MOBILE OPERATED FOUR AXIS MATERIAL HANDLING SYSTEM

ABSTRACT

            The main aim of this project is to fabricate design and fabrication of mobile operated four axis material handling robot system. A system is a mechanical or virtual intelligent agent that can perform tasks automatically or with guidance, typically by remote control. This system is used for loading unloading the object in one place and place that objects in required places. Some industrial works are harmful for humans this system 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 system does all those things it mainly reduces the manual work our system is designed at low cost as well as high efficient one. This project is to give the way for providing bigger effective system for industrial applications. The reason for choosing project is, the most extensively form of machine is used in most of the industries like car manufacturing, shipyards, assembling machine etc. Material handling systems are equipment that relate to the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Here the system can move in four degrees of freedom and it is powered by air and pneumatic cylinders.

TABLE OF CONDENT

NO                                           CONDENT                             PAGE NO

1        NEED OF THE PROJECT                                                   1

2        LITERARY REVIEW                                                                    2

3        INTRODUCTION                                                                 6

3.1COMPONENTS AND DESCRIPTION                 6

3.2PNEUMATIC SYSTEMS                                                8

3.3MAJOR EQUIPMENT CATEGORIES                10

3.4PNEUMATIC CYLINDER                                    11

3.5COMPRESSIBILITY OF GASES                         11

3.6GASES USED IN PNEUMATIC SYTEMS          12

3.7AIR COMPRESSOR                                              17

3.8MULTI-STAGE, TELESCOPING CYLINDER   20

3.9PRINCIPLES OF MATERIAL HANDLING        23

3.10CHARACTERISTICS OF MATERIALS           25

4         WORKING OPERATION                                                   33

5          ADVANTAGES                                                                   34           

6         APPLICATIONS                                                                             35

7          CONCLUSION                                                                    36

8          REFERENCES                                                                    37

9          PHOTOGRAPHY                                                               39

DESIGN AND FABRICATION OF 

 FOUR AXIS MATERIAL HANDLING ROBOT SYSTEM

ABSTRACT

The main aim of this project is to fabricate design and fabrication of four axis material handling robot system. A system is a mechanical or virtual intelligent agent that can perform tasks automatically or with guidance, typically by remote control. This system is used for pick the object in one place and place that objects in required places. Some industrial works are harmful for humans this system is mainly used for reduce the risk process and consuming time and avoid labors. Human are tired for hard work such as assembly line, material handling etc. This system does all those things it mainly reduces the manual work our system is designed at low cost as well as high efficient one. This project is to give the way for providing bigger effective system for industrial applications. The reason for choosing project is, the most extensively form of machine is used in most of the industries like car manufacturing, shipyards, assembling machine etc. Material handling systems are equipment that relate to the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Here the system can move in four degrees of freedom and it is powered by electric motor.

CHAPTER-I

NEED OF THE PROJECT

This system is used for pick the object in one place and place that objects in required places. Some industrial works are harmful for humans this system is mainly used for reduce the risk process and consuming time and avoid labors. Human are tired for hard work such as assembly line, material handling etc. this system does all those things it mainly reduces the manual work our system is designed at low cost as well as high efficient one.

This project is to give the way for providing bigger effective system for industrial applications.

The reason for choosing project is, the most extensively form of machine is used in most of the industries like car manufacturing, shipyards, assembling machine etc.

CHAPTER-II

INTRODUCTION

Robotics is the branch of technology that deals with the design, construction, operation, structural disposition, manufacture and application of robots and computer systems for their control, sensory feedback, and information processing. 

A robot is a mechanical or virtual intelligent agent that can perform tasks automatically or with guidance, typically by remote control. In practice a robot is usually an machine that is guided by computer and electronic programming. Robots can be autonomous, semi-autonomous or remotely controlled.

The concept and creation of machines that could operate autonomously dates back to classical times, but research into the functionality and potential uses of robots did not grow substantially until the 20th century. Today, robotics is a rapidly growing field, as we continue to research, design, and build new robots that serve various practical purposes, whether domestically, commercially, or militarily. Many robots do jobs that are hazardous to people such as defusing bombs, exploring shipwrecks, and mine

History

The word robot was introduced to the public by the Czech writer Karel Čapek in his play R.U.R. (Rossum's Universal Robots), published in 1920. The play begins in a factory that makes artificial people called robots creatures who can be mistaken for humans – though they are closer to the modern ideas of androids. Karel Čapek himself did not coin the word. He wrote a short letter in reference to an etymology in the Oxford English Dictionary in which he named his brother Josef Čapek as its actual originator.

In 1927 the Maschinenmensch ("machine-human") gynoid humanoid robot (also called "Parody", "Futura", "Robotrix", or the "Maria impersonator") was the first and perhaps the most memorable depiction of a robot ever to appear on film was played by German actress Brigitte Helm in Fritz Lang's film Metropolis.

In 1942 the science fiction writer Isaac Asimov formulated his Three Laws of Robotics and, in the process of doing so, coined the word "robotics" (see details in "Etymology" section below).

In 1948 Norbert Wiener formulated the principles of cybernetics, the basis of practical robotics.

Fully autonomous robots only appeared in the second half of the 20th century. The first digitally operated and programmable robot, the Unimate, was installed in 1961 to lift hot pieces of metal from a die casting machine and stack them. Commercial and industrial robots are widespread today and used to perform jobs more cheaply, or more accurately and reliably, than humans. They are also employed in jobs which are too dirty, dangerous, or dull to be suitable for humans. Robots are widely used in manufacturing, assembly, packing and packaging, transport, earth and space exploration, surgery, weaponry, laboratory research, safety, and the mass production of consumer and industrial goods.

Locomotion

Rolling robots

For simplicity most mobile robots have four wheels or a number of continuous tracks. Some researchers have tried to create more complex wheeled robots with only one or two wheels. These can have certain advantages such as greater efficiency and reduced parts, as well as allowing a robot to navigate in confined places that a four wheeled robot would not be able to.

