Fyp-pick-and-place-robot-140928030139-phpapp02.pdf

ABSTRACT

Mankind has always strived to give life like qualities to its artifacts in an attempt to find substitutes for himself to carry out his orders and also to work in a hostile environment. The popular concept of a mechanical arm is of a machine that looks and works like a human arm. The industry is moving from current state of automation to Robotization, to increase productivity and to deliver uniform quality. The industrial robots of today may not look the least bit like a human being although all the research is directed to provide more and more anthropomorphic and humanlike features and super-human capabilities in these. One type of robot commonly used in industry is a robotic manipulator or simply a mechanical arm. It is an open or closed kinematic chain of rigid links interconnected by movable joints. In some configurations, links can be considered to correspond to human anatomy as waist, upper arm and forearm with joint at shoulder and elbow. At end of arm a wrist joint connects an end effector which may be a tool and its fixture or a gripper or any other device to work. Here how a pick and place mechanical arm can be designed for a workstation where loading and packing of lead batteries is been presented. All the various problems and obstructions for the loading process has been deeply analyzed and been taken into consideration while designing the pick and place mechanical arm.

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INDEX CHAPTER 1 INTRODUCTION…………………………………………9 1.1History of mechanical arm……………………………………………… 11 1.2Law of mechanical arm ……………………………………………….. 15 1.3Components of mechanical arm …………………………………………15 CHAPTER 2 CLASSIFICATION OF MECHANICAL ARM …….

20

2.1 Types of mechanical arm as per Application…………………………. 20 2.2 Types of mechanical arm by Locomotion & Kinematics…………….

23

CHAPTER 3 SELECTION OF TASK……………………………………25 3.1 Tasks……………………………………………………………………25 3.2 Selection of Tasks………………………………………………………27 3.3 Why Pick & Place mechanical arm..........................................................27 3.4 Defining work station………………………………………………..

28

CHAPTER 4 DESIGN PROCEDURE………………………………… 29 4.1 Factors to be considered while designing……………………………… 29 CHAPTER 5 STEPS OF DESIGNING…………………………………..32 5.1 Selection of Product…………………………………………………….32 5.2 Designing of Work space………………………………………………..32 5.3 Degree of Freedom………………………………………………………33 CHAPTER 6 WORKS TO BE DONE…………………………………. 35 6.1 Selection of Parts….…………………………………………………… 35 6.2 Completion of Model…………………………………………………. 35 6.3 Interfacing with the human……………………………………………36 CHAPTER 7 HARDWARE REQUIREMENT………………………..37 2|P a g e

7.1 VEHICLE PART………………………………………………………37 7.2 ARM PARTS…………………………………………………………..37 7.3 WIRED REMOTE……………………………………………………..37 CHAPTER 8 MAIN PARTS OF PROJECT…………………………. .38 8.1 Mechanical Arm Vehicle…………………………………………..... 38 8.2 Mechanical arm……………………………………………………….39 8.3 End Effector………………………………………………….……….40 8.4 Control Board………………………………………………………. 41 CHAPTER 9 MERITS,DEMARITS AND APPLICATION……..…..42 9.1 Advantages…………………………………………………………….42 9.2 Disadvantages………………………………………………………….43 9.3 Application…………………………………………………………….43  REFERENCE……………………………………………………...45

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 LIST OF FIGURES

FIGURES 1.1 MECHANICAL ARM STRUCTURE. 1.2 POWER SOURCE BATTERY. 1.3 MOTOR. 2.1 MECHANICAL GRIPPER. 2.2 INDUSTRIAL MECHANICAL ARM. 2.3 MOBILE VEHICLE 3.1 AGRICULTURAL ARM. 3.2 DEGREE OF FREEDOM. 3.3 INTERFACING OF MECHANICAL ARM WITH HUMAN. 3.4 MECHANICAL ARM. 3.5 MECHANICAL ARM VEHICLE. 3.6 END EFFECTOR. 3.7 WIRED REMOTE. 3.8 BLOCK DIAGRAM.

