ABSTRACT

A robot is a reprogrammable, multifunctional manipulator designed to move materials, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks Robot is an intelligent and human operated self controlled. Robotics has made a revolution in the field of industry and in many domestic applications. Robotic plays a vital role such as cooking, serving and majority robots used in field of industry and industrial applications. Some of the industrial applications are in automobile industries, beverages manufacturing industries, aero-space industries, computer assembly, and .etc We have made of prototype of a pick and place robot which is used in beverages manufacturing industries. We have studied and analysed and made this robot. The purpose of pick and place robot is to pick the object which is in production line and place in the desired place or place according to destination.

INTRODUCTION
Robotics is a prominent component of manufacturing automation which affects human labour at all levels, from unskilled workers to professional engineers and manager of production. Future robots may find applications outside of the factory in banks, restaurants, and even homes. It is possible, likely, that robotics will become a field, like todays computer technology, which is pervasive throughout our Society. Well it is a system that contains sensors, control systems, manipulators, power supplies and software all working together to perform a task. Designing, building, programming and testing a robot is a combination of physics, mechanical engineering, electrical engineering, structural engineering, mathematics and computing. In some cases biology, medicine, chemistry might also be involved. The study of robotics means that students are actively engaged with all of these disciplines in a deeply problem-posing problem Robot can be defined as programmable multi-functional manipulator. It is used to move or hold work pieces or specialized devices and it can able to perform verity of tasks The use of robots is necessary to meet production demands. There are many advantages to incorporating robots such as, decreasing cost and waste material while speeding production. Robots are also removing the risks to employees by performing dangerous tasks. Since the first industrial machine-tending robot was introduced in North America in the 1960s, the industry has grown to more than 135,000 robots in operation, according to figures from the Robotic Industries Association (RIA).

INTELLIGENT ROBOTS: These are very advanced state of robot and posses sufficient artificial and machine intelligence. Somewhat analogous to the sensory perception of the neuromuscular co-ordination that human being of capable of intelligent robots cannot only explore the environment on their own perceptions and evaluate them in real time. But also execute the necessary motor functions Match the action of the sensor inputs. Advance robots have been built with mobility to not only move over flour but also to climb. Compactly assemble with no board sensors, instruments and power supplies. INTELLIGENCE LEVEL

The intelligent control robot is capable of performing some of the functions and tasks carried out by human beings.

It can detect changes in the work environment by means of sensory perception. Intelligent robot is equipped with a variety of sensors and sensor apparatus providing visual (computer vision) and tactile (touching) capabilities to respond instantly to variable situations.

Much like humans, the robot observes and evaluates the immediate environment by perception and pattern recognition.

Extensive research has been and still concerned with how to equip robots with seeing eyes and tactile fingers.

Artificial intelligence (ai) that will enable the robots to respond, adapt, reason, and make decisions to react to change is also an inherent capability of the intelligent robot.

HISTORY: 1922: RossumsUniversalRobots 1954: First programmable robot 1978: First PUMA robot 1983: Started teaching in Robotics In the early 1800s mechanical puppets were first built in Europe, just for entertainment value. And these were called robots since there parts were driven by linkage and cams. In 1801 Joseph Maria Jacquard made the next great change and invented the automatic draw loom. The draw loom would punch cards and was used to control the lifting of thread in fabric factories. This was the first to be able to store a program and control a machine. After that there were many small changes in robotics but we were slowly moving forward. The first industrial robots were Unimates developed by George Devol and Joe Engelberger in the late 50s and early 60s. The first patents we by Devol but Engelberger formed Unimation which was the first market robots. So Engelberger has been called the father of robotics. For a while the economic viability of these robots proved disastrous and thing slowed down for robotics. But the industry recovered and by the mid-80s robotics was back on track. George DevolJr, in 1954 developed the multijointed artificial arm which leads to the modern robots. But mechanical engineer Victor Scheinman, developed the truly flexible arm know as the Programmable Universal Manipulation Arm (PUMA).

BASIC ELEMENTS OF ROBOT: The main parts of robot are Manipulator Controller Sensors End effectors Power Source MANIPULATOR: It consists of base, arm and wrist similar to a human arm. It also includes power source either electric, hydraulic or pneumatic on receiving signals from robot this mechanical unit will be activated. The movement of manipulator can be in relation to its coordinates system which may be Cartesian, cylindrical etc. depending on the controller, the movements may be point to point motion or continuous motion. CONTROLLER: The instructions (programme) to the robot to perform the desired tasks are input through the key board of this unit. A teach pendant is also provided for giving non-textual commands input. The controller converts the input program to suitable signals which activate the manipulator to perform the desired tasks.