Two-wheeled balancing robots

Balancing robots generally use a gyroscope to detect how much a robot is falling and then drive the wheels proportionally in the opposite direction, to counter-balance the fall at hundreds of times per second, based on the dynamics of an inverted pendulum. Many different balancing robots have been designed. While the Segway is not commonly thought of as a robot, it can be thought of as a component of a robot, such as NASA's Robonaut that has been mounted on a Segway.

One-wheeled balancing robots

A one-wheeled balancing robot is an extension of a two-wheeled balancing robot so that it can move in any 2D direction using a round ball as its only wheel. Several one-wheeled balancing robots have been designed recently, such as Carnegie Mellon University's "Ballbot" that is the approximate height and width of a person, and Tohoku Gakuin University's "BallIP". Because of the long, thin shape and ability to maneuver in tight spaces, they have the potential to function better than other robots in environments with people.

Spherical orb robots

Several attempts have been made in robots that are completely inside a spherical ball, either by spinning a weight inside the ball, or by rotating the outer shells of the sphere.These have also been referred to as an orb bot or a ball bot

Six-wheeled robots

Using six wheels instead of four wheels can give better traction or grip in outdoor terrain such as on rocky dirt or grass.

Tracked robots

Tank tracks provide even more traction than a six-wheeled robot. Tracked wheels behave as if they were made of hundreds of wheels, therefore are very common for outdoor and military robots, where the robot must drive on very rough terrain. However, they are difficult to use indoors such as on carpets and smooth floors. Examples include NASA's Urban Robot "Urbie".

Walking applied to robots

Walking is a difficult and dynamic problem to solve. Several robots have been made which can walk reliably on two legs, however none have yet been made which are as robust as a human. There has been much study on human inspired walking, such as AMBER lab which was established in 2008 by the Mechanical Engineering Department at Texas A&M University. Many other robots have been built that walk on more than two legs, due to these robots being significantly easier to construct. Hybrids too have been proposed in movies such as I, Robot, where they walk on 2 legs and switch to 4 (arms+legs) when going to a sprint. Typically, robots on 2 legs can walk well on flat floors and can occasionally walk up stairs. None can walk over rocky, uneven terrain. Some of the methods which have been tried are:

Dynamic balancing (controlled falling)

A more advanced way for a robot to walk is by using a dynamic balancing algorithm, which is potentially more robust than the Zero Moment Point technique, as it constantly monitors the robot's motion, and places the feet in order to maintain stability. This technique was recently demonstrated by Anybots' Dexter Robot,which is so stable, it can even jump. Another example is the TU Delft Flame.

Passive dynamics

Perhaps the most promising approach utilizes passive dynamics where the momentum of swinging limbs is used for greater efficiency. It has been shown that totally unpowered humanoid mechanisms can walk down a gentle slope, using only gravity to propel themselves. Using this technique, a robot need only supply a small amount of motor power to walk along a flat surface or a little more to walk up a hill. This technique promises to make walking robots at least ten times more efficient than ZMP walkers, like ASIMO.

Other methods of locomotion

Flying

A modern passenger airliner is essentially a flying robot, with two humans to manage it. The autopilot can control the plane for each stage of the journey, including takeoff, normal flight, and even landing. Other flying robots are uninhabited, and are known as unmanned aerial vehicles (UAVs). They can be smaller and lighter without a human pilot onboard, and fly into dangerous territory for military surveillance missions. Some can even fire on targets under command. UAVs are also being developed which can fire on targets automatically, without the need for a command from a human. Other flying robots include cruise missiles, the Entomopter, and the Epson micro helicopter robot. Robots such as the Air Penguin, Air Ray, and Air Jelly have lighter-than-air bodies, propelled by paddles, and guided by sonar.

Snaking

Several snake robots have been successfully developed. Mimicking the way real snakes move, these robots can navigate very confined spaces, meaning they may one day be used to search for people trapped in collapsed buildings. The Japanese ACM-R5 snake robot can even navigate both on land and in water.

Skating

A small number of skating robots have been developed, one of which is a multi-mode walking and skating device. It has four legs, with unpowered wheels, which can either step or roll. Another robot, Plen, can use a miniature skateboard or rollerskates, and skate across a desktop.

Climbing

Several different approaches have been used to develop robots that have the ability to climb vertical surfaces. One approach mimicks the movements of a human climber on a wall with protrusions; adjusting the center of mass and moving each limb in turn to gain leverage. An example of this is Capuchin, built by Stanford University, California. Another approach uses the specialised toe pad method of wall-climbing geckoes, which can run on smooth surfaces such as vertical glass. Examples of this approach include Wallbot and Stickybot. China's "Technology Daily" November 15, 2008 reported New Concept Aircraft (ZHUHAI) Co., Ltd. Dr. Li Hiu Yeung and his research group have recently successfully developed the bionic gecko robot "Speedy Freelander".According to Dr. Li introduction, this gecko robot can rapidly climbing up and down in a variety of building walls, ground and vertical wall fissure or walking upside down on the ceiling, it is able to adapt on smooth glass, rough or sticky dust walls as well as the various surface of metallic materials and also can automatically identify obstacles, circumvent the bypass and flexible and realistic movements. Its flexibility and speed are comparable to the natural gecko. 

Swimming (like a fish)

It is calculated that when swimming some fish can achieve a propulsive efficiency greater than 90%.Furthermore, they can accelerate and maneuver far better than any man-made boat or submarine, and produce less noise and water disturbance. Therefore, many researchers studying underwater robots would like to copy this type of locomotion.Notable examples are the Essex University Computer Science Robotic Fish, and the Robot Tuna built by the Institute of Field Robotics, to analyze and mathematically model thunniform motion.The Aqua Penguin, designed and built by Festo of Germany, copies the streamlined shape and propulsion by front "flippers" of penguins. Festo have also built the Aqua Ray and Aqua Jelly, which emulate the locomotion of manta ray, and jellyfish, respectively.