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CHAPTER 1 INTRODUCTION

Mechanical is the branch of engineering science & Technology related to machinery,

and

their design,

manufacture,

application, and structural

disposition. Robotics is related to electronics, mechanics, and software. Robotics research today is focused on developing systems that exhibit modularity, flexibility, redundancy, fault-tolerance, a general and extensible software environment and seamless connectivity to other machines, some researchers focus on completely automating a manufacturing process or a task, by providing sensor based intelligence to the mechanical arm, while others try to solidify the analytical foundations on which many of the basic concepts in robotics are built. In this highly developing society time and man power are critical constrains for completion of task in large scales. The automation is playing important role to save human efforts in most of the regular and frequently carried works. One of the major and most commonly performed works is picking and placing of jobs from source to destination. Present day industry is increasingly turning towards computer-based automation mainly due to the need for increased productivity and delivery of end products with uniform quality. The inflexibility and generally high cost of hard-automation systems, which have been used for automated manufacturing tasks in the past, have led to a broad based interest in the use of mechanical arm capable of performing a variety of manufacturing functions in a flexible environment and at lower costs. The use of Industrial mechanical arm characterizes some of contemporary trends in automation of the manufacturing process. However, present day industrial mechanical arm also exhibit a 5|P a g e

monolithic mechanical structure and closed-system software architecture. They are concentrated on simple repetitive tasks, which tend not to require high precision. The pick and place mechanical arm is a human controlled based system that detects the object, picks that object from source location and places at desired location. For detection of object, human detect presence of object and move machine accordingly.

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1.1 HISTORY OF MECHANICAL ARM: The various developments in the field of mechanical arm with the progress in scientific technology have been revealed as follows:  1954: The first programmable mechanical arm is designed by George Devol. He coins the term Universal Automation.  1956: Devol and engineer Joseph Engelberger form the world's first robot company, Unimation.  1960: Unimation is purchased by Condec Corporation and development of Unimate Robot Systems begins. American Machine and Foundry, later known as AMF Corporation, markets a robot, called the Versatran, designed by Harry Johnson and Veljko Milenkovic.  1962: The first industrial mechanical arm was online in a General Motors automobile factory in New Jersey. It was Devol and Engelberger's UNIMATE. It performed spot welding and extracted die castings.  1969: Nachi starts its robotic business.  1973: German robotics company, KUKA, creates the first industrial robot with six electromechanically-driven axes. It is called the Famulus.  1974: A mechanical arm (the Silver Arm) that performed small-parts assembly using feedback from touch and pressure sensors was designed. Professor Scheinman, the developer of the Stanford Arm, forms Vicarm Inc. to market a version of the arm for industrial applications. The new arm is controlled by a minicomputer.  1974: Industrial mechanical arm were developed and installed in Fanuc factory. Dr. Inaba, President of FANUC was rewarded with "the 6th 7|P a g e

Annual Memorial Award of Joseph Marie Jacquard" by the American NC Society. The production and sale of DC servo motors were started under GETTYS MANUFACTURING CO., INC license.  1977: The Motoman L10 was introduced. It featured five axes and a maximum workload of 10 kg, which included the gripper. It weighed 470kg. The Motoman L10 was the first robot that Yaskawa introduced on the market.  1977: ASEA, a European robot company, offers two sizes of electric powered industrial robots. Both robots use a microcomputer controller for programming and operation. Unimation purchases Vicarm Inc. during this year.  1978: Vicarm, Unimation creates the PUMA (Programmable Universal Machine for Assembly) robot with support from General Motors. Many research labs still use this assembly robot.  1979: Nachi developed the first motor-driven mechanical arm for spot welding.  1979: OTC DAIHEN was known as OTC America. OTC was an acronym for the Osaka Transformer Company. Located in Charlotte, NC, OTC was originally a supplier of welding equipment for other transplant companies. They expanded to become a provider to the Japanese auto market of GMAW supplies. In these early years, OTC Japan introduced its first generation of dedicated arc welding robots.  1980: The industrial robot industry starts its rapid growth, with a new robot or company entering the market every month.

