic cones on the road and one person who is on the truck to handle storage and
retrieval of traffic cones in the truck. This project will reduce the manpower
involves and their tiredness in placing the traffic cones because it is an automatic
system. The robot arm system will be applied in this project in order to have an
automatic traffic cones dispenser and collector system
This robot arm is being designed to ease the process of dispensing and
collecting of traffic cones to close a lane on a highway for the construction progress
on the road or any other cases that might use traffic cones. Usually this transfer
process of the traffic cones is being carried out using man power and it is being
repeated for a period of time. So by using this automatic system it can increase the
efficiency of work and can save the time of working.
The workers might be exposed in danger situation while dispensing and
collecting the traffic cones along the highway and it can cause injuries to the
workers. It is because the working environment is very dangerous to the workers on
the busiest highway where the workers placing the traffic cones is far from each
other along the highway and it has high risk and may lead to an accident occur to
the workers. By using this particular robot, the workers will no longer have to bend
and lift up this heavy traffic cones that might lead to an accident because of
negligence or not responsible drivers on the highway. It is very important to work
4
in safety environment by using automatic traffic cones collector and dispenser
system because it can reduce the risk level of dangerous to the workers.
1.4 Objectives
The main objectives of the project are:
i. To design the robotic arm control system that can perform traffic cones
dispenser and collector system.
ii. To determine the proper position of the robot for dispensing and collecting
the traffic cones.
iii. To develop computer control for microcontroller for this control system.
1.5 Scopes of Project
The scopes of this project are:
i. Understanding the concept of robotic function and movement as
implementation from related subjects such as robotics and control systems.
ii. Design the robot arm that can perform dispensing and collecting the traffic
cones.
iii. Determine the proper position for robot performance in order to dispense
and collect the traffic cones.
iv. Developing a controller algorithm for this control system by using
microcontroller.
1.6 Thesis Organization
This project report has been structured and was carefully planned to give a better
explanation for the overall project. This thesis is divided into five chapters and
organized as follows:
5
Chapter 1: Explain briefly about the introduction, objectives, and the
organizational of the thesis.
Chapter 2: Contains literature review from the past works that related for this
project. It consists of computer controlled robotic arm, loading-
unloading path optimization of the AS/RS, robot arm force control
through system linearization by nonlinear feedback, fast pick and
place at robot singularities, humanoid robot system design based on
dc reduction servo motor and lastly the journal about enhanced
position sensing device for mobile robot applications using an
optical sensor.
Chapter 3: Explain on project methodology that shows the flow of the methods
used. The design of robotic arm, microcontroller, actuator, sensor
and the object that used in this project which is traffic cones are also
being discussed.
Chapter 4: Present the results, analysis and discussion obtained from the
project. All the pictures, data equations obtained and the graphs
obtained from oscilloscope are also included.
Chapter 5: Conclusion is made based on the discussion in earlier chapter and
suggestion about future development must be regarding to this study
by developing a new approach.
6
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
In this chapter it will discuss published information in a particular subject area
within a certain time period. The research focuses on mostly about robot arm
including microcontroller, actuator and sensor to move the robot and desired
positions required.
2.2 Computer Controlled Robotic Arm
From the research of a journal that had been done by Ahuja N. and
Sreedaran R. (2003), from Indian Institute of Technology described about how an
automated mechanical arm is develop by using C language programming to control
the operation of robot arm [4]. The software for this robotic arm is written in a high
level language converted into a Hex code and burnt onto the EPROM of the PIC.
The data stored the reference values and appropriate signals and sent it to the motor
driver IC’s. This data then actuate the motors to bring the gripper to the specified
coordinates and it will grip or release the object.
In order to control the robot arm to take the feedback signals and to actuate
the motors the IC had been programmed. This IC communicates with the computer
via the serial port at a specified baud rate. There is an advantage in using serial port
compared to parallel port which is it makes the hardware machine become
independent.
The figure shows how the electronic control and the feedback of the circuit
controlling this Robotic Arm. The programmable
while the output of the
2.3 Loading-Unloading Path Optimization of the AS/RS
The journal is about the optimization of loading
AS/RS and improves
Retrieval Systems (AS/RS) is very important in modern logistics
economize on land, reduce the labor intensity, improve
storage system and many more. It will shorten the moving distance for loading and
unloading the goods,
operating time or energy consumption
used in this paper [5].