Speech recognition

Interpreting the continuous flow of sounds coming from a human, in real time, is a difficult task for a computer, mostly because of the great variability of speech.The same word, spoken by the same person may sound different depending on local acoustics, volume, the previous word, whether or not the speaker has a cold, etc.. It becomes even harder when the speaker has a different accent. Nevertheless, great strides have been made in the field since Davis, Biddulph, and Balashek designed the first "voice input system" which recognized "ten digits spoken by a single user with 100% accuracy" in 1952.Currently, the best systems can recognize continuous, natural speech, up to 160 words per minute, with an accuracy of 95%.

Robotic voice

Other hurdles exist when allowing the robot to use voice for interacting with humans. For social reasons, synthetic voice proves suboptimal as a communication medium, making it necessary to develop the emotional component of robotic voice through various techniques.

Gestures

One can imagine, in the future, explaining to a robot chef how to make a pastry, or asking directions from a robot police officer. In both of these cases, making hand gestures would aid the verbal descriptions. In the first case, the robot would be recognizing gestures made by the human, and perhaps repeating them for confirmation. In the second case, the robot police officer would gesture to indicate "down the road, then turn right". It is likely that gestures will make up a part of the interaction between humans and robots. A great many systems have been developed to recognize human hand gestures.

Facial expression

Facial expressions can provide rapid feedback on the progress of a dialog between two humans, and soon may be able to do the same for humans and robots. Robotic faces have been constructed by Hanson Robotics using their elastic polymer called Frubber, allowing a large number of facial expressions due to the elasticity of the rubber facial coating and embedded subsurface motors (servos). The coating and servos are built on a metal skull. A robot should know how to approach a human, judging by their facial expression and body language. Whether the person is happy, frightened, or crazy-looking affects the type of interaction expected of the robot. Likewise, robots like Kismet and the more recent addition, Nexi can produce a range of facial expressions, allowing it to have meaningful social exchanges with humans.

Artificial emotions

Artificial emotions can also be generated, composed of a sequence of facial expressions and/or gestures. As can be seen from the movie Final Fantasy: The Spirits Within, the programming of these artificial emotions is complex and requires a large amount of human observation. To simplify this programming in the movie, presets were created together with a special software program. This decreased the amount of time needed to make the film. These presets could possibly be transferred for use in real-life robots.

Personality

Many of the robots of science fiction have a personality, something which may or may not be desirable in the commercial robots of the future. Nevertheless, researchers are trying to create robots which appear to have a personality:i.e. they use sounds, facial expressions, and body language to try to convey an internal state, which may be joy, sadness, or fear. One commercial example is Pleo, a toy robot dinosaur, which can exhibit several apparent emotions.

Control

The mechanical structure of a robot must be controlled to perform tasks. The control of a robot involves three distinct phases - perception, processing, and action (robotic paradigms). Sensors give information about the environment or the robot itself (e.g. the position of its joints or its end effector). This information is then processed to calculate the appropriate signals to the actuators (motors) which move the mechanical.

The processing phase can range in complexity. At a reactive level, it may translate raw sensor information directly into actuator commands. Sensor fusion may first be used to estimate parameters of interest (e.g. the position of the robot's gripper) from noisy sensor data. An immediate task (such as moving the gripper in a certain direction) is inferred 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 robot may need to build and reason with a "cognitive" model. Cognitive models try to represent the robot, 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.

Autonomy levels

Control systems may also have varying levels of autonomy.

1 Direct interaction is used for haptic or tele-operated devices, and the human has nearly complete control over the robot's motion. 

2 Operator-assist modes have the operator commanding medium-to-high-level tasks, with the robot automatically figuring out how to achieve them. 

3 An autonomous robot may go for extended periods of time without human interaction. Higher levels of autonomy do not necessarily require more complex cognitive capabilities. For example, robots 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 Teleoperation. 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 robot manages itself to complete it. 

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

Robotics research

Much of the research in robotics focuses not on specific industrial tasks, but on investigations into new types of robots, alternative ways to think about or design robots, and new ways to manufacture them but other investigations, such as MIT's cyberflora project, are almost wholly academic.

A first particular new innovation in robot design is the opensourcing of robot-projects. To describe the level of advancement of a robot, the term "Generation Robots" can be used. This term is coined by Professor Hans Moravec, Principal Research Scientist at the Carnegie Mellon University Robotics Institute in describing the near future evolution of robot technology. First generation robots, Moravec predicted in 1997, should have an intellectual capacity comparable to perhaps a lizard and should become available by 2010. Because the first generation robot would be incapable of learning, however, Moravec predicts that the second generation robot would be an improvement over the first and become available by 2020, with the intelligence maybe comparable to that of a mouse. The third generation robot should have the intelligence comparable to that of a monkey. Though fourth generation robots, robots with human intelligence, professor Moravec predicts, would become possible, he does not predict this happening before around 2040 or 2050.