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 1981: Takeo Kanade builds the direct drive arm. It is the first to have motors installed directly into the joints of the arm. This change makes it faster and much more accurate than previous robotic arms.  1985: OTC DAIHEN became the official OEM supplier of robots to the Miller Electric Company. Miller chose to assign different model numbers to the robots sold in the North American market. The prefixed the letters in the model with "MR," for Miller Robot. Miller no longer supports the robots that were manufactured in this era. The Japanese models featured their own number and name.  1987: ASEA of Vasteras, Sweden (founded 1883) and BBC Brown Boveri Ltd of Baden, Switzerland, (founded 1891) announce plans to form ABB Asea Brown Boveri Ltd., headquartered in Zurich, Switzerland. Each parent will hold 50 percent of the new company.  1988: The Motoman ERC control system was introduced with the ability to control up to 12 axes, more than any other controller at the time.  1989: Nachi Technology Inc., U.S.A. is established.  1992: FANUC Robot School was established. GM Fanuc Robotics Corporation was restructured to FANUC's wholly owned share holding company, FANUC Robotics Corporation, together with its subsidiaries, FANUC Robotics North America, Inc. and FANUC Robotics Europe GmbH. A Prototype of the intelligent robot was built.  1994: The Motoman MRC control system was introduced with the ability to control up to 21 axes. It could also synchronize the motions of two robots.

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 1995: Miller departed from the robotic business. OTC launched the Dynamic Robotic Division and moved the headquarters to Ohio to focus on selling robots to new users.  1996: Nachi expands robotics business, cutting tool, and bearing product ranges.  1998: The introduction of the XRC controller allowed the control of up to 27 axes and the synchronized control of three to four robots. The Motoman UP series introduced a simpler robot arm that was more readily accessible for maintenance and repair. Honda was instrumental in driving the development of both the UP series of arms and the XRC arm control.  2003: OTC DAIHEN introduced the Almega AX series, a line of arc welding and handling robots. The AX series robots integrate seamlessly with the OTC D series welding power supplies for advanced control capabilities

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1.2 LAW OF ROBOTICS: Isaac Asimov conceived the mechanical arm as humanoids hand, devoid of feelings, and used them in a number of stories. His mechanical arm were welldesigned, fail-safe machines, whose brains were programmed by human beings. Anticipating the dangers and havoc such a device could cause, he postulated rules for their ethical conduct. mechanical arm were required to perform according to three principles known as “Three laws of mechanical arm”’ which are as valid for real mechanical arm as they were for Asimov’s mechanical arm and they are: 1. A mechanical arm should not injure a human being or, through inaction, allow a human to be harmed. 2. A mechanical arm must obey orders given by humans except when that conflicts with the First Law. 3. A mechanical arm must protect its own existence unless that conflicts with the First or Second law. These are very general laws and apply even to other machines and appliances. They are always taken care of in any mechanical arm design.

1.3 COMPONENTS OF MECHANICAL ARM: 1. Structure The structure of a mechanical arm is usually mostly mechanical and can be called a kinematic chain. The chain is formed of links, actuators, and joints which can allow one or more degrees of freedom. Most contemporary mechanical arm use open serial chains in which each link connects the one before to the one after it. These mechanical arm are often resemble the human 11 | P a g e

arm. mechanical arm used as manipulators have an end effector mounted on the last link. This end effector can be anything from a welding device to a mechanical hand used to manipulate the environment.

2. Power Source At present mostly (lead-acid) batteries are used, but potential power sources could be: 

Pneumatic (compressed gases)



Hydraulics (compressed liquids)



Flywheel energy storage



Organic garbage (through anaerobic digestion)



Still untested energy sources (e.g. Nuclear Fusion reactors)

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3. Actuation Actuators are like the "muscles" of a mechanical arm, the parts which convert stored energy into movement. By far the most popular actuators are electric motors that spin a wheel or gear, and linear actuators that control industrial mechanical arm in factors. But there are some recent advances in alternative types of actuators, powered by electricity, chemicals, or compressed air.

4. Touch Current mechanical arm

receive far less tactile information than the human

hand. Recent research has developed a tactile sensor array that mimics the mechanical properties and touch receptors of human fingertips. The sensor array is constructed as a rigid core surrounded by conductive fluid contained by an elastomeric skin. Electrodes are mounted on the surface of the rigid core and are connected to an impedance-measuring device within the core. When the artificial skin touches an object the fluid path around the electrodes is deformed, producing impedance changes that map the forces received from the object.