SENSORS: For certain robot applications, the type of workstation control using interlocks is not adequate. The robot must take on more human like senses and capabilities in order to perform the task in satisfactory way. These senses and capabilities include vision and hand-eye coordination, touch and hearing. END EFFECTOR: The end effector is the special-purpose tooling which enables the robot to perform a particular job. In the terminology of robotics, an end effector can be defined as a device which is attached to the robots wrist to perform a specific task. The task may be work part handling, spot welding, spray painting, or any of a great variety of other functions. For purpose of organization, we will divide the various types of end effectors into two categories: grippers and tools.

POWER SOURCES

The Three Power Sources Used In Current Robots Are: Electric: All Robots Use Electricity as the Primary Source of Energy. Electricity Turns The Pumps That Provide Hydraulic And Pneumatic Pressure. It Also Powers The Robot Controller And All The Electronic Components And Peripheral Devices. In All Electric Robots, The Drive Actuators, As Well As The Controller, Are Electrically Powered. Because Electric Robot Do Not Require A Hydraulic Power Unit, They Conserve Floor Space And Decrease Factory Noise. No Energy Conversion Is Required. Pneumatic: These Are Generally Found In Relatively Low-Cost Manipulators with Low Load Carrying Capacity. Pneumatic Drives Have Been Used For Many Years For Powering Simple Stop-To-Stop Motions. It Is Inherently Light Weight, Particularly When Operating Pressures Are Moderate. Hydraulic: Are either Linear Position Actuators or a Rotary Vane Configuration. Hydraulic Actuators Provide A Large Amount Of Power For A Given Actuator. The High Power-To-Weight Ratio Makes The Hydraulic Actuator An Attractive Choice For Moving Moderate To High Loads At Reasonable Speeds And Moderate Noise Level.

Hydraulic Motors Usually Provide A More Efficient Way Of Energy To Achieve A Better Performance, But They Are Expensive And Generally Less Accurate.

CLASSIFICATION OF ROBOTS: Robots are classified as: ACCORDING TO TYPE OF CONTROL: Point-to-Point Robots Continuous Point Robots Computed trajectory robots and Servo-controlled Robots. POINT TO POINT ROBOT: Robots move from one point to another but cannot stop middle or intermediate position THE CONTINOUS PATH ROBOT: The type of robots can move to a prescribed numbers of points along the same path and can stop at required position COMPUTED TRAJECTORY ROBOTS: These types of robots can move in a path of a specified direction. SERVO CONTROLLED ROBOTS: These robots have some means of sensing the current position and it can send to prescribed or required position

ACCORDING TO CAPABILITIES: Sequence controlled robots Adaptive robots Intelligent robots SEQUENCE CONTROLLED ROBOTS: These are operated with a fixed sequence of actions according to the instructions. ADAPTIVE ROBOTS: They can reach according to environment using this sensors the performance is optimized by adjusting controls to changing the parameters. INTELLIGENT ROBOTS: These are very advanced state of robot and posses sufficient artificial and machine intelligence. Some what analogous to the sensory perception of the neuromuscular co-ordination that human being of capable of intelligent robots cannot only explore the environment on their own perceptions and evaluate them in real time. But also execute the necessary motor functions Match the action of the sensor inputs. Advance robots have been built with mobility to not only move over flour but also to clime. Compactly assemble with no board sensors, instruments and power supplies.

ACCORDING TO THE CONFIGURATIONS: A large numbers of combinations are possible to design a robot for example; a robot manipulator having 3 degree of freedom can be designed by using different combinations of steps of joint (5X5X5) 125 ways. Further variations are possible when we consider the sizes fourths variations are possible when we consider the sizes ranges of motion, orientation, etc. There are five commonly used configurations Cartesian Cylindrical Polar Jointed arm

CORTESIAN CO-ORDINATE ROBOTIC ARM: Axes in the robot arm are perpendicular. One axe is part of a pole, while the other axe is a telescoping arm. One of the two parts of the arm is attached to a base, which the robot arm can rotate on. This part of the arm is long and thin. The other robot arm wraps around the long and thin robot arm and can rotate around it. This allows the robot arm to rotate around the base in order to grab something in any direction. The robot arm has the ability to telescope, allowing it to reach out and interact with other objects.