The modeling of the loading
products warehouse with n items is executed according to the loading
order and the time, T which consumed by the stacker can be expressed as:
compared to parallel port which is it makes the hardware machine become
Figure 2.1: Control circuit of robotic arm
The figure shows how the electronic control and the feedback of the circuit
Robotic Arm. The programmable PIC is connected to the computer
he output of the PIC is connected to the DC motor driver IC.
Unloading Path Optimization of the AS/RS
journal is about the optimization of loading-unloading
AS/RS and improves the loading-unloading efficiency. Automated Storage and
Retrieval Systems (AS/RS) is very important in modern logistics nowadays
economize on land, reduce the labor intensity, improves the automation level of the
age system and many more. It will shorten the moving distance for loading and
unloading the goods, improve the ware location utilization and reduc
energy consumption. The method of genetic algorithm
].
The modeling of the loading-unloading path optimization of the finished
products warehouse with n items is executed according to the loading
order and the time, T which consumed by the stacker can be expressed as:
7
compared to parallel port which is it makes the hardware machine become
The figure shows how the electronic control and the feedback of the circuit
is connected to the computer
unloading path of the
Automated Storage and
nowadays. It may
the automation level of the
age system and many more. It will shorten the moving distance for loading and
reduce the stacker
genetic algorithm is being
unloading path optimization of the finished
products warehouse with n items is executed according to the loading-unloading
order and the time, T which consumed by the stacker can be expressed as:
8
� =������� ���,�
�
� �+��������,������ �, n�is�even�number
��
� �
���,��
� �+�������,������ + ��,��, n�is�odd�number
�"#�
� �
$
Where Tk,0 represents the time needed by the stacker to make a round trip
between the current shelves number and the origin while Tin k, out k represents the
time needed by the stacker to move from the current loading location to the next
unloading location. On the other hand Tn,0 represents the time needed by the stacker
to return to the origin after delivering the last shelves.
2.4 Robot Arm Force Control Through System Linearization by Nonlinear
Feedback
From the research of a journal that had been done by Tarn T.J., Bejczy A.K.
and Yun X. from the department of Systems Science and Mathematics, Washington
University describes that a new dynamic force control method of robot arms is
developed based on differential geometric feedback linearization technique of
nonlinear time-varying systems [6].
At the robot wrist the method uses active force-moment measurements. The
computer simulations show that the proposed controller improves the position error.
The controller design has the following features which is the main features is the
dynamics of the robot arm is fully considered in the process of deriving the
feedback law, the control algorithm is independent of tasks to be performed. It
shows that the controller is an intelligent. The table shows force feedback can
reduce the position error occur by the robot.
Table 2.2
2.5 Fast pick and Place at Robot Singularities
This journal had been done by
National University that investigates whether singular configurations may be good
sites for high-speed pick or place operations. From
accomplish the pick and place task because it allows the robot to keep some o
kinetic energy and it can lead to faster cycle times [
Singularities can be defined as
of two or more robot axes resulting in unpredictable robot motion and velocities
The singularities usually
has more axes than nec
certain configurations that require extremely high joint rates to move at some
nominal speed.
Figure
Table 2.2: Position Error Reduction by Force Feedback
Fast pick and Place at Robot Singularities
s journal had been done by Kieffer J.C and Cahill A.J. from Australian
National University that investigates whether singular configurations may be good
speed pick or place operations. From these singularities
accomplish the pick and place task because it allows the robot to keep some o
kinetic energy and it can lead to faster cycle times [7].
Singularities can be defined as a condition caused by the collinear alignment
of two or more robot axes resulting in unpredictable robot motion and velocities
The singularities usually occurs when robot axes are redundant which means that it
more axes than necessary to cause the same motion or when the robot is in
certain configurations that require extremely high joint rates to move at some
Figure 2.3: Robot arm manipulator and straight path.