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5. Vision Computer vision is the science and technology of machines that see. As a scientific discipline, computer vision is concerned with the theory behind artificial systems that extract information from images. The image data can take many forms, such as video sequences and views from cameras. In most practical computer vision applications, the computers are preprogrammed to solve a particular task, but methods based on learning are now becoming increasingly common. Computer vision systems rely on image sensors which detect electromagnetic radiation which is typically in the form of either visible light or infra-red light. The sensors are designed using solid-state physics. The process by which light propagates and reflects off surfaces is explained using optics. Sophisticated image sensors even require quantum mechanics to provide a complete understanding of the image formation process.

6. Manipulation Mechanical arm which must work in the real world require some way to manipulate objects; pick up, modify, destroy, or otherwise have an effect. Thus the 'hands' of a mechanical arm are often referred to as end effectors, while the arm is referred to as a manipulator. Most mechanical arm arms have replaceable effectors, each allowing them to perform some small range of tasks. Some have a fixed manipulator which cannot be replaced, while a few have one very general purpose manipulator, for example a humanoid hand.

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1

Mechanical Grippers: One of the most common effectors is the gripper. In its simplest manifestation it consists of just two fingers which can open and close to pick up and let go of a range of small objects. Fingers can for example be made of a chain with a metal wire run trough it.

2

Vacuum Grippers: Pick and place robots for electronic components and for large objects like car windscreens, will often use very simple vacuum grippers. These are very simple astrictive devices, but can hold very large loads provided the pretension surface is smooth enough to ensure suction.

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CHAPTER 2 CLASSIFICATION OF MECHANICAL ARM Industrial mechanical arm are found in a variety of locations including the automobile and manufacturing industries. Mechanical arm cut and shape fabricated parts, assemble machinery and inspect manufactured parts. Some types of jobs mechanical arm do: load bricks, die cast, drill, fasten, forge, make glass, grind, heat treat, load/unload machines, machine parts, handle parts, measure, monitor radiation, run nuts, sort parts, clean parts, profile objects, perform quality control, rivet, sand blast, change tools and weld. Outside the manufacturing world mechanical arm perform other important jobs. They can be found in hazardous duty service, maintenance jobs, fighting fires, medical applications, military warfare and on the farm.

2.1 TYPES OF MECHANICAL ARM AS PER APPLICATIONS

Nowadays, mechanical arm do a lot of different tasks in many fields. And this number of jobs entrusted to mechanical arm is growing steadily. That's why one of the best ways how to divide mechanical arm into types is a division by their application.

2.1.1 Industrial Mechanical Arm: mechanical arm today are being utilized in a wide variety of industrial applications. Any job that involves repetitiveness, accuracy, endurance, speed, and reliability can be done much better by robots, which is why many industrial jobs that used to be done by humans are increasingly being done by mechanical arm.

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2.1.2 Mobile Mechanical Arm:

Also known as Automated Guided

Vehicles, or AGVs, these are used for transporting material over large sized places like hospitals,container ports, and warehouses, using wires or markers placed in the floor, or lasers, or vision, tosense the environment they operate in. An advanced form of the AGV is the SGV, or the Self Guided Vehicle, like PatrolBot Gofer, Tug, and Speci-Minder, which can be taught to autonomously navigate within a space.

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2.1.3 Agriculture Mechanical Arm: Although the idea of Mechanical Arm planting seeds, ploughing fields, and gathering the harvest may seem straight out of a futuristic science fiction book, nevertheless there are several Mechanical Arm in the experimental stages of being used for agricultural purposes,

such

as

mechanical

arm

that

can

pickapples.

2.1.4 Telemechanical Arm: These mechanical arm are used in places that are hazardous to humans, or are inaccessible or far away. A human operator located at a distance from a telemechanical arm controls its action, which was accomplished with the arm of the space shuttle. Telemechanical arm are also useful in nuclear power plants where they, instead of humans, can handle hazardous material or undertake operations potentially harmful for humans.

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2.1.5 Service Mechanical Arm: The Japanese are in the forefront in these types of mechanical arm. Essentially, this category comprises of any mechanical arm that is used outside an industrial facility, although they can be sub-divided into two main types of mechanical arm: one, mechanical arm used for professional jobs, and the second, mechanical arm used for personal use. Amongst the former type are the above mentioned mechanical arm used for military use, and then there are mechanical arm that are used for underwater jobs, or mechanical arm used for cleaning hazardous waste, and the like.

