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com

A PROJECT REPORT ON

PICK AND PLACE ELECTRICAL CONTROLLED MECHANICAL ARM

Submitted in partial fulfillment of the requirements
For the award of the degree
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED BY:
HARPREET SINGH

SUBMITTED TO :
(1028040021)

KAMLESH NAYAL

(1028040027)

UPKAR SINGH

(1028040065)

GURPREET SINGH

(1028040020)

MR. DHEERAJ GUNWANT (HOD)

MR. MAHAVEER SINGH (PROF.)

DEPARTMENT OF
MECHANICAL ENGINEERING
APEX INSTITUTE OF TECHNOLOGY
AFFILIATED TO UTTAR PRADESH TECHNICAL UNIVERSITY

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APEX INSTITUTE OF TECHNOLOGY, KAUSHALGANJ

MECHANICAL ENGINEERING DEPARTMENT

CERTIFICATE
This is to certify that following candidates of Batch IV, Mechanical Engineering, SemesterVIII, have satisfactorily completed the project report on DESIGN OF PICK & PLACE
ELECTRICAL CONTROLLED MECHANICAL ARM during the term ending in MAY2014.

PREPARED BY:
HARPREET SINGH (1028040021)
KAMLESH NAYAL (1028040027)
UPKAR SINGH

(1028040065)

GURPREET SINGH (1028040020)

GUIDED BY:

HEAD OF DEPARTMENT:

Mr. MAHAVER SINGH

Mr. DHEERAJ GUNWANT

ACKNOWLEDGEMENT
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The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mentioning of the people whose constant guidance and encouragement
made it possible. We take pleasure in presenting before you, our project, which is result of
studied blend of both research and knowledge.
We express our earnest gratitude to our internal guide, Professor, Department of ME, our project
guide, for his constant support, encouragement and guidance. We are grateful for his cooperation
and his valuable suggestions.
Finally, we express our gratitude to all other members who are involved either directly or
indirectly for the completion of this project.

DECLARATION

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We, the undersigned, declare that the project entitled PICK AND PLACE ELECTRICAL
CONTROLLED MECHANICAL ARM, being submitted in partial fulfillment for the award of
Bachelor of Technology Degree in mechanical Engineering, affiliated to UPTU, is the work
carried out by us.

HARPREET SINGH (1028040021)

KAMLESH NAYAL (1028040027)
UPKAR SINGH

(1028040065)

GURPREET SINGH (1028040020)

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.

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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 human36
CHAPTER 7 HARDWARE REQUIREMENT..37
7.1 VEHICLE PART37
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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 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.
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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 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.

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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.
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.
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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.
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 well-designed, 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 Asimovs 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 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.

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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)

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.
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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.

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 pre-programmed to solve a
particular task, but methods based on learning are now becoming increasingly common.

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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.

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.

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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.

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

20

arm

that

can

pickapples.

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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.

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 -

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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.

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, die-casting, 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.

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.
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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.

CHAPTER 4
DESIGN PROCEDURE

4.1 FACTORS

TO BE CONSIDERED
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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 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.
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Operator-assist modes have the operator commanding medium-to-high-level 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.
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.

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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.
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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.

We

FIG 5.2 DEGREE OF FREEDOM.

the

can use the arm to get

idea

of

degrees

of

freedom. Keeping the arm straight, moving it from shoulder, we can move in three ways. Upand-down movement is called pitch. Movement to the right and left is called yaw. By rotating the
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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

FIG 6.1 BLOCK DIAGRAM OF INTERFACING OF MECHANICAL ARM.

HUMAN BEING

to

Future work is
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

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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.

CHAPTER 7
HARDWARE REQUIREMENT
7.1 VEHICLE PARTS
Card Board

29*20 cm

Stearing System

Akermens stearing system with 12 volt dc 10

Rpm moter

Tyres

dia. 8 cm

Driver (Moters)

12 volt dc 100 rpm moter

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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

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.

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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.

8.3 END EFFECTOR

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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 effectorsthey 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

CHAPTER 9
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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.

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WELDING ROBOT APPLICATIONS

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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