9
Position Error Reduction by Force Feedback
from Australian
National University that investigates whether singular configurations may be good
these singularities, it can
accomplish the pick and place task because it allows the robot to keep some of its
a condition caused by the collinear alignment
of two or more robot axes resulting in unpredictable robot motion and velocities.
when robot axes are redundant which means that it
or when the robot is in
certain configurations that require extremely high joint rates to move at some
2.6 Humanoid Robot System Design Based on DC Reduction Servo Motor
In this journal it describes about how DC reduction servo motor is used to
humanoid robot system that consist of mechanical part and control part syst
Servo motor is used to drive each joint [
The DC reduction servo motor has 3
one power supply line and one ground line
servo motor and another one line is the control signal
signal from the controller.
shown in graph below:
Figure 2.4: The relation between the angle and the pulse width
2.7 Enhanced Position Sensing Device for
an Optical Sensor
This journal describes about smooth position detection capabilities is
needed. Built device was attached to a mobile robot so that the robot can be driven
from the position information of the rotary encode
sensing device. The results to validate the applicability of the proposed concept
from both rotary encoder and optical device are presented in this paper [
In these paper rotary encoders is used to measure rotary angles, l
movement, speed, velocity, distance and position. Rotary encoders are sensors that
generate digital feedback signals in response to movement and convert that
Humanoid Robot System Design Based on DC Reduction Servo Motor
In this journal it describes about how DC reduction servo motor is used to
humanoid robot system that consist of mechanical part and control part syst
Servo motor is used to drive each joint [8].
The DC reduction servo motor has 3 input lines. The two lines which are
r supply line and one ground line provide power for the DC reduction
motor and another one line is the control signal line which receives the PWM
signal from the controller. The relation between the angle and the pulse width is
shown in graph below:
: The relation between the angle and the pulse width
Enhanced Position Sensing Device for Mobile Robot Applications Using
an Optical Sensor
This journal describes about smooth position detection capabilities is
needed. Built device was attached to a mobile robot so that the robot can be driven
from the position information of the rotary encoder and the new optical position
sensing device. The results to validate the applicability of the proposed concept
from both rotary encoder and optical device are presented in this paper [
In these paper rotary encoders is used to measure rotary angles, l
movement, speed, velocity, distance and position. Rotary encoders are sensors that
generate digital feedback signals in response to movement and convert that
10
Humanoid Robot System Design Based on DC Reduction Servo Motor
In this journal it describes about how DC reduction servo motor is used to
humanoid robot system that consist of mechanical part and control part system.
input lines. The two lines which are
provide power for the DC reduction
which receives the PWM
The relation between the angle and the pulse width is
: The relation between the angle and the pulse width
Mobile Robot Applications Using
This journal describes about smooth position detection capabilities is
needed. Built device was attached to a mobile robot so that the robot can be driven
r and the new optical position
sensing device. The results to validate the applicability of the proposed concept
from both rotary encoder and optical device are presented in this paper [9].
In these paper rotary encoders is used to measure rotary angles, linear
movement, speed, velocity, distance and position. Rotary encoders are sensors that
generate digital feedback signals in response to movement and convert that
movement of a mechanical position of a tool or signal into an electrical signal that
is measurable [10].
Figure 2.4 above shows the basic block diagram of the position sensing
device. External device can be a computer, microcontroller or
Therefore a new interface was developed
between the main microcontroller and the optical sensing device.
movement of a mechanical position of a tool or signal into an electrical signal that
Figure 2.5: Position sensing device
above shows the basic block diagram of the position sensing
device. External device can be a computer, microcontroller or any other controller.
Therefore a new interface was developed in order to keep the communication
microcontroller and the optical sensing device.
11
movement of a mechanical position of a tool or signal into an electrical signal that
above shows the basic block diagram of the position sensing
any other controller.
order to keep the communication
12
CHAPTER 3
METHODOLOGY
3.1 Introduction
In order for a project to be successful, a good methodology is very
important to show the flow of the methods used. The design process is also must be
provided in this chapter. The design of robotic arm, microcontroller, actuator,
sensor and cones object that used in this project are also being discussed.
3.2 Project Methodology
All the information regarding the problem to dispense and collect the traffic
cones issues is being gathering in order to develop an automatic controller system.