2.2 TYPES OF MECHANICAL ARM BY LOCOMOTION & KINEMATICS As you can understand, mechanical arm application alone does not provide enough information when talking about a specific mechanical arm. For example an industrial mechanical arm - usually, when talking about industrial mechanical arm we think of stationary mechanical arm in a work cell that do a specific task.

2.2.1 Cartesian Mechanical Arm

: Used for pick and place work,

application of sealant, assembly operations, handling machine tools and arc welding. It's a mechanical arm whose arm has three prismatic joints, whose axes are coincident with a Cartesian coordinator.

2.2.2 Cylindrical Mechanical Arm

: Used for assembly operations,

handling at machine tools, spot welding, and handling at die-casting machines. It's a mechanical arm whose axes form a cylindrical coordinate system.

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2.2.3 Spherical/Polar Mechanical Arm : Used for handling at machine tools, spot welding, die-casting, fettling machines, gas welding and arc welding. It's a mechanical arm whose axes form a polar coordinate system.

2.2.4 SCARA Mechanical Arm : Used for pick and place work, application of sealant, assembly operations and handling machine tools. It's a mechanical arm which has two parallel rotary joints to provide compliance in a plane.

2.2.5 Articulated Mechanical Arm : Used for assembly operations, diecasting, fettling machines, gas welding, arc welding and spray painting. It's a mechanical arm whose arm has at least three rotary joints.

2.2.6 Parallel Mechanical Arm : One use is a mobile platform handling cockpit flight simulators. It's a mechanical arm whose arms have concurrent prismatic or rotary joints.

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CHAPTER 3 SELECTION OF TASK 3.1

TASKS

The various tasks which a pick and place mechanical arm can perform are as follows:-

3.1.1 Pick-And-Place The use of mechanical arm for placing products in cartons and transfer of cartons and products between different stations in the packaging lines is very common in all industries. High speed pick-and-place mechanical arm for placing small items like candy and cookies in packages are often combined with a visual observation system for identifying products.

3.1.2 Handling Of Flexible Packages Flexible packaging material is the generic term for soft packages made of film, foil or paper sheeting. Popular forms are stand-up pouches, bags, sachets and envelopes. These packages are often formed, filled and sealed in a vertical or horizontal form-fill-seal machine. The package is then finally put into a case by top loading.

3.1.3 Cartooning Machines Cartooning machines erect boxes from flat sheets of corrugated material. The erected boxes are then filled with products or individual cartons and are then prepared for the palletizing process. As with most packaging machines, vacuum cups, vacuum pumps and other pneumatic components are an essential part of the cartooning.

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3.1.4 Rotary Cartoners Rotary cartoner is one of the most popular types of cartooning machines. These machines use a series of vacuum bars equipped with suction cups that move in a continuous rotary motion. Rotary cartoners utilize a "pick-and-carry" motion to move cartons.

3.1.5 Pick & Place Mechanical Arm The use of specialized machines for high speed pick-and-place of small items with suction cups is very common in the electronics and consumer industries. This application is typically characterized by short cycle times, high acceleration forces and large variations on the parts to be handled.

3.1.6 Seal Machines During the pouch/bag forming phase vacuum is often applied to transport belts that help provide a grip on both sides of the pouch/bag material. The vacuum belt moves the pouch material from a web roll into position to receive the product from the filler. Holes in the belt allow vacuum to hold the pouch while the belt is rotating and the pouch is been removed.

3.1.7 Bag Opening Vacuum and suction cups are used to pick and open paper and plastic bags. Suction cups with stiffer bellows and a soft sealing lip are preferred in these quite often high-speed applications .

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3.2 SELECTION OF TASK  From the various tasks which can be done using the pick and place Mechanical Arm we have particularly the process of picking & placing process.  We have decided to pick an box (Dimensions 45x45x65mm approx, Weight 1.5 kg) from the conveyor.  Then placing it at the center table , also picking a automobile tyre from the work station and moving towards the center table.  Placing of tyre at center table and again movement to the work station to pick an another thing.  So the picking & placing is done using this pick and place mechanical arm.

