Documentos de Académico
Documentos de Profesional
Documentos de Cultura
A PROJECT REPORT
Submitted by
GAURANG MARVANIA [Reg No: 11807024]
GOURANGA NEOG [Reg No: 11807026]
MAHARSHI THAKER [Reg No: 11807100]
1
SRM UNIVERSITY
(Under Section 3 of UGC Act,1956)
BONAFIDE CERTIFICATE
THAKER (Reg No. 11807100)”, who carried out the project work under my
supervision. Certified further, that to the best of my knowledge the work reported herein
does not form any other project report or dissertation on the basis of which a degree or
SIGNATURE SIGNATURE
M.R. STALIN JOHN Dr. B.K. VINAYAGAM
Guide HOD/Mechatronics
Assistant Professor(SG) Professor
Department of Mechanical Engineering Department of Mechatronics
2
Internal Examiner External Examiner
3
ACKNOWLEDGEMENT
B.K. VINAYAGAM for having given me an opportunity to carry out this project and
an Educator in the journey of completion of the project. With his time to time association
ship, we have derived valuable information, insight and inspiration about successfully
completing the project. He has always been very cooperative and kind hearted and have
sincerely.
We would also like thank the Faculty Members without whom this project would have
been a distant reality. We also extend our heartfelt thanks to our family and well wishers.
We owe a great many thanks to a great many people who helped and supported us during
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ABSTRACT
The Project deals with an automated material handling system. It synchronizes the
movement of robotic arm to pick the objects moving on a conveyor belt. It aims in
classifying the coloured objects which are coming on the conveyor by picking and
placing the objects in its respective pre-programmed place. Thereby eliminating the
monotonous work done by human, achieving accuracy and speed in the work. The project
involves colour sensors that senses the object’s colour and sends the signal to the
microcontroller. The microcontroller sends signal to eight relay circuit which drives the
various motors of the robotic arm to grip the object and place it in the specified location.
Based upon the colour detected, the robotic arm moves to the specified location, releases
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TABLE OF CONTENTS
BONAFIDE CERTIFICATE
ACKNOWLEDGEMENT
ABSTRACT
1. INTRODUCTION 1
1.1 HISTORY 1
1.1.1 BENEFITS OF 2
CONVEYORS
1.2 LITERATURE SURVEY 4
2. METHODOLOGY 6
2.1.2 TRANSFORMER 8
2.1.4 RELAYS 10
2.1.5 DC MOTORS 11
3. EXPERIMENTAL SETUP 14
3.1.1 FRAMES 14
3.1.2 ROLLERS 14
6
3.1.3 SUPPORTS 14
3.1.3 GRIPPER 21
4. ELECTRONIC CIRCUITS 22
4.2 INTERFACING OF 24
MICROCONTROLLER
4.2.1 FEATURES 24
5. MICRO CONTROLLER 40
PROGRAMMING
7
6. FUTURE WORKS 52
7. CONCLUSION 53
9. REFERENCES 54
10. APPENDIX 55
CHAPTER 1
INTRODUCTION
1.1 HISTORY
8
Hymle Goddard of Logan Company patented the first roller conveyor in 1908. Its
initial applications were not very popular, and it wasn't until it was introduced in the
automotive industry that it was able to prosper. In 1919, the first powered and free
conveyors were introduced into the mass production of automobiles. The conveyor
quickly became a popular means of transporting heavy materials within manufacturing
facilities.
The application of the conveyor branched out to coal mining in the 1920s, where
the technology underwent considerable changes. Conveyor belts were designed made of
layers of cotton and rubber coverings. During the manufacturing increase of World War
II, manufacturers created synthetic materials to make belting because of the scarcity of
natural components. Today's conveyor belting is made from an almost endless list of
synthetic polymers and fabrics and can be tailored to any requirements. Possible uses of
conveyors have broadened considerably since the early days and they are used in almost
any industry where materials have to be handled, stored or dispensed. The longest
conveyor belt currently in use operates in the phosphate mines of the Western Sahara and
is over 60 miles long.
• Load: The type of product being handled (unit load or bulk load)
Conveyors offer a wide range of benefits, many of which are readily apparent.
Before the invention and implementation of conveyors, warehouse and factory workers
needed to physically travel with an object from place to place. Not only was this
cumbersome for the employee, it was inefficient for the company and, essentially, a huge
waste of time. The conveyor brings a project to the worker, rather than a worker having
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to travel to a project. Conveyors can be used to transport parts to workers or locations
throughout a plant or warehouse and, eventually, to the shipping dock for delivery.
The history of conveyor belts begins in the latter half of the 17th century. Since
then, conveyor belts have been an inevitable part of material transportation. But it was in
1795 that conveyor belts became a popular means for conveying bulk materials. In the
beginning, conveyor belts were used only for moving grain sacks to short distances.
The conveyor belt system and working were quite simple in the early days. The
conveyor belt system had a flat wooden bed and a belt that traveled over the wooden bed.
Earlier, conveyor belts were made of leather, canvas or rubber. This primitive conveyor
belt system was very popular for conveying bulky items from one place to another. In the
beginning of the 20th century, the applications of conveyor belts became wider.
Hymle Goddard of Logan Company was the first to receive the patent for the
roller conveyor in 1908. The roller conveyor business did not prosper. A few years later,
in 1919, powered and free conveyors were used in automotive production. Thus,
conveyor belts became popular tools for conveying heavy and large goods within
factories.
During the 1920s, conveyor belts were common, and also underwent tremendous
changes. Conveyor belts were used in coal mines to handle runs of coal for more than
8kms, and were made using layers of cotton and rubber covers. The longest conveyor belt
now in use is 60 miles long, in the phosphate mines of Western Sahara.
