Professional Documents
Culture Documents
Project Title
Wasiq Saleem
2011---NUST---PNEC---BE---372
Fazeel Ayaz
2011---NUST---PNEC---BE---364
Project
Advisor
15
Certificate
This is to certify that the Design Assessment board entitled, Design and
implementation of a Robotic manipulator for Remotely Operated Vehicle
submitted by Wasiq Saleem and Fazeel Ayaz in partial fulfillment of the
requirements for the award of Final Year Project of Bachelor of Engineering
Degree in Electronics Engineering at Pakistan Navy Engineering College
(PNEC), National University of Sciences & Technology (NUST) is an
authentic work carried out by them under my supervision and guidance.
To the best of our knowledge, the matter embodied in this Report has not been
submitted to any other University/Institute for the award of any Degree or Diploma.
Table
of
Contents
ABSTRACT
INTRODUCTION
GRIPPER
ELBOW
7
8
9
MATERIAL
OF
FABRICATION
Method
of
Fabrication
Controlling
Mechanism
18
SERVO MOTOR
19
ABSTRACT
A robot is a system combining many subsystems that interact among themselves as well as
with the environment in which the robot works. In robotics, end effectors/gripper is a device
at the end of a robotic arm, designed to interact with the environment. Gripper is an end
effectors or tool to grasp any physical. To achieve this function we intend to integrate a
simple linkage actuation mechanism. The gripper to be used in our robotic manipulator
performs basic function of picking, holding and grasping of objects by means of a DC motor.
The design and flexibility of a human hand is the main tool in designing our robotic
manipulator. It can be function near to humans ability of grasping and manipulation if
coupled with wrist and elbow.
Robots are normally used in conjunction with auxiliary devices such as machines and
fixtures but in our case it is ROV. Due to technological advancement robot has become an
integral device, hence it has can be used where presence of human is not feasible. The gripper
can perform the basic function of picking, holding, rotating and grasping of objects by means
of a DC motor.
Introduction:
Oceans are an attractive environment because of abundant mineral resources, energy, space,
and so on, and recently lots of research is being carried out in this field. However, the
extreme conditions such as high water pressure, invisibility and non-oxygen become great
barriers for human to access directly. Underwater robotic manipulator are designed and
fabricated in a way in perform efficiently like human arm, hence replacing their need. In
order to realize underwater robotics, the intelligence and accuracy of robots are crucial
factors to be researched and ROVs are the new tools for major underwater exploration
operations. The need for ROVs to perform more and more complex task and to propagate in
areas where humans cant is an inspiration in terms of research and work done in this field.
Therefore, manipulators which are mounted on ROVs are expected to play a crucial role for
complex tasks
A robotic manipulator is a mechanical structure functioning like a human arm. It is
programmed to function in a matter in which we want it to. During designing of this
arm, links are connected via joints allowing either a linear motion or a rotational
motion in various planes. In industrial robots sensor are used for feedback which
indicates the controller about the hardness by which the gripping is done by arm or
directs the arm in directions in which it should move to perform the task or even tells
the system about presence of object in front of it.
Various aspects needs to be considered while designing a robotic arm that are
torque calculation for motor used, amount of weight it can carry, interfacing to
remote controller, ways for interfacing it with ADC (analog-to-digital
converter).We have designed this robotic arm using servos, ATmega32
microcontroller with interfacing analog joystick controller.
Gripper:
It is the mentor of the robotic arm we intend to fabricate, as it will enable us to do
all the required underwater tasks.
Elbow
The material we are using for this part is made of Aluminum, which is light and
cheap. To support the structure and to maintain it balance during movement rods
are inserted between the arm in horizontal direction. About 90% of the whole
space, which this elbow takes, is empty which makes the weight of the robotic
arm quite low. When ROV is working in the water the structure of the robotic arm
can vibrate a little because of the pressure inside water to overcome this problem
the Aluminum parts are thin so they can stretch a bit making them elastic.
The Elbow joint was of primary importance in the design of our robotic arm. Due to
the weight of the arm and its overall length, the imposing moment on this joint is
substantial.
This part should be made to attach the Arm firmly with ROV. The position of the
elbow will not change during movement of the Arm and because it has to sustain
all the load of the rest of the Arm the Gear Ration is kept high. The dimensions
are kept small in order to make space for the rest of the electronics that are to be
attached with the ROV.
This part of the robotic arm has to bear the entire load that is on rest of the arm.
The material to be used for this is also aluminum.
The various stages we went through while designing is frequently depicted in these
sequence of events.
Laser Cutting
The laser cutting process uses a strong focused laser beam, produced by a laser diode.
The high energetic laser beam heats the surface of the material and melts.Laser cutting
offers a high precision, CNC controlled method of cutting plastic, metallic and thin
ceramic components. It is a mechanised, thermal, non-contact process capable of
cutting most materials with a high degree of precision and accuracy.