3.3 WHY PICK & PLACE MECHANICAL ARM We have selected the pick and place mechanical arm for this particular process due to the following reasons: Using of Human labour for the loading and unloading of the box and tyre will consume more time.  Even though Number of laborers is required more, the loading and unloading time should include allowances if laborers are considered. 

Moreover the work can be done easily using a single pick and place mechanical arm, which is used for both loading and unloading purpose.

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3.4 DEFINING WORK STATION The work station for this operation of pick & place is been designed in such a way that:-

 The box coming from the far distances is been sensed by a human and the moment of the mechanical arm is been controlled by the mechanical arm.  As one by one the boxes comes, the mechanical arm picks one box and moves towards the centre table , keeps the boxes on the it.  Then picks the tyre from there and moves towards the center table and places the tyre there. 

Further mechanical arm movement continuous towards the return journey takes a Box from table and again the above procedure is been carried out .

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CHAPTER 4 DESIGN PROCEDURE

4.1 FACTORS

TO BE CONSIDERED

The various factors to be considered while designing of pick and place mechanical arm are been discussed as follows. The factors are all important while designing procedure of the mechanical arm. 4.1.1 Controls The mechanical structure of a mechanical arm must be controlled to perform tasks. The control of a mechanical arm involves three distinct phases perception, processing, and action. human

knows information about the

environment (e.g. the position of its joints or its end effector). This information is then processed to calculate the appropriate power to the actuators (motors) which move the mechanical. The processing phase can range in complexity. At a reactive level, it may translate raw information directly into actuator power. human sense fusion may first be used to estimate parameters of interest (e.g. the position of the robot's gripper) . An immediate task (such as moving the gripper in a certain direction) is done from these estimates. Techniques from control theory convert the task into commands that drive the actuators. At longer time scales or with more sophisticated tasks, the mechanical arm may need to build and reason with a "cognitive" model. Cognitive models try to represent the mechanical arm, the world, and how they interact. Pattern 25 | P a g e

recognition and computer vision can be used to track objects. Mapping techniques can be used to build maps of the world. Finally, motion planning and other artificial intelligence techniques may be used to figure out how to act. For example, a planner may figure out how to achieve a task without hitting obstacles, falling over, etc.

4.1.2 Autonomy

Levels

Control systems may also have varying levels of autonomy.  Direct interaction is used for hap tic or tale-operated devices, and the human has nearly complete control over the mechanical arm motion.  Operator-assist modes have the operator commanding medium-to-highlevel tasks, with the mechanical arm figuring out how to achieve them.  An autonomous mechanical arm may go for extended periods of time without human interaction. Higher levels of autonomy do not necessarily require more complex cognitive capabilities. For example, mechanical arm in assembly plants are completely autonomous, but operate in a fixed pattern. Another classification takes into account the interaction between human control and the machine motions. 1.

Teleportation:

- A human controls each movement; each machine

actuator change is specified by the operator. 2.

Supervisory: - A human specifies general moves or position changes and the machine decides specific movements of its actuators .

3. Task-level autonomy: - The operator specifies only the task and the mechanical arm manages itself to complete it. 26 | P a g e

4. Full autonomy: - The machine will create and complete all its tasks without human interaction.

4.1.3 Safety Requirements The various safety requirements which were considered while designing the mechanical arm are decided as follows:  The mechanical arm should not be programmed such that it should damage the Battery while holding it in its gripper.  Correct holding position should be set as if it not set then while movement of the mechanical arm it may drop the Lead Batteries which can arise a Hazardous situation in the industry.  The mechanical arm should be interfaced properly with the sensors been placed near the Belt conveyor so as to know when the belt conveyor is to be stopped or to be started to move the batteries ahead.  Load carrying capacity should be maintained as it should be always more than the default load which is to be shifted.

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CHAPTER 5 STEPS OF DESIGN 5.1 SELECTION OF PRODUCT From the number of products available we selected the Box and tyre

of

automobiles for been used in our project. We had number of options for the selection of product, as per our requirement the Box and tyre was matching the conditions. The other products which we considered were as follows : Bearing:- Due to radial cross section of the bearing, it would be little bit difficult for the mechanical arm Gripper to hold the bearing in it and transport from one place to another holding it. So we rejected this product. 