The researches have been design and implement after gathering information from
the internet and journals. The block diagram, flowchart, schematic and layout
diagram to develop this automatic traffic cones dispenser and collector system are
showed in the figure.
13
Figure 3.1: Block diagram of this overall control system
The Figure 3.1 shows the block diagram for the overall control system. A
microcontroller circuit is being used as the basic circuit to control the motor which
is actuator of the robot arm. The computer had been used to program the
microcontroller in order to move the robot arm to the desired object.
The programmed from the computer had been embedded to the
microcontroller by using pickit3 burner. The microcontroller will control the robot
arm doing dispensing of the traffic cones from the storage and collect the traffic
cones back to the storage system.
The PIC18F46K22 microcontroller had been used in this project. For the
actuator, three different types of motor had been used which are cube servo, dc
motor and servo motor had been used to represent each joint of the robot arm
(plant). Potentiometer is used for measurement in this project to measure the
position needs for this robot arm.
The flowchart in Figure 3.2 shows the overall step of methodology in
completing this project. It is start with collecting all the data and information in
background of studies about robot arm hardware and C programming language
software is used as the controller of the robot. From gathering the information, how
the robot arm can be able to perform and grip the traffic cones has been explored.
+
Controller Actuator Plant
Measurement -
Desired
trajectory
Actual
trajectory
14
Figure 3.2: The overall flowchart for the methodology
Start
Hardware setup
Designing of robot arm
Integrate hardware and
software
Background Study
Development of the C programming
Able to grip
traffic cones
Conclusion
End
Result & Analysis
No
Yes
15
3.3 Hardware Overview
The hardware overview in the figure below shows the information about
this project. The robot is placed on the road/highway model in order to dispense
traffic cones outside from storage and collect back to the storage.
The traffic cones had been stack up in the storage and the distance between
traffic cones and the manipulator which is robot arm is 23 centimeters (cm). On the
other hand, the distance between the traffic cones next to each other also are
adjustable to 23 cm difference.
Figure 3.3: Overall hardware overview for traffic cones dispenser and collector
system
Figure 3.4: The distance between traffic cones next to each other
In the figure 3.5, it can
while the programmed in the computer
system.
Figure 3.5: The control system for traffic cones dispenser and collector system
There are various type dimensions of traffic cones that use on the highway.
In this project the traffic cones that had been used is reduce to smaller size
compared to the actual size of traffic cones. The mini traffic cones that had been
used in this project are made by
the task for dispenses
, it can be seen that the microcontroller will control the robot arm
programmed in the computer will be the control unit for the whole
: The control system for traffic cones dispenser and collector system
There are various type dimensions of traffic cones that use on the highway.
In this project the traffic cones that had been used is reduce to smaller size
compared to the actual size of traffic cones. The mini traffic cones that had been
ct are made by manila card material in order for robot arm to
the task for dispenses and collects the traffic cones.
Figure 3.6: Mini traffic cone
16
that the microcontroller will control the robot arm
be the control unit for the whole
: The control system for traffic cones dispenser and collector system
There are various type dimensions of traffic cones that use on the highway.
In this project the traffic cones that had been used is reduce to smaller size
compared to the actual size of traffic cones. The mini traffic cones that had been
in order for robot arm to do
3.4 Developing Hardware and Software
3.4.1 Articulate/Revolute type of
In this project
has five degree of freedom (DOF)
has five rotary joints
manipulator and the elbow
movement in a compact space. The articulated robot arm has the spherical
work envelope. The advantage for using this type of articulate robot arm is it c
reach above or below obstacles
also has largest work area for least work space
point.
Figure 3.7: The spherical
The robot arm
traffic cones out from the
the storage. The figure 3.8 shows the total five DOF including end
robot arm in this project.
Hardware and Software
/Revolute type of Robot arm
n this project the robot arm type used is articulate or revolute
degree of freedom (DOF). This type of robot resembles human arm
rotary joints. Two common revolute designs are the elbow ty
he elbow type configuration provides relatively large freedom
movement in a compact space. The articulated robot arm has the spherical
work envelope. The advantage for using this type of articulate robot arm is it c
reach above or below obstacles because of spherical-shaped work envelope. It is
argest work area for least work space and has two or four ways to reach a
: The spherical-shaped work envelope for Articulate Robot.