3D printing
3D printing (or additive manufacturing, AM) is any of various processes used to make
a three-dimensional object. In 3D printing, additive processes are used, in which
successive layers of material are laid down under computer control. These objects can
be of almost any shape or geometry, and are produced from a 3D model or other
electronic data source. A 3D printer is a type of industrial robot.
Advantages
Additive manufacturing gives great freedom in design.
Metal 3D printing can produce highly customized parts with added improved
functionalities that are not possible through traditional processes.
Different types of alloys suits perfectly the needs of lightweight applications.
Mixing different raw materials as titanium, aluminium, stainless steel or nickel
based alloys and constantly discovering new alloys with various strength and
temperature resistance is close to impossible trough conventional
manufacturing methods.
Doesnt require any additional tooling.
Controlling
Mechanism
During early discussions we thought to use BLDC motors to provide controlling
for the robotic arm. BLDC motors have high torque and normal BLDC motors
can lift up to 10 kg of load from the ground. But the idea of using BLDC motors
was punctured because they require very high current and since our arm would be
working in the water about 10s of amperes of current could damage the whole
system if some fault occurs. Other problem with BLDC motor was its complex
controlling mechanism. We needed Hall sensors to detect the position of the poles
inside the BLDC motors to keep the motor rotating as we desire. Further
problems that forced us to use servo motor was that we couldnt find our required
BLDC motor on internet and in different markets in Karachi. Using Servo motors
comforted us in many ways.
Advantages for us for using servo motors:
It was easy to find the best one which suited our project.
The controlling mechanism was simple.
Servomotors that are used in boats are water proof (Water proof servo motor
was a bonus for us).
We easily decided what number of servo motors do we need
Servo motors required less current than first chosen BLDC motors.
We had a good past experience on working with servo motors (we had done
many mini projects before in which we used servo motors).
Servomotors dont cost much.
No additional motor controlling drivers were required .We only needed a micro
controller and a power supply.
Servos are best for robotics.
At the start of our project we decided to make a 3D robotic arm but due to the
flexibility in controlling which servomotors provided we shifted to a higher level, we
decided to make a 4D robotic manipulator.
When we are working with servomotor the speed of rotation becomes a main
problem. As the load increases the speed of the servomotor slows down. In order
to maintain the speed we had to decrease the load by decreasing the weight of
the arm. That was also a reason why we decided to use Aluminum instead of
other metal.
Our decision was to use Vigor VSD-11YMB HV servo motor which has
maximum torque of 40 kgf.cm.
After when we had selected which servo motor are we using we searched more and
more on servo motors because we wanted to make our robotic arm suitable for our
ROV. Before going into further detail I would like to explain first about servo
motors.
Servo motors:
Servo refers to an error sensing feedback control, which is used to correct the performance of a system.
Servo or RC Servo Motors are DC motors equipped with a servo mechanism for precise control of
angular position. The RC servomotors usually have a rotation limit from 90 to 180. But servos do not
rotate continually. Their rotation is restricted in between the fixed angles. The Servos are used for
precision positioning. They are used in robotic arms and legs, sensors canners and in RC toys like RC
helicopter, airplanes and cars.
The Servomotors come with three wires or leads. Two of these wires are to provide ground and positive
supply to the servo DC motor. The third wire is for the control signal. These wires of a servomotor are
color coded. The red wire is the DC supply lead and must be connected to a DC voltage supply in the
range of 4.8V to 6V.The black wire is to provide ground. The color for the third wire (to provide control
signal) varies for different manufacturers. It can be yellow (in case of Hitec), white
(in case of Futaba), brown etc. Unlike DC motors, reversing the ground and positive supply connections
does not change the direction (of rotation) of a servo. This may, in fact, damage the servomotor. That is
why it is important to properly account for the order of wires in a servomotor.
#define ServoPINtwo
#define ServoPINthree
#define ServoPINfour
#define PotPinone
A1
#define PotPintwo
A1
#define PotPinthree
A2
#define PotPinfour
A3
void setup()
{
myservo_one.attach(ServoPINone); // attaches the servo on pin 9 to the servo object
myservo_two.attach(ServoPINtwo);
myservo_three.attach(ServoPINthree);
myservo_four.attach(ServoPINfour);
}
void loop()
{ //for servo one
PotValueone = analogRead(PotPinone);
moves pot
Circuit
Diagram
Gimbal mechanism allows us to control two servos with a single joystick. It also
allowed us to limit the number of joystick to only 2 joysticks for four servos. If this
was not the case and we had to go with four joysticks in one controller board then we
had to design a large controller which would then look very ugly.
This joystick also contains a switch which activates pushed down on the cap. The
switch is the small black box on the rear of the joystick. If pushed down on the cap,we
can see a lever pushing down on the head of the switch. The lever works no matter
what position the joystick is in. Cool!
Transmission
meduim:
There
are
two
types
of
transmission
meduim
(i)
wired
and
(ii)
wireless.
The
second
group
under
Mr.