Bags Of Iron Ore: - The fines bagging system was pre-decided but due to the weight limit we switched over the other products .

5.2 DESIGNING OF WORKSPACE The designing of work space have been done by keeping following points in mind: It should utilize Minimum time for doing the job.  No obstructions should be there in between the workspace envelope.  Idle time should be reduced as much as possible.  Efficient and safe transportation of the Box should be under gone. The design of work space includes a center table upon which the box from the plant and it is been transferred to the centre table Using the mechanical arm. There is moment of 90 degrees; the mechanical arm picks a Box from the centre table after placing the Box. Then the mechanical arm proceed towards the automobile tyre where it unloads and repeat the same procedure. 28 | P a g e

5.3 DEGREE OF FREEDOM The number of DOF that a manipulator possesses is the number of independent position variables that would have to be specified in order to locate all parts of the mechanism; it refers to the number of different ways in which a mechanical arm can move in the particular direction. In the case of typical industrial mechanical arm, because a manipulator is usually an open kinematic chain, and because each joint position is usually defined with a single variable, the number of joints equals the number of degrees of freedom.

FIG 5.2 DEGREE OF FREEDOM.

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We can use the arm to get the idea of degrees of freedom. Keeping the arm straight, moving it from shoulder, we can move in three ways. Up-and-down movement is called pitch. Movement to the right and left is called yaw. By rotating the whole arm as screwdriver is called roll. The shoulder has three degrees of freedom. They are pitch, yaw and roll. Moving the arm from the elbow only, holding the shoulder in same position constantly. The elbow joint has the equivalent of pitch in shoulder joint, thus the elbow has one degree of freedom. Now moving the wrist straight and motion less, we can bend the wrist and up and down, side to side and it can also twist a little. The lower arm has the same three degrees of freedom. Thus the mechanical arm has totally seven degrees of freedom. Three degrees of freedom are sufficient to bring the end of a mechanical arm to any point within its workspace, or work envelope in three dimensions.

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CHAPTER 6 WORKS TO BE DONE 6.1 SELECTION OF PARTS Various components of appropriate specifications should be selected so as to complete the fabrication and assembly of the mechanical arm. If the selection is not done properly then the proper working of the mechanical arm cannot be obtained. It includes the parts like selection of actuators, motors, wires etc. Thus the selection procedure of various components is also an important issue for the project work.

6.2 COMPLETION OF MODEL

HUMAN BEING

FIG 6.1 BLOCK DIAGRAM OF INTERFACING OF MECHANICAL ARM.

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Future work is to fabricate and manufacture the complete body structure of the mechanical arm, then the assembly of all the manufactured parts are to be done so that the required load is lifted and been transported to the targeted place.

6.3 INTERFACING WITH THE HUMAN In the industrial design field of human-machine interaction, the user interface is where interaction between humans and machines occurs. The goal of interaction between a human and a machine at the user interface is effective operation and control of the machine, and feedback from the machine which aids the operator in making operational decisions. A user interface is the system by which people (users) interact with a machine. The user interface includes hardware (physical) and machine component. User interfaces exist for various systems, and provide a means of: 

Input, allowing the users to manipulate a system,



Output, allowing the system to indicate the effects of the users' manipulation

After completion of the model of the pick and place mechanical arm and selection of task both should be interfaced. The interfacing of mechanical arm and human using it

is the most important thing in the project. then final

movement should be set using the human control. The movement of mechanical arm should be precisely managed causing no harm to the operator, and also the box which are to be moved from one station to another.

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CHAPTER 7 HARDWARE REQUIREMENT 7.1 VEHICLE PARTS  Card Board

29*20 cm

 Stearing System

Akermen’s stearing system with 12 volt dc 10 Rpm moter

 Tyres

dia. 8 cm

 Driver (Moters)

12 volt dc 100 rpm moter

7.2 ARM PARTS All arm are manufactured with alloy GI pipes there dimensions are as follow: Arm 1-

with 360 degree rotation

Arm 2-

with 110 degree rotation upward and downward

Arm 3-

with 120 degree rotation upward and downward

Gripper –

it has a span of 16 cm

All arm and gripper are driven by 100 rpm 12 volt dc moter.