The robot arm had been placed on the road/highway in order t
traffic cones out from the storage or collect the traffic cones on the road back in
The figure 3.8 shows the total five DOF including end-
robot arm in this project.
17
or revolute robot arm that
type of robot resembles human arm that
are the elbow type
type configuration provides relatively large freedom of
movement in a compact space. The articulated robot arm has the spherical-shaped
work envelope. The advantage for using this type of articulate robot arm is it can
shaped work envelope. It is
wo or four ways to reach a
shaped work envelope for Articulate Robot.
in order to dispense the
storage or collect the traffic cones on the road back into
-effector of the
18
Figure 3.8: 5 DOF for Articulate Robot Arm.
The traffic cones are stored on the storage box, so the robot arm will
pickups the traffic cones one by one and positions them on a road/highway model at
pre-determined positions. The robot arm could lay a long line traffic cones along
the road and because of six axes robot arm, the traffic cones are able to pick up and
placed accurately. When collect the traffic cones, the robotic arm grips the traffic
cones on the road, picks them up and stacks them on the storage box.
The position setting of the robot is very important in this project in order for
robot arm can grab the traffic cones. The potentiometer is used to detect the
position needs for the robot to reach the object and it acts as a sensor in this project.
The figure 3.9 below shows the dimension of the robot arm for this project.
Figure 3.9: Dimension of 5 DOF Robot Arm.
The figure 3.
the robot arm. The power circuit
attached to voltage regulator
ground of the LM1117
cube servo that connect directly to the microcontroller pins
is connected to motor driver and then motor driver
servo connections, each
driver and connected to the
pin from each motor, LCD
seen on the schematic.
Figure 3.
3.10 shows the schematic diagram for these overall
The power circuit that used in this project is 12V power
attached to voltage regulator LM1117 with a 10uF capacitor hooked to output
1117 to keep a steady 5V DC. There are 3 wires coming out from
cube servo that connect directly to the microcontroller pins. The 2 wires
connected to motor driver and then motor driver is connected to the PIC pins. For
ach servo has 3 wires also coming out and it is connected to the
driver and connected to the power source, ground and microcontroller
motor, LCD screen and joysticks is tied to a unique pin on the
seen on the schematic.
Figure 3.10: Schematic diagram of the robot arm
19
overall five axes of
12V power supply that
hooked to output and
There are 3 wires coming out from
. The 2 wires DC motor
to the PIC pins. For
is connected to the
microcontroller. Every signal
is tied to a unique pin on the PIC as
From the schematic diagram, the printed circuit board (PCB) had been
designed by using Altium software for connection of all the components to
integrate the hardware part of this robot arm. Figure 3.11 and 3.12 below show the
PCB design and layout of the robot arm:
Figure 3.11
Figure 3.12
From the schematic diagram, the printed circuit board (PCB) had been
designed by using Altium software for connection of all the components to
integrate the hardware part of this robot arm. Figure 3.11 and 3.12 below show the
layout of the robot arm:
Figure 3.11: PCB design component layout of the robot arm
Figure 3.12: PCB layout of the robot arm for etching process
20
From the schematic diagram, the printed circuit board (PCB) had been
designed by using Altium software for connection of all the components to
integrate the hardware part of this robot arm. Figure 3.11 and 3.12 below show the
of the robot arm
for etching process
21
Figure 3.13: Robot arm development
START
Mechanical Module
Design concept
Robotic arm structure
Part Assemble
Mechanism Test
Electronic Module
Circuit and PCB design
Circuit Assemble
Circuit Test
Programming Module
Write a program based on tasks
Program Test
Testing and troubleshooting
END
No
Yes
No
No
Yes
Yes
Figure 3.13 shows the flowchart for robot arm development for this project.
It can be categorized into three parts which are mechanical module, electronic
module and programming module.
arm mechanism and electronic cir
program development
to locate the arm at the desired position.
3.4.2 Microcontroller
Microcontrollers
the designer to interface
anything else required
For this project,
project. This microcontroller
write-erase until thousand times.
kilobyte program memory to save the position desired for the movement of the
robot in order to do dispensing and collecting the traffic cones.
will be program by C language in the computer
Figure 3.
shows the flowchart for robot arm development for this project.