Dynamics and kinematics

The study of motion can be divided into kinematics and dynamics. Direct kinematics refers to the calculation of end effector position, orientation, velocity, and acceleration when the corresponding joint values are known. Inverse kinematics refers to the opposite case in which required joint values are calculated for given end effector values, as done in path planning. Some special aspects of kinematics include handling of redundancy (different possibilities of performing the same movement), collision avoidance, and singularity avoidance. Once all relevant positions, velocities, and accelerations have been calculated using kinematics, methods from the field of dynamics are used to study the effect of forces upon these movements. Direct dynamics refers to the calculation of accelerations in the robot once the applied forces are known. Direct dynamics is used in computer simulations of the robot. Inverse dynamics refers to the calculation of the actuator forces necessary to create a prescribed end effector 

 Types of robot 

engineering

Humanoid 

Android Biomorphic Hexapod Industrial Articulated Domestic Entertainment Military Medical Service Disability Agricultural Food service BEAM robotics

Microbotics Nanorobotics List of robots Fictional robots 

Stationary 

• Ground 

• Underwater 

• Aerial 

• Space 

Polar robots 

Wheels 

Tracks 

Walking 

Running 

Swimming 

Climbing 

Hopping 

Metachronal motion 

Crawling 

Manual,remote tele-op Guarded tele-op 

Line-following robot Autonomously randomized robot Autonomously guided robot 

Sliding autonomy 

Roboticist Evolutionary 

Simulator 

Suite 

Open-source 

Software 

Adaptable 

Developmental 

Paradigms 

Audio 

• Biochemical 

• Ceramic 

• Chemical 

• Control 

• Electrical 

• Electronic 

• Entertainment 

• Geotechnical Hydraulic Mechanical Mechatronics Optical 

Classifications

AGRICULTURE MEDICAL ENGINEERING EDUCATION OTHER S

Agricultural engineering 

• Aquaculture 

• Fisheries science 

• Food chemistry 

• Food engineering 

• Food microbiology 

Food technology • Bioinformatics 

• Biological engineering 

• Biomechatronics 

• Biomedical engineering 

• Biotechnology 

• Cheminformatics 

• Genetic engineering 

• Healthcare science 

• Medical research 

• Medical technology 

• Nanomedicine 

• Neuroscience 

• Pharmacology 

Tissue engineering 

• Acoustical engineering 

• Architectural engineering 

• Building services engineering 

• Civil engineering 

• Construction engineering 

• Domestic technology 

• Facade engineering 

• Fire protection engineering 

• Safety engineering 

• Sanitary engineering 

Structural engineering 

• Educational software 

• Digital technologies in education 

• ICT in education 

• Impact 

• Multimedia learning 

• Virtual campus 

Virtual education

• Nuclear engineering 

• Nuclear technology 

• Petroleum engineering 

Soft energy technology 

The various types of robots



ASIMO is physically anthropomorphic

CHARACTERISTICS OF ROBOT

While there is no single correct definition of "robot," a typical robot will have several, or possibly all, of the following characteristics.

It is an electric machine which has some ability to interact with physical objects and to be given electronic programming to do a specific task or to do a whole range of tasks or actions. It may also have some ability to perceive and absorb data on physical objects, or on its local physical environment, or to process data, or to respond to various stimuli. This is in contrast to a simple mechanical device such as a gear or a hydraulic press or any other item which has no processing ability and which does tasks through purely mechanical processes and motion. 

. 

DEVELOPMENT OF ROBOTS

Ancient beginnings

Many ancient mythologies include artificial people, such as the mechanical servants built by the Greek god Hephaestus (Vulcan to the Romans), the clay golems of Jewish legend and clay giants of Norse legend, and Galatea, the mythical statue of Pygmalion that came to life.

Since cerca 400 BCE, myths of Crete that were incorporated into Greek mythology include Talos, a man of bronze who guarded the Cretian island of Europa from pirates.

In ancient Greece, the Greek engineer Ctesibius (c. 270 BC) "applied a knowledge of pneumatics and hydraulics to produce the first organ and water clocks with moving figures." In the 4th century BC, the Greek mathematician Archytas of Tarentum postulated a mechanical steam-operated bird he called "The Pigeon". Hero of Alexandria (10–70 AD), a Greek mathematician and inventor, created numerous user-configurable automated devices, and described machines powered by air pressure, steam and water. 

In ancient China, the 3rd century BC text of the Lie Zi describes an account of humanoid automata, involving a much earlier encounter between King Mu of Zhou (Chinese emperor 10th century BC) and a mechanical engineer known as Yan Shi, an 'artificer'. The latter proudly presented the king with a life-size, human-shaped figure of his mechanical 'handiwork' made of leather, wood, and artificial organs. There are also accounts of flying automata in the Han Fei Zi and other texts, which attributes the 5th century BC Mohist philosopher Mozi and his contemporary Lu Ban with the invention of artificial wooden birds (ma yuan) that could successfully fly.[13] In 1066, the Chinese inventor Su Song built a water clock in the form of a tower which featured mechanical figurines which chimed the hours. The beginning of automata is associated with the invention of early Su Song's astronomical clock tower featured mechanical figurines that chimed the hours. 

Modern developments

The Japanese craftsman Hisashige Tanaka (1799–1881), known as "Japan's Edison" or "Karakuri Giemon", created an array of extremely complex mechanical toys, some of which served tea, fired arrows drawn from a quiver, and even painted a Japanese kanji character. 

A remotely operated vehicles were demonstrated in the late 19th in the form of several types of remotely controlled torpedos. The early 1870's saw remotely controlled torpedos by John Ericsson (pneumatic), John Louis Lay (electric wire guided), and Victor von Scheliha (electric wire guided). In 1898 Nikola Tesla publicly demonstrated a "wireless" radio-controlled torpedo that he hoped sell to the US Navy. 

In 1926, Westinghouse Electric Corporation created Televox, the first robot put to useful work. They followed Televox with a number of other simple robots, including one called Rastus, made in the crude image of a black man. In the 1930s, they created a humanoid robot known as Elektro for exhibition purposes, including the 1939 and 1940 World's Fairs. In 1928, Japan's first robot, Gakutensoku, was designed and constructed by biologist Makoto Nishimura.

The first electronic autonomous robots with complex behaviour were created by William Grey Walter of the Burden Neurological Institute at Bristol, England in 1948 and 1949. They were named Elmer and Elsie. These robots could sense light and contact with external objects, and use these stimuli to navigate. 