7.3 WIRED REMOTE It overall has 6 switches connected to different moters, one power switch wich distribute power to all one by one according to task. Power adapter is used to convert 240 volt ac supply to 12 volt dc supply

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CHAPTER 8 MAIN PARTS OF PROJECT

8.1 MECHANICAL ARM VEHICLE A mechanical arm vehicle is an automatic machine that is capable of locomotion. Mobile mechanical arm have the capability to move around in their environment and are not fixed to one physical location. By contrast, industrial mechanical arm are usually more-or-less stationary, consisting of a jointed arm (multi-linked manipulator) and gripper assembly (or end effector), attached to a fixed surface. Mobile mechanical arm are a major focus of current research and almost every major university has one or more labs that focus on mobile mechanical arm research. Mobile mechanical arm are also found in industrial, military and security settings. Domestic mechanical arm are consumer products, including entertainment mechanical arm and those that perform certain household tasks such as vacuuming or gardening

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8.2 MECHANICAL ARM : A mechanical arm, have similar functions to a human arm; the arm may be the sum total of the mechanism or may be part of a more complex robot. The links of such a manipulator are connected by joints allowing either rotational motion (such as in an articulated robot) or translational (linear) displacement. The links of the manipulator can be considered to form a kinematic chain. The terminus of the kinematic chain of the manipulator is called the end effector and it is analogous to the human hand.

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8.3 END EFFECTOR The end effector, or mechanical arm, can be designed to perform any desired task such as welding, gripping, spinning etc., depending on the application. For example mechanical arms in automotive assembly lines perform a variety of tasks such as welding and parts rotation and placement during assembly. In robotics, an end effector is the device at the end of a mechanical arm, designed to interact with the environment. The exact nature of this device depends on the application of the machine. the end effector means the last link (or end) of the mechanical arm. At this endpoint the tools are attached. In a wider sense, an end effector can be seen as the part of a mechanical arm that interacts with the work environment. This does not refer to the wheels of a mobile mechanical arm or the feet of a humanoid robot which are also not end effectors—they are part of the mechanical arm mobility. End effectors may consist of a gripper or a tool. The gripper can be of two, three or even five fingers. Surgical robots have end effectors that are specifically manufactured for the purpose.

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8.4 CONTOLS: The control of mechanical arm is done through moters which take dc power supply through wired remote. The power comes from ac source and adapter converts it into 12V dc supply. A remote control vehicle is defined as any vehicle that is remotely controlled by a means that does not restrict its motion with an origin external to the device. This is often a radio control device, cable between control and vehicle. A remote control vehicle or RCV differs from a robot in that the RCV is always controlled by a human and takes no positive action autonomously

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CHAPTER 9 ADVANTAGES, DISADVANTAGES AND APPLICATIONS 9.1 ADVANTAGES  Quality: Industrial automated mechanical arm have the capacity to dramatically improve product quality. Applications are performed with precision and high repeatability every time. This level of consistency can be hard to achieve any other way.  Production: With mechanical arm, throughput speeds increase, which directly impacts production. Because an automated mechanical arm has the ability to work at a constant speed without pausing for breaks, sleep, vacations, it has the potential to produce more than a human worker.  Safety: mechanical arm increase workplace safety. Workers are moved to supervisory roles where they no longer have to perform dangerous applications in hazardous settings.  Savings: Improved worker safety leads to financial savings. There are fewer healthcare and insurance concerns for employers. Automated mechanical arm also offer untiring performance which saves valuable time. Their movements are always exact, minimizing material waste.

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

9.3 APPLICATIONS  Application robots are being used worldwide to increase quality and meet production requirements.  RobotWorx integrates new and reconditioned robotic systems for a wide spectrum of robot applications. Our expert engineers will help your company find the solution for any application.

 WELDING ROBOT APPLICATIONS 39 | P a g e

          

Arc Welding Electron Beam Flux Core Welding Laser Welding MIG Welding Plasma Cutting Plasma Welding Spot Welding TIG Welding Welding Automation Material Handling Robot Applications

DIAGRAM SHOWING WIRING SYSTEM OF PROJECT:

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REFERENCES  www.google.com  www.wikipedia.com  www.robologix.com  www.robotics.com  www.seattlerobotics.org/encoder/aug97/basics.html

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