Noman
Ashraf
which
is
designing
ROV
has
stick
towards
a
wired
medium
for
transferring
data.They
have
planned
to
bind
all
the
power
and
the
signal
wires
togather
and
attach
it
with
ROV
as
a
single
cable.So,
as
they
have
demanded
we
cant
go
for
a
wireless
channel
because
other
wise
we
would
have
ROV
that
will
be
controlled
by
a
wired
mechanism
and
a
Robotic
arm
attached
that
will
be
controlled
via
wireless
channel.There
are
other
reasons
for
why
a
wire
medium
is
better
for
this
project.
Wireless
medium
for
this
project
is
not
suitable
in
all
situations
shown
below:
1) Very
expensive
To
cope
with
the
above
situation
we
require
under
water
wired
communication.
Ethernet
Cable(Cat-5):
Category 5 cable (cat 5) is a twisted pair cable for carrying signals. This type
of cable is used in structured cabling for computer networks such as Ethernet.
The cable standard provides performance of up to 100 MHz and is suitable
for10BASE-T, 100BASE-TX (Fast Ethernet), and 1000BASE-T (Gigabit Ethernet).
Cat 5 is also used to carry other signals such as telephony and video.This cable is
commonly connected using punch-down blocks and modular connectors. Most
category 5 cables are unshielded, relying on the balanced line twisted pair design
and differential signalling for noise rejection.
Category 5 has been superseded by the category 5e (enhanced)
specification and category 6 cable.
Cable
standard
The specification for category 5 cable was defined in ANSI/TIA/EIA-568-A.
Each of the four pairs in a cat 5 cable has differing precise number of twists per metre
to minimize crosstalk between the pairs. Although cable assemblies containing 4
pairs are common, category 5 is not limited to 4 pairs. Backbone applications involve
using up to 100 pairs. This use of balanced lines helps preserve a high signal-to-noise
ratio despite interference from both external sources and crosstalk from other pairs.
The cable is available in both stranded and solid conductor forms. The stranded form
is more flexible and withstands more bending without breaking. Permanent wiring
(for example, the wiring inside the wall that connects a wall socket to a central patch
panel) is solid-core, while patch cables (for example, the movable cable that plugs into
the wall socket on one end and a computer on the other) are stranded.
The specific category of cable in use can be identified by the printing on the side of
the cable.
Most Category 5 cables can be bent at any radius exceeding approximately four times the
outside diameter of the cable. The maximum length for a cable segment is 100 m which is
enough for this project .
Applications
This type of cable is used in structured cabling for computer networks such
as Ethernet over twisted pair. Cat 5 is also used to carry other signals such
as telephony and video.
Power Supply:
About 48V(DC) and 40A(max) will be available for us from the main power supply
board.The reason for these limitations are that since we are working under water we
cant allow very high currents and voltages under water.There are two problems now,
(i) 48V is much greater than our operating voltage that is 5-7 V ,so we have to step
down the voltage using DC-DC converters.(ii)40A is for whole ROV so the current is
also limited.
Component
Operating voltage
Thrusters
10A x 4
12V
Camera
2A x 2
12V
Lights
0.5 x 2
24V
Servo motors
4Ax4
5-7V
Arduino microcontroller
0.5A x 2
5V
The output voltage and current of a DC-DC converter is the average of the above
waveforms. As t1 gets smaller average value decreases and so the output voltage.
The value of k(duty cycle) is between 0-1.If k decrease the output voltage will also
decrease. But the current will increase by amount 1/k , this is because the power at
input is equal to the power at output.
By decreasing the voltage at the output the current rating of the supply can be
increased by the same ratio. For example if the whole robotic arm requires 20A and
5V then this would be equal to 48V and 2A.We can increase the current at the output
by decreasing the voltage using buck converters.
Takes 48V input and outputs 24V.The maximum output current is 10A.It water proof
and has high conversion efficiency. Working temperature is between -40 C ~ +85 C.
Features:
Buck
DC
Voltage
Converter
24V
to
5V
Features:
Input voltage: DC 24V
Output voltage: DC 5V
Output Current: 10A MAX
Enough power, stable performance
Efficiency: more than 96%
Used in Motors, audio, gps navigation, surveillance, LED car display, air
conditioning, electric fans, solar energy, photovoltaic energy, DVD, LED
lights, motors, pumps, electrical appliances and industrial equipment .
Application
!
!
!
!
Science
Seafloor mapping
Rapid response to oceanographic and
Geothermal events
Geological sampling
Environment
! Long term monitoring (e.g., hydrocarbon Spills, radiation
leakage, pollution)
! Environmental remediation
! Inspection of underwater structures, including pipelines,
dams, etc.
Military
! Shallow water mine search and disposal
! Submarine off-board sensors
Ocean mining
! Ocean survey and resource assessment and oil industry
! Construction and maintenance of undersea structures
Other applications
Ship hull inspection and ship tank internal inspection
Nuclear power plant inspection
Underwater communication & power cables installation
and inspection
! Entertainment-underwater tours
! Fisheries-underwater ranger
!
!
!
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