It can be categorized into three parts which are mechanical module, electronic
module and programming module. The project starts by design and constructing of
arm mechanism and electronic circuit for the mechanism. Then it continues with
program development by C programming. Application of the potentiometer
to locate the arm at the desired position.
3.4.2 Microcontroller
Microcontrollers can be defined as robot brains. Microcontrollers
the designer to interface sensors, specialized control electronics together
g else required for the project and contain the overall logic of the robot.
For this project, PIC18F46K22 microcontroller had been used for this
This microcontroller use FLASH memory technology so that
erase until thousand times. This microcontroller has 40 pin
kilobyte program memory to save the position desired for the movement of the
do dispensing and collecting the traffic cones. This microcontroller
by C language in the computer as a controller of the system
Figure 3.14: 40 Pins PIC18F46K22 microcontroller
22
shows the flowchart for robot arm development for this project.
It can be categorized into three parts which are mechanical module, electronic
The project starts by design and constructing of
cuit for the mechanism. Then it continues with
of the potentiometer is used
Microcontrollers can allow
together along with
and contain the overall logic of the robot.
had been used for this
use FLASH memory technology so that it can be
40 pin and has 64
kilobyte program memory to save the position desired for the movement of the
microcontroller
the system.
23
The table 3.15 shows the details specifications for microcontroller
PIC18F46K22. It has the best memory to store the program and save the best
position in this PIC for robot arm movement in this project.
Table 3.15: Specification of PIC18F46K22
PARAMETER NAME VALUE
Program Memory Type Flash
Program Memory (KB) 64
CPU speed (MIPS) 16
RAM Bytes 3,896
Data EEPROM (bytes) 1024
Digital Communication Peripherals 2-UART, 2-A/E/USART, 2-SPI, 2-
I2C2-MSSP(SPI/I2C)
Capture/Compare/PWM Peripherals 2 CCP. 2 ECCP
Timers 3 X 8-bit, 4 X 16-bit
ADC 28 ch, 10-bit
Comparators 2
Temperature Range (C) -40 to 125
Operating Voltage Range (V) 1.8 to 5.5
Pin Count 40
XLP Yes
Cap Touch Channels 28
3.4.3 Actuator
In this project there
types of motor chosen are very important to build the joints of robot arm. All
aspects and criteria must be considered in order to make sure that robot arm can
move to the desired position required.
3.4.3.1 Cube Servo
There are two cube servos that
in this project and the type of cube servos that are used is G15 Cube Servo.
Cube Servo is a modular type smart serial servo which incorporates gear reducer,
has high torque DC motor and can control circuit
It has its own high strength and can sustain high external force.
rotate 360° with resolution up to 0.33°.
This cube servo is the best type of motor
project, cube servo is used because it is suitable for position control of the robot
arm. Other than that, c
daisy chain connection to
In this project there are three different types of motor had been use.
types of motor chosen are very important to build the joints of robot arm. All
aspects and criteria must be considered in order to make sure that robot arm can
move to the desired position required.
There are two cube servos that are used for robot arm at first and third DOF
in this project and the type of cube servos that are used is G15 Cube Servo.
Cube Servo is a modular type smart serial servo which incorporates gear reducer,
has high torque DC motor and can control circuitry with networking functionality.
It has its own high strength and can sustain high external force. It is also able to
rotate 360° with resolution up to 0.33°.
This cube servo is the best type of motor to use for robotics model.
servo is used because it is suitable for position control of the robot
arm. Other than that, cube servo uses serial half duplex communication and a
daisy chain connection to multiple servos to create a servo network on a single line.
Figure 3.16: Cube Servo
24
are three different types of motor had been use. The
types of motor chosen are very important to build the joints of robot arm. All
aspects and criteria must be considered in order to make sure that robot arm can
at first and third DOF
in this project and the type of cube servos that are used is G15 Cube Servo. G15
Cube Servo is a modular type smart serial servo which incorporates gear reducer,
ry with networking functionality.
It is also able to
use for robotics model. For this
servo is used because it is suitable for position control of the robot
ervo uses serial half duplex communication and allows
multiple servos to create a servo network on a single line.
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