The first truly modern robot, digitally operated and programmable, was invented by George Devol in 1954 and was ultimately called the Unimate. Devol sold the first Unimate to General Motors in 1960, and it was installed in 1961 in a plant in Trenton, New Jersey to lift hot pieces of metal from a die casting machine and stack them. Devol’s patent for the first digitally operated programmable robotic arm represents the foundation of the modern robotics industry. 

Commercial and industrial robots are now in widespread use performing jobs more cheaply or with greater accuracy and reliability than humans. They are also employed for jobs which are too dirty, dangerous or dull to be suitable for humans. Robots are widely used in manufacturing, assembly and packing, transport, earth and space exploration, surgery, weaponry, laboratory research, and mass production of consumer and industrial goods. 

LAWS OF ROBOT

“ 1. A robot may not injure a human being or, through inaction, allow a human being to come to harm.

2. A robot must obey any orders given to it by human beings, except where such orders would conflict with the First Law.

3. A robot must protect its own existence as long as such protection does not conflict with the First or Second Law. ”

Modern robots

A laparoscopic robotic surgery machine

Mobile robot

Mobile robots have the capability to move around in their environment and are not fixed to one physical location. An example of a mobile robot that is in common use today is the automated guided vehicle orautomatic guided vehicle (AGV). An AGV is a mobile robot that follows markers or wires in the floor, or uses vision or lasers. AGVs are discussed later in this article.

Mobile robots are also found in industry, military and security environments. They also appear as consumer products, for entertainment or to perform certain tasks like vacuum cleaning. Mobile robots are the focus of a great deal of current research and almost every major university has one or more labs that focus on mobile robot research.

Modern robots are usually used in tightly controlled environments such as on assembly lines because they have difficulty responding to unexpected interference. Because of this most humans rarely encounter robots. However domestic robots for cleaning and maintenance are increasingly common in and around homes in developed countries. Robots can also be found in military applications.

Industrial robots (manipulating)

Main articles: Industrial robot and Manipulator

Industrial robots usually consist of a jointed arm (multi-linked manipulator) and an end effector that is attached to a fixed surface. One of the most common type of end effector is a gripper assembly.

The International Organization for Standardization gives a definition of a manipulating industrial robot in ISO 8373:

"an automatically controlled, reprogrammable, multipurpose, manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications." 

This definition is used by the International Federation of Robotics, the European Robotics Research Network (EURON) and many national standards committees.[43]

A Pick and Place robot in a factory

Service robot

Most commonly industrial robots are fixed robotic arms and manipulators used primarily for production and distribution of goods. The term "service robot" is less well-defined. IFR has proposed a tentative definition, "A service robot is a robot which operates semi- or fully autonomously to perform services useful to the well-being of humans and equipment, excluding manufacturing operations.

Modular robot 

Modular robots is a new breed of robots that are designed to increase the utilization of the robots by modularizing the robots. The functionality and effectiveness of a modular robot is easier to increase compared to conventional robots.

CHAPTER-IV

CONSTRUCTION

1. SERVO MOTOR

An electric generator is a device that converts mechanical energy to

Electrical energy. The reverse conversion of electrical energy into mechanical energy is done by a motor; motors and generators have many similarities. A generator forces electrons in the windings to flow through the external electrical circuit. It is somewhat analogous to a water pump, which creates a flow of water but does not create the water inside. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, compressed air or any other source of mechanical energy. 

8

A dynamo machine consists of a stationary structure, which provides a constant magnetic field and a set of rotating windings which turn within that field. On small machines the constant magnetic field may be provided by one or more permanent magnets; larger machines have the constant magnetic field provided by one or more electromagnets, which are usually called field coils. 

Large power generation dynamos are now rarely seen due to the now 

nearly universal use of alternating current for power distribution and solid 

state electronic AC to DC power conversion. But before the principles of AC 

were discovered, very large direct-current• dynamos were the only means of 

power generation and distribution. Now power generation dynamos are 

mostly a curiosity.

The DC Motor or Direct Current Motor to give it its full title, is the most commonly used actuator for producing continuous movement and whose speed of rotation can easily be controlled, making them ideal for use in applications were speed control, servo type control, and/or positioning is required. A DC motor consists of two parts, a "Stator" which is the stationary part and a "Rotor" which is the rotating part. The result is that there are basically three types of DC Motor available.

Brushed Motor - This type of motor produces a magnetic field in a wound rotor (the part that rotates) by passing an electrical current through a commutator and carbon brush assembly, hence the term "Brushed". The stators (the stationary part) magnetic field is produced by using either a wound stator field winding or by permanent magnets. Generally brushed DC motors are cheap, small and easily controlled.

Brushless Motor - This type of motor produce a magnetic field in the rotor by using permanent magnets attached to it and commutation is achieved electronically. They are generally smaller but more expensive than conventional brushed type DC motors because they use "Hall effect” switches in the stator to produce the required stator field rotational sequence. But they have better torque/speed characteristics, are more efficient and have 

a longer operating life than equivalent brushed types. 

Servo Motor - This type of motor is basically a brushed DC motor 

with some form of positional feedback control connected to the rotor shaft. 

They are connected to and controlled by a PWM type controller and are 

mainly used in positional control systems and radio controlled models. 

Normal DC motors have almost linear characteristics with their speed 

of rotation being determined by the applied DC voltage and their output 

torque being determined by the current flowing through the motor windings. 

The speed of rotation of any DC motor can be varied from a few revolutions 

per minute (rpm) to many thousands of revolutions per minute making them 

suitable for electronic, automotive or robotic applications. By connecting 

them to gearboxes or gear-trains their output speed can be decreased while at 

the same time increasing the torque output of the motor at a high speed. 

A conventional brushed DC Motor consist basically of two parts, the 

stationary body of the motor called the Stator and the inner part which 

rotates producing the movement, called the Rotor or "Armature" for DC machines.