CYLINDRICAL CO-ORDINATE ROBOTIC ARM: This arm has a cylinder that is attached to a base. This cylinder revolves on the base, allowing the robot arm to interact with objects in all directions. This robot arm has a long metal shaft which is connected to the cylinder and another long metal shaft by elbows that are capable of bending via the internal mechanisms of gears or screwjacks. For the other long metal shaft, one end is attached to the previous metal shaft, while the other end is attached to a wrist that is capable of rotating. The rotating functions are controlled with a rack and pinion system. The rack and pinion is operated by a long, grooved strip and a grooved

gear. The long grooved strip moves in one direction or another, turning the gear via the friction caused by the grooves on the gear and strip.

POLAR ROBOT ARM: This robot arm has two pivotal joints, consisting of rings turning on pivots. There is one prismatic joint which consists of one rectangular object sliding within a larger rectangular object. All of this is encased in a sphere which the robot arm is attached to. The two rotary joints are perpendicular, allowing the robot arm to rotate to the left and right and also rotate up and down. The prismatic joint allows the arm to stretch out and interact with objects.

JOINT ROBOT ARM The joints on this arm have a Z-shape with axes on both ends. There is a pivotal joint on both ends of this Z-shaped arm and one pivotal joint in the middle. The bottom part of the SCARA arm is attached to a pedestal, which attaches to the rest of the robot.

DEGREES OF FREEDOM

The Degree Of Freedom Or Grip Of A Robotic System Can Be Compared To The Way In Which The Human Body Moves.

For Each Degree Of Freedom A Joint Is Required. The Degrees Of Freedom Located In The Arm Define The Configuration. Each of the Five Basic Motion Configurations Discuss Previously Utilizes Three Degrees of Freedom in the Arm.

Three Degrees Of Freedom Located In The Wrist Give The End Effector All The Flexibility.

A Total of Six Degrees Of Freedom Is Needed to Locate a Robots Hand at Any Point in Its Work Space.

Although Six Degrees Of Freedom Are Needed For Maximum Flexibility, Most Robot Employee Only Three To Five Degrees Of Freedom.

The More The Degrees Of Freedom, The Greater Is The Complexity Of Motions Encountered.

Degrees Of Freedom

The Three Degrees Of Freedom Located In The Arm Of A Robotic System Are:

The Rotational Reverse: Is The Movement of the Arm Assembly about a Rotary Axis, Such As Left-And-Right Swivel of the Robots Arm about a Base.

The Radial Traverse: Is The Extension And Retraction Of The Arm Or The In-And-Out Motion Relative To The Base.

The Vertical Traverse: Provides The Up-And-Down Motion Of The Arm Of The Robotic System.

The Three Degrees Of Freedom Located In The Wrist, Which Bear The Names Of Aeronautical Terms, Are

Pitch Or Bend: Is The Up-And-Down Movement Of The Wrist. Yaw: Is The Right-And-Left Movement Of The Wrist. Roll Or Swivel: Is The Rotation Of The Hand.

PATH CONTROL

Commercially Available Industrial Robots Can Be Classified Into Four Categories According To The Path Control System.
o

Limited-Sequence: Do Not Use Servo-Control To Indicate Relative Positions Of The Joints.

They Are Controlled By Setting Limit Switches And/Or Mechanical Stops Together With A Sequencer To Coordinate And Time The Actuation Of The Joints.

With This Method Of Control, The Individual Joints Can Only Be Moved To Their Extreme Limits Of Travel.

Point-To-Point: These Robots Are Most Common And Can Move From One Specified Point To Another But Cannot Stop At Arbitrary Points Not Previously Designated.

Controlled Path: Is A Specialized Control Method That Is A Part Of General Category Of A Point-To-Point Robot But With More Precise Control.

The Controlled Path Robot Ensures That The Robot Will Describe The Right Segment Between Two Taught Points.

Controlled-Path Is A Calculated Method And Is Desired When The Manipulator Must Move In The Perfect Path Motion.

Continuous Path: Is An Extension Of The Point-To-Point Method. This Involves The Utilization Of More Points And Its Path Can Be Arc, A Circle, Or A Straight Line.

Because Of The Large Number Of Points, The Robot Is Capable Of Producing Smooth Movements That Give The Appearance Of Continuous Or Contour Movement.

