design and development of autonomous industrial robot

The project is a Robotic Arm that can identify different objects located in its workspace according to their shape and color and places the objects in a certain location with the  help of a video camera as a visual feedback. The arm has 4 Degrees of Freedom (DOF)   with a DC-Motor at

Project Title

design and development of autonomous industrial robot

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

The project is a Robotic Arm that can identify different objects located in its workspace according to their shape and color and places the objects in a certain location with the  help of a video camera as a visual feedback. The arm has 4 Degrees of Freedom (DOF)   with a DC-Motor at each joint. The DC-Motor is position-controlled using a PID controller   to position the link at the required angle; the feedback of the angle is measured using    rotary-encoders.

This project introduces intelligence to industries to reduce human errors and increase    the quality and mass production of industries. It can operate under hazardous circumstances(high pressure, high temperature and locations that can be unstable for human operation) so it reduces that risk for human injures. It can be updated and controlled easily to achieve a larger number of applications. It reduces the costs as it can perform a task that is done by many workers using only one operator.

Goal of work the goal of this project is to control the angles of a robotic arm joints using a  controller. 

Project Objectives

The objective of this project is to make a cost-effective robot with a special designed gripper to grab any kind of spray gun to paint the required area. The gripper is made of a balloon like material. The gripper will conform around the gun and then apply paint with the spray gun. This will allow us to reduce time and cost of painting objects as well as increase the efficiency and quality of work. our main focus is to make a robot that can stop if any obstacle come in its way. industrial robot mainly works in a sphere but in this robot we integrate hydraulic pump in its arm so it can access point outside sphere. 

Project Implementation Method

A robotic arm is a robot manipulator, usually programmable, with similar functions to a human arm. The links of such a manipulator are connected by joints allowing either rotational motion or translational (linear) displacement. There are mainly two types of links; revolute and prismatic.

Robotics involves the simultaneous motion in 3D space of several objects. In the particular case of robotic arms in motion, the resulting end-effectors' trajectory is caused by the synchronous activation of several motors along the robotic mechanism.

A Joint is the part of the arm that connects two links together. Each link represents one degree-of-freedom (DOF). The application of the arm decides how many DOF are required. Larger number of DOF gives great flexibility but more complexity. Each joint requires an actuator (usually a motor) to perform its required job; bend or rotate or translate.

It is a 4-DOF robotic arm, two main links (L1, L2) connected to a link that holds the end-effector (L3). The end-effector is a gripper that opens and closes as required which makes the arm capable of holding the required objects.

To analyze the motion of robot manipulators, reference frames ; a frame is 3-axis group[X Y Z], the frames are attached to each link starting at frame Fo, attached to the fixed link (the base), all the way to frame Fn, attached to the robot end-effector (assuming the robot has n joints).

Benefits of the Project

Robotic arm used for many purpose in industries 

Quality/Accuracy/Precision

This would apply to quite a variety of production line tasks, like welding, assembling a product, spray painting, or cutting and finishing.

Efficiency/Speed/Production Rate

The mechanical nature of the equipment and the computerized control, make industrial robotics technology more efficient and speedy, leading to higher production rates than with human labor. Another aspect of efficiency is that robots can be mounted from the ceiling and have no problem with working upside down. This can lead to a savings in floor space.

Ability to Work in Environments that are Inhospitable to Humans

This is an interesting set of advantages of robotics. There are a number of tasks that are too dangerous, too exposed to toxins, or just plain too dirty for humans to conveniently do them. These are ideal robotics tasks. This includes tasks as simple as spray painting, because there is no need to worry about the robot inhaling the paint fumes! It also includes such daunting tasks as defusing bombs and such dirty tasks as cleaning sewers.

Freedom from Human Limitations like Boredom

This set of advantages of robotics is due to the fact that human characteristics like boredom from doing a repetitive task don’t interfere with the functioning of a robot. There is some overlap with the first two categories of advantages of robotics, because the lack of interference from boredom leads to greater accuracy, quality, and rate of production. There is more to this set of advantages of robotics, however. Since a robot doesn’t need to rest or eat, and never gets sick, a robotic arm can work 24/7, with only limited occasional downtime for scheduled maintenance.

Technical Details of Final Deliverable

The arm has 5 degrees of freedom: a rotating base (pivot); a "shoulder" motor; an "elbow" motor; two "wrist" motors, one for up-down movements and one for left-right rotation. And the arm has a sixth motor for a gripper.
I made some different designs of the various parts, these are the best "thought of", the result of many "make and try"! Now it resembles the structure of real industrial arms.
The length of the part between the elbow and wrist is almost equal to the length of the "hand",( this allows a good balance of the weights) allowing equilibrium.
The shoulder servo is "reinforced" by a spring when the arm is inclined forward. In this position the load on the shoulder servo is maximised, rapidly decreasing when the arm returns to a vertical position. Using the spring allows the use of a little and less expensive servo.
The shoulder servo absorbs the weight of the arm. To help it the vertical arm has a pivot, rotating in a support joined to the base. It creates a more rigid assembly.
The horizontal part ("forearm") is counterbalanced with a weight opposite to the gripper. Then the elbow servo is partially unloaded from the "parasite" torque generated from the wrist and grippers own weight .
The base has steel plates bolted underneath, corresponding in position to the arm. This helps to acquire the necessary stability, also when the arm is totally extended horizontally.
The materials I used where mainly plywood and pieces of wooden dowl, "because I have a lot of these", and it's easy to work on it with my simple tools (drill mini drill, saw, etc.). Indeed I built many parts with a special plywood for air models, it's only 2 mm thick but very rigid and strong! Maybe better than aluminium. Some parts are made of white plastic (PVC) or semi-transparent plexiglass, also good materials, and easy to work with.
Many parts are joined with screws and bolts (3 or 4 mm diameters), some others are glued with epoxy or similar glue.
I use these servo for the shoulder and elbow, the joints with more load. 

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Core Technology

Robotics

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com