The motors wound stator is an electromagnet which consists of electrical coils connected together in a circular configuration to produce a North-pole then a South-pole then a North-pole etc, type stationary magnetic field system (as opposed to AC machines whose stator field continually rotates with the applied frequency) with the current flowing within these field coils being known as the motor field current. 

The stators electromagnetic coils can be connected in series, parallel or both together (compound) with the armature. A series wound DC motor has the stator field windings connected in series with the armature while a shunt wound DC motor has the stator field windings connected in parallel with the armature.

The rotor or armature of a DC machine consists of current carrying conductors connected together at one end to electrically isolated copper segments called the commutator. The commutator allows an electrical connection to be made via carbon brushes (hence the name "Brushed" motor) to an external power supply as the armature rotates. The magnetic field setup by the rotor tries to align itself with the stationary stator field causing the rotor to rotate on its axis, but cannot align itself due to commutation delays. 

The rotational speed of the motor is dependent on the strength of the rotors magnetic field and the more voltage that is applied to the motor the faster the rotor will rotate. By varying this applied DC voltage the rotational speed of the motor can also be varied.

Conventional (Brushed) DC Motor

                 Permanent magnet

              

    

      

2pole Permanent                                                                    4-Pole Wound 

    Field Motor                                                                      Magnet Motor

   

Permanent magnet (PMDC) brushed motors are generally much  smaller and cheaper than their equivalent wound stator type DC motor cousins as they have no field winding. In permanent magnet DC (PMDC) motors these field coils are replaced with strong rare earth (i.e. Samarium Cobolt, or Neodymium Iron Boron) type magnets which have very high magnetic energy fields. This gives them a much better linear speed/torque characteristic than the equivalent wound motors because of the permanent and sometimes very strong magnetic field, making them more suitable for use in models, robotics and servos. 

Although DC brushed motors are very efficient and cheap, problems 

associated with the brushed DC motor is that sparking occurs under heavy 

load conditions between the two surfaces of the commutator and carbon 

brushes resulting in self generating heat, short life span and electrical noise 

due to sparking, which can damage any semiconductor switching device 

such as a 110SFET or transistor. To overcome these disadvantages, 

Brushless DC Motors were developed.

The brushless DC motor (BDCM) is very similar to a permanent 

magnet DC motor, but does not have any brushes to replace or wear out due 

to commutator sparking. Therefore, little heat is generated in the rotor 

increasing the motors life. The design of the brushless motor eliminates the need for brushes by using a more complex drive circuit was the rotor 

magnetic field is a permanent magnet which is always in synchronization 

with the stator field allows for a more precise speed and torque control. Then 

the construction of a brushless DC motor is very similar to the AC motor 

making it a true synchronous motor but one disadvantage is that it is more 

expensive than an equivalent "brushed" motor design.

The control of the brushless DC motors is very different from the 

normal brushed DC motor, in that it this type of motor incorporates some 

means to detect the rotors angular position (or magnetic poles) required to 

produce the feedback signals required to control the semiconductor 

switching devices. The most common position/pole sensor is the Hall 

element, but some motors use optical sensors. Using the Hall sensors 

signals, the polarity of the electromagnets is switched by the motor control 

drive circuitry. Then the motor can be easily synchronized to a digital clock 

signal, providing precise speed control. Brushless DC motors can be 

constructed to have, an external permanent magnet rotor and an internal 

electromagnet stator or an internal permanent magnet rotor and an external 

electromagnet stator.

4.1.1 TORQUE CAPABILITIES OF MOTORS

When optimally designed for a given active current (i.e., torque current), voltage, pole-pair number, excitation frequency (i.e., synchronous speed), and core flux density, all categories of electric motors or generators will exhibit virtually the same maximum continuous shaft torque (i.e., operating torque) within a given physical size of electromagnetic core. Some applications require bursts of torque beyond the maximum operating torque, such as short bursts of torque to accelerate an electric vehicle from standstill. Always limited by magnetic core saturation or safe operating temperature rise and voltage, the capacity for torque bursts beyond the maximum operating torque differs significantly between categories of electric motors or generators.

Electric machines without a transformer circuit topology, such as Field-Wound (i.e., electromagnet) or Permanent Magnet (PM) Synchronous electric machines cannot realize bursts of torque higher than the maximum designed torque without saturating the magnetic core and rendering any increase in current as useless. Furthermore, the permanent magnet assembly of PM synchronous electric machines can be irreparably damaged, if bursts of torque exceeding the maximum operating torque rating are attempted.

Electric machines with a transformer circuit topology, such as Induction (i.e., asynchronous) electric machines, Induction Doubly-Fed electric machines, and Induction or Synchronous Wound-Rotor Doubly-Fed (WRDF) electric machines, exhibit very high bursts of torque because the active current (i.e., Magneto-Motive-Force or the product of current and winding-turns) induced on either side of the transformer oppose each other and as a result, the active current contributes nothing to the transformer coupled magnetic core flux density, which would otherwise lead to core saturation.

Electric machines that rely on Induction or Asynchronous principles short-circuit one port of the transformer circuit and as a result, the reactive impedance of the transformer circuit becomes dominant as slip increases, which limits the magnitude of active (i.e., real) current. Still, bursts of torque that are two to three times higher than the maximum design torque are realizable.

The Synchronous WRDF electric machine is the only electric machine with a truly dual ported transformer circuit topology (i.e., both ports independently excited with no short-circuited port). The dual ported transformer circuit topology is known to be unstable and requires a multiphase slip-ring-brush assembly to propagate limited power to the rotor winding set. If a precision means were available to instantaneously control torque angle and slip for synchronous operation during motoring or generating while simultaneously providing brushless power to the rotor winding set the active current of the Synchronous WRDF electric machine would be independent of the reactive impedance of the transformer circuit and bursts of torque significantly higher than the maximum operating torque and far beyond the practical capability of any other type of electric machine would be realizable. Torque bursts greater than eight times operating torque have been calculated

2. RECHARGEABLE BATTERY

A rechargeable battery (also known as a storage battery) is a group of one or more secondary cells. Rechargeable batteries use electrochemical reactions that are electrically reversible. Rechargeable batteries come in many different sizes and use different combinations of chemicals. Commonly used secondary cell ("rechargeable battery") chemistries are lead acid, nickel cadmium (NiCd), nickel metal hydride (NiMH), lithium ion (Li-ion), and lithium ion polymer (Li-ion polymer).