ROBOT SPECIFICATION: ACCURACY: How close does the robot get to the desired point? When the robot's program instruct the robot to move to a specified point, it does not actually perform as per specified. The accuracy measures such variance. That is, the

distance between the specified position that a robot is trying to achieve (programming point), and the actual X, Y and Z resultant position of the robot end effector. Repeatability: The ability of a robot to return repeatedly to a given position. It is the ability of a robotic system or mechanism to repeat the same motion or achieve the same position. Repeatability is a measure of the error or variability when repeatedly reaching for a single position. Repeatability is often smaller than accuracy. Degree of Freedom (DOF): Each joint or axis on the robot introduces a degree of freedom. Each DOF can be a slider, rotary, or other type of actuator. The number of DOF that a manipulator possesses thus is the number of independent ways in which a robot arm can move. Industrial robots typically have 5 or 6 degrees of freedom. Resolution: The smallest increment of motion or distance that can be detected or controlled by the robotic control system. It is a function of encoder pulses per revolution and drive (e.g. reduction gear) ratio. And it is dependent on the distance between the tool center point and the joint axis. Envelope: A three-dimensional shape that defines the boundaries that the robot manipulator can reach; also known as reach envelope. Maximum envelope: the envelope that encompasses the maximum designed movements of all robot parts, including the end effector, work piece and attachments. Restricted envelope: it is that portion of the maximum envelope which a robot is restricted by limiting devices.

 Operating envelope: it is the restricted envelope that is used by the robot while performing its programmed motions. Reach: The maximum horizontal distance from the center of the robot base to the end of its wrist. Maximum Speed: A robot moving at full extension with all joints moving simultaneously in complimentary directions at full speed. The maximum speed is the theoretical values which does not consider under loading condition... Payload: The maximum payload is the amount of weight carried by the robot manipulator at reduced speed while maintaining rated precision. Nominal payload is measured at maximum speed while maintaining rated precision. These ratings are highly dependent on the size and shape of the payload due to variation in inertia.

USE OF ROBOTS IN INDUSTRY: Today most robots used are found in factories and they are referred to as industrial robots. Ten years ago, 9 out of 10 robots were being bought by auto companies - now, less than 50% of robots are bought by car manufacturers.

 Robots are used in warehouses, laboratories, research, energy plants, hospitals, space exploration etc Robots are a way business owners can be more competitive Cutting Operations Part inspection, sorting, cleaning, polishing

PICK AND PLACE ROBOT:

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 e.g. most of the industrial jobs like welding, painting, assembly, container filling etc. one of the major and most commonly performed work is picking and placing of jobs from source to destination. For this purpose, pick and place robot maybe used.

Pick and place systems are designed to perform repetitive picking and placing tasks in production or laboratory facilities, and are usually employed for their precision and cost effectiveness. McClellan Automation has the capability to design and build custom pick and place equipment to your specifications. Pick and place machines designed by our automation engineers are distinguished by their exceptional efficiency and precision, resulting in an increase in output as well as long-term savings for our Customers.

DESCRIPTION: We have made proto type of pick and place robotic arm which is used in beverage industries

The main parts of a proto type pick and place robot: 1) Remote controller 2) MCU circuit 3) Robotic arm
REMOTE CONTROLLER:-

It consists of a transmitter and toggle switches. Here we have used encoder in transmitter to transmits the signals to receiver part by using re communication MCU CIRCIT BOARD:It consists of MCU, step down transformer, receiver, regulator, relay module. We are using 8051 32bit micro controller an embedded c language program is dumped in micro controller to control the RF communication signals. We are using the step down transformer to convert the 230volts to 18volts but the circuit requires 5volts so a regulator is used to convert the 18v to 5v. RECIEVER Receiver consists of decoder receives signals from the remote controller by RF communication. RELAY MODULE It consists of 2 relays each relay consists of 1 led and overall module consists of 3 leds and the third led is always on ROBOTIC ARM

The robotic arm is connected to micro controller unit (mcu) circuit board. The robotic arm can cover distance within 12inches. It consists of 5 motors these 5 motors are controlled by operating of remote control the 5 motors used in robotic arm are One motor is used for base rotation of 260degrees.

Second motor is used for the shoulder movement with an angle of 160degrees.

 Third motor is used for elbow movement with an angle of 240degrees.

 Fourth motor is used for wrist movement with an angle of 120degrees.

Fifth motor is used for gripper movement opens with a width of 1.7inches.

In robotic arm gripper plays vital role in picking the objects. So we are going to discuss about gripper GRIPPERS: Grippers are end effectors used to grasp and hold objects. The objects are generally work parts that are to be moved by the robot. These part-handling applications include machine loading and unloading, picking parts from a conveyer, and arranging parts on to a pallet. We tend to think of grippers as mechanical grasping devices, but there are alternative ways for holding objects involving the use of magnets, suction cups, or other means. Grippers can be classified as single grippers or double grippers although this classification applies best to mechanical grippers. The single gripper is distinguished by the fact that only one grasping device is mounted on the robots wrist. A double gripper has two grasping devices attached to the wrist and is used top handle two separate objects. The two grasping devices can be actuated independently. The double gripper is especially useful in machine loading and unloading applications. With a single gripper,