Rechargeable batteries can offer economic and environmental benefits compared to disposable batteries. Some rechargeable battery types are available in the same sizes as disposable types. While the rechargeable cells have a higher initial cost, rechargeable batteries can be recharged many times. Proper selection of a rechargeable battery system can reduce toxic materials sent to landfills compared to an equivalent series of disposable batteries. For example, battery manufacturers of NiMH rechargeable batteries claim a service life of 100-1000 charge cycles for their batteries.

a) 4.2.1 USAGE AND APPLICATIONS

Rechargeable batteries currently are used for applications such as automobile starters, portable consumer devices, light vehicles (such as motorized wheelchairs, golf carts, electric bicycles, and electric forklifts), tools, and uninterruptible power supplies. Emerging applications in hybrid electric vehicles and electric vehicles are driving the technology to reduce cost, reduce weight, and increase lifetime. 

Unlike non-rechargeable batteries (primary cells), rechargeable batteries have to be charged before use. The need to charge rechargeable batteries before use deterred potential buyers who needed to use the batteries immediately. However, new low self discharge batteries allow users to purchase rechargeable battery that already hold about 70% of the rated capacity, allowing consumers to use the batteries immediately and recharge later.

Grid energy storage applications use industrial rechargeable batteries for load leveling, where they store electric energy for use during peak load periods, and for renewable energy uses, such as storing power generated from photovoltaic arrays during the day to be used at night. By charging batteries during periods of low demand and returning energy to the grid during periods of high electrical demand, load-leveling helps eliminate the need for expensive peaking power plants and helps amortize the cost of generators over more hours of operation.

The National Electrical Manufacturers Association has estimated that U.S. demand for rechargeable is growing twice as fast as demand for non-rechargeable. 

4.2.2 CHARGING AND DISCHARGING

During charging, the positive active material is oxidized, producing electrons, and the negative material is reduced, consuming electrons. These electrons constitute the current flow in the external circuit. The electrolyte may serve as a simple buffer for ion flow between the electrodes, as in lithium-ion and nickel-cadmium cells, or it may be an active participant in the electrochemical reaction, as in lead-acid cells.

Diagram of the charging of a secondary cell battery.

The energy used to charge rechargeable batteries mostly comes from AC current (mains electricity) using an adapter unit. Most battery chargers can take several hours to charge a battery. Most batteries can be charged in far less time than the most common simple battery chargers are capable of. Duracell and Rayovac now sell chargers that can charge AA- and AAA-size NiMH batteries in just 15 minutes; Energizer sells chargers that can additionally charge C/D-size and 9 V NiMH batteries. However, high rates of charging (eg. 15 minute charger, 1 hour chargers) will cause long term damage to NiMH and most other rechargeable batteries. 

 Battery is susceptible to damage due to reverse charging if they are fully discharged. Fully integrated battery chargers that optimize the charging current are available.

Also, attempting to recharge non-rechargeable batteries has a small chance of causing a battery explosion.

Flow batteries, which are not commonly used by consumers, are recharged by replacing the electrolyte liquid.

Battery manufacturers' technical notes often refer to VPC. This is volts per cell, and refers to the individual secondary cells that make up the battery. For example, to charge a 12 V battery (containing 6 cells of 2 V each) at 2.3 VPC requires a voltage of 13.8 V across the battery's terminals.

Most NiMH AA or AAA batteries rate their cells at 1.2 V. However, this is not a problem in most devices because alkaline batteries drop in voltage as the energy is depleted. Most devices are designed to continue to operate at a reduced voltage of between 0.9 and 1.1 V

b) 4.2.3 REVERSE CHARGING

Reverse charging, which damages batteries, is when a rechargeable battery is recharged with its polarity reversed. Reverse charging can occur under a number of circumstances, the three most common being:

• When a battery is incorrectly inserted into a charger.

• When an automotive type battery charger is connected in reverse to the battery terminals. This usually occurs when a completely discharged battery is being charged, otherwise sparking will occur.

• When a series string is deeply discharged.

When one cell completely discharges ahead of the rest, the stronger cells will apply a reverse current to the discharged cell. This is commonly referred to as "cell reversal". Cell reversal significantly shortens the life of the affected cell and therefore shortens the overall life of the battery. In some extreme cases, the reversed cell can begin to emit smoke or catch fire. Some Ni-Cad type cells exhibit a "memory" effect. Some Ni-Cad type cells that are not fully charged and discharged periodically can lose their ability to retain a full charge, i.e. exhibit reduced capacity. Cycling a multi cell battery into deep discharge to overcome this memory effect can cause cell reversal and do more harm than good. In critical applications using Ni-Cad batteries, such as in aircraft, each cell is individually discharged by connecting a load clip across the terminals of each cell, thereby avoiding cell reversal, then charging the cells in series.

c) DEPTH OF DISCHARGE

Depth of discharge (DOD) is normally stated as a percentage of the nominal ampere-hour capacity; 0% DOD means no discharge. Since the usable capacity of a battery system depends on the rate of discharge and the allowable voltage at the end of discharge, the depth of discharge must be qualified to show the way it is to be measured. Due to variations during manufacture and aging, the DOD for complete discharge can change over time / discharge cycles. Generally a rechargeable battery system will tolerate more charge/discharge cycles if the DOD is lower on each cycle. 

BLOCK DIAGRAM

CHAPTER-V

COMPONENTS

Power source

• DC Motor

• Electric switches

• Wires

• Control unit

• Actuator

• Frame

Actuation

Actuators are like the "muscles" of a system, 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 systems in factories. But there are some recent advances in alternative types of actuators, powered by electricity, chemicals, or compressed air.

Electric motors

The vast majority of systems use electric motors, often brushed and brushless DC motors in portable systems or AC motors in industrial systems and CNC machines.

Linear actuators

Various types of linear actuators move in and out instead of by spinning, particularly when very large forces are needed such as with industrial systemics. They are typically powered by compressed air ( actuator) or an oil (hydraulic actuator).

Series elastic actuators

A spring can be designed as part of the motor actuator, to allow improved force control. It has been used in various systems, particularly walking humanoid systems.

DC motors

Recent alternatives to DC motors are piezo motors or ultrasonic motors. These work on a fundamentally different principle, whereby tiny piezoceramic elements, vibrating many thousands of times per second, cause linear or rotary motion. There are different mechani of operation; one type uses the vibration of the piezo elements to walk the motor in a circle or a straight line.Another type uses the piezo elements to cause a nut to vibrate and drive a screw. The advantages of these motors are nanometer resolution, speed, and available force for their size. These motors are already available commercially, and being used on some systems.

.

Manipulation

Systems need to manipulate objects; pick up, modify, destroy, or otherwise have an effect. Thus the "hands" of a system are often referred to as end effectors, while the "arm" is referred to as a manipulator. Most system 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.

For the definitive guide to all forms of system end-effectors, their design, and usage consult the book "System Grippers".

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 through it. Hands that resemble and work more like a human hand include the Shadow Hand, the Robonaut hand Hands that are of a mid-level complexity include ie the Delft hand, 

Vacuum grippers

Vacuum grippers are very simple astrictive devices, but can hold very large loads provided the prehension surface is smooth enough to ensure suction.

Material handling systems for electronic components and for large objects like car windscreens, often use very simple vacuum grippers.

SERVO MOTOR:

A servo motor is a widely used device that translates electrical pulses into mechanical movement. It is used for precise position control.  Increase or decrease the RPM (speed) of it.

To vary the RPM of motor we have to vary the PRF (Pulse Repetition frequency). Number of applied pulses will vary number of rotations and last to change direction we have to change pulse sequence.

CHAPTER-VI

WORKING PRINCIPLE

The switch is connected at the bed of the robotic vehicle. This is used to operate the motor using the battery. The motor is connected with the wheel arrangement with the help of the spur gear.

 When the first user keep the tools in this vehicle the trolley moves 

automatically to the second user. 

If the second user took the tools from the trolley the trolley stops with the second user. After that when the second user keeps a tool it moves to the next user. It can be used in industries, hospitals etc.

WORKING OF MATERIAL HANDLING SYSTEM IS EXPLAINED BY FOLLOWING STEPS

1. Initially it is assume the rest position of entire system, i.e. state when no object  is placed. 

3. As soon as object is placed at the picking platform, the switch gives the power outputs . This signal is sent to the controller and dc servo motor which is used for moving the arm. 

4. For understanding operation, let us rename the two motors used here. Let the name of gantry motor be M1 and that for end effecter motor is M2. 

5. Now as controller detects that object is placed, it moves motor M1 in say clockwise direction for a fixed time due to which whole arm moves towards picking platform. 

6. As it reaches there, M1 stops and now motor M2 is started in say clockwise direction to hold the object by closing jaw. This motor also, is on for particular fixed time instant. 

7. As M2 gets off, motor M1 is moved again in opposite (here anticlockwise) direction till the time it reaches the placing platform. 

8. As it reaches placing platform, the motor M1 stops and M2 is switched ON in opposite (here anticlockwise) direction till it releases object properly on desired place. 

9. If after this no object is detected, the system is in rest position. Otherwise if another object is detected, steps are repeated till step 

CHAPTER-VII

APPLICATIONS

* Materials Handling

* Industrial System applications

* Debarring

* Welding

* Handling

* Trimming and Sealing

* Spraying and palletizing

FUTURE APPLICATION

* Coal mining

* Military Operation

* Fire fighting Operation

* Undersea Systems

* Garbage Collection and Waste Disposal Operation.

ADVANTAGES

 Future development

 Technological trends

 Simple mechanism

 Less space

 High performance

 Various techniques have emerged to develop the science of systemic and systems. One method is evolutionary, in which a number of differing systems are submitted to tests. 

 Those which perform best are used as a model to create a subsequent "generation" of systems. 

 Another method is developmental systemic, which tracks changes and development within a single system in the areas of problem-solving and other functions.

CONCLUSION:

This system is used for pick the object in one place and place that objects in required places. Some industrial works are harmful for humans this system 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 system does all those things it mainly reduces the manual work our system is designed at low cost as well as high efficient one.

This project is to give the way for providing bigger effective system for industrial applications.

REFERENCES

• K. S. Fu & R.C. Gonzalez & C.S.G. Lee, System: Control, Sensing, Vision, and Intelligence (CAD/CAM, system, and computer vision) 

• C.S.G. Lee & R.C. Gonzalez & K.S. Fu, Tutorial on system 

• “SP200 With Open Control Center. Systemic Prescription Dispensing System”, accessed November 22, 2008. 

• “McKesson Empowering HealthCare. System RX”, accessed November 22, 2008. 

• “Aethon. You Deliver the Care. TUG Delivers the Rest”, accessed November 22, 2008.

• Marco Ceccarelli, "Fundamentals of Mechanics of Systemic Manipulators" 

• Journal of Field Systemics 

• Systemics education website 

• R. Andrew Russell (1990). System Tactile Sensing. New York: Prentice Hall. ISBN 0-13-781592-1