the robot would have to unload the finish part before picking up the raw part. This would consume valuable time in the production cycle because the machine would have to remain open during these handling motions. Another way of classifying depends on whether the part is grasped on its exterior surface or its internal surface. The first type is called external gripper and second type is referred to as an internal gripper. The reason for using a gripper instead of attaching the tool directly to the robots wrist is typically because the job requires several tools to be manipulated by the robot during the work cycle. The gripper serves as a quick change device to provide the capability for a rapid changeover from one tool to the next. In addition to end effectors, other types of fixturing and tooling are required in many industrial robot applications. These include holding fixtures, welding fixtures, and other forms of holding devices to position the work part or tooling during work cycle grippers. WORKING OF PICK AND PLACE ROBOTIC ARM When power is supplied from power source to transformer (step down) the input is 230volts and its output is 18volts. But 5volts is enough to run the circuit so regulator is used to decrease the voltage from 18volts to 5volts.

If power is supplied to remote control by 9volts battery then the leds on each switch board will turn on and the leds on receiver turn off. It indicates that the signals have been reached from transmitter to receiver.

If any fault is there in remote control circuit the respective relay leds will turn on on relay module

When any switch is pressed on switch board the receiver receives signals from transmitter on remote control. Now the signals from the receiver sent to micro controller unit. The micro controller receives signals from receiver and read the programme and gives the instructions to relays. According to the instructions the relays will control the motors of robot arm. In proto-type robotic arm it consists of 5 different types of movements which are operated by switches in remote controller This has 3 switch boards namely SB1, SB2 and SB3 (from right) Switch board 1(SB1) The first board consists of 4 switches which controls gripper and wrist. the Gripper movements opened and closed are carried out by G1 and G2 switches. G1Opening G2Closing The wrist movements up and down carried out by W1 and W2 switches. W1Down W2Up Switch board 2(SB2) The SB2 consists of 4 switches which control shoulder and elbow. The shoulder movements are operated by S1 and S2 switches

S1Down S2Up The elbow movements operated by E1 and E2 switches E1Up E2Down Switch board 3 (SB3) SB3 consists of 4 switches which controls base and light. The base movements are operated by B1Clockwise B2Anticlockwise The light ON/OFF controlled by L1----L2ON/OFF

ADVANTAGES: They include higher productivity reduced labour costs reduced downtime increased quality and consistency and inventory and scrap savings In addition the same robot can potentially be used for a variety of tasks

DIS ADVANTAGES: Reprogramming the controller and replacing fixturing in the work cell and the end-effectors this can be expensive and time consuming. The single most prohibitive aspect of using robotic automation is the initial investment required in purchasing the robot itself.

CHARACTERISTICS GENERAL APPLICATION

Hazardous or un-comfortable working conditions: In job situations where there are potential dangers or health hazards due to heat, radiation, or toxicity, or where the workplace is uncomfortable and unpleasant, a robot should be considered as a substitute for the human worker. Repetitive tasks: If the work cycle consists of a sequence of elements which do not vary from cycle to cycle. It is possible that a robot could be programmed to perform the task. Difficult handling: If the work part or tool involved in the operation is awkward or heavy, it might be possible for a robot to perform the task. Multi shift operation: If the initial investment cost of the robot can be spread over two or three shifts, the labour savings will result in a quicker payback.

APPLICATION AREAS: Material transfer. Machine loading. Welding. Spray coating.

Processing operation. Assembly. Inspection.

BIBLIOGRAPHY. McGraw-Hill INTERNATIONAL EDITION, industrial engineering series, industrial robotics, MIKELL P.GROOVER, MITCHELL WEISS, ROGER N.NAGEL, NICHOLAS G.ODREY PRENTICE HALL OF INDIA PRIVATE LIMITED, New delhi-110001, 1994. MIKELL P.GROOVER, EMORY W.ZIMMERS, JR.

J.F. ENGLEBERGER, ROBOTICS IN PRACTICE, AMACOM (AMERICAN MANAGEMENT ASSOCIATION), NEW YORK, 1980. R. HINSON,CASE STUDY: ROBOTS IN MACHINE LOAD/UNLOAD OPERATIONS,

CONCLUSION:

This robot is used for pick the object in one place and place that objects in required places. Some industrial works are harmful for humans this robot is mainly used for reduce the risk process and consuming time and avoid labours. Human are tired

for hard work such as assembly line, material handling etc. this robot does all those things it mainly reduces the manual work our robot is designed At low cost as well as high efficient one. This project is to give the way for providing bigger effective robot for Industrial applications.