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One of the turning points in the history of conveyor belts was the introduction of
synthetic conveyor belts. It was introduced during the Second World War, mainly
because of the scarcity of natural materials such as cotton, rubber and canvas. Since then,
synthetic conveyor belts have become popular in various fields.
With the increasing demand in the market, many synthetic polymers and fabrics
began to be used in the manufacture of conveyor belts. Today, cotton, canvas, EPDM,
leather, neoprene, nylon, polyester, polyurethane, urethane, PVC, rubber, silicone and
steel are commonly used in conveyor belts. Nowadays, the material used for making a
conveyor belt is determined by its application.
Tsalidis and Dentsoras (1998) describes in this paper that conveyor belt design is
examined as an application of a proposed Design Parameters Space Search technique.
First, the main characteristics of the belt-conveyor design process are presented as they
appear in the current literature. Furthermore, a proposed general knowledge-
representation platform is described, and its ability to house the relevant conveyor design
knowledge is also shown. The extended search technique of the design space is discussed,
and an integrated example of a belt-conveyor design is presented, based on the proposed
representation platform and the extended search technique.
Huang et al., (2007) describes in this paper deals with the time-minimum trajectory
planning of a 2-DOF translational parallel robot named the Diamond for rapid pick-and-
place operations. Kinematics and dynamics of the robot are formulated using a parametric
function, allowing the representation of the input torque and velocity constraints to be
converted to those in terms of the path length. A modified algorithm for achieving the
minimized traversal time is proposed by taking into account the path jerk limit. Lithium-
ion battery sorting using the Diamond robot is taken as an example to demonstrate the
applicability of this approach.
Dogan Ibrahim (2007) aims to show the special features of the C language when
programming microcontrollers. He says that the industry standard C51 optimizing C
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compiler is used throughout. This compiler has been developed by Keil Elektronik
GmbH. C51 is available on both MS-DOS and Windows-based operating systems and the
compiler implements the American National Standards Institute (ANSI) standard for the
C language. There are many other high-level language compilers available for
microcontrollers, including PASCAL, BASIC, and other C compilers. Some of these
compilers are freely available as shareware products and some can be obtained from the
Internet with little cost. These compilers can be used for learning the features of a
specific product and in some cases small projects can be developed with such compilers.
The C51 compiler has been developed for the 8051 family of microcontrollers. This is
one of the most commonly used industry standard C compilers for the 8051 family, and
can generate machine code for most of the 20-pin and 40-pin 8051 devices and its
derivatives, including the following microcontrollers: Intel and others 8051, 80C51, and
87C51 Atmel 89C51, 89C52, 89C55, 89S8252, and 89S53.51 an
Sahu, et al.,(2007) describes the outline of the development of the colour sensor meant
for the radiation-robot used for the alignment of sample for various experiments in a
radiation environment near nuclear beam line of 3MV Tandem pelletron Accelerator at
Institute of Physics, Bubaneswar. In this paper a comparative study between the APD and
LDR for their sensitivity towards different colours also discussed. A cost effective as well
as with reasonable accuracy and precision, a colour sensor is developed with a array of
LDRs, where the biasing voltage is very less compared to APD based colour sensor. This
sensor is used in a micro-controller based robotic arm and successfully able to distinguish
8 colors. This can be enhanced to 256 colors. This work is the first developmental stage
of the robot, which will be used for alignment of the sample sensing laser of different
colour in high-dose radiation environment.
Khojastehnazhand,et al., (2010) Grading systems give many kinds of information such as
size, colour, shape, defect, and internal quality. Among these colour and size are the most
important features for accurate classification and/or sorting of citrus such as oranges,
lemons and tangerines. Basically, two inspection stages of the system can be identified:
external fruit inspection and internal fruit inspection. The former task is accomplished
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through processing of colour images, while internal inspection requires special sensors
for moisture, sugar and acid contents. In this paper, an efficient algorithm for grading
lemon fruits is developed and implemented in visual basic environment. The system
consists of two CCD cameras, two capture cards, an appropriate lighting system, a
personal computer and other mechanical parts. The algorithm initially extracts the fruit
from the background. The samples of different grades of lemon are situated in front of the
cameras and are calibrated off-line. Then information on the HSI colour values and
estimated volumes of fruits are extracted and saved in a database. By comparing the
information during sorting phase with the available information inside the database, the
final grade of the passing fruits is determined. This algorithm can be easily adapted for
grading and/or inspection of other agricultural products such as cucumber and eggplant.
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CHAPTER 2
METHODOLOGY
230 Volts AC Power Supply
Sensing Circuit
14
The microcontroller receives the signal
from
sensing unit.
The working of object sorting system using colour sensor and pick and place
robot is described in steps as follows:
Objects on the running conveyor are classified into three categories based on the
colour. When the object passes through the sensing circuit it identifies the colour of the
object on the conveyor and sends signals to the micro-controller.
This circuit can be used to sense and differentiate between different colours. This
circuit demonstrates the principle and operation of a simple colour sensor using LDR.
The circuit is divided into three parts: Detector (LDR), Comparator and Output.
When light of a particular colour falls on LDR, its resistance decreases and an
output voltage is produced. This voltage is dependent on the intensity and wavelength of
different colour. For it is needed to set reference voltage of comparator according to the
requirement.
For example, If set reference voltage at positive pin with 0.38volts, the LDR
becomes sensitive to blue light. When blue light falls on the LED, an output of
approximate voltage 0.28V is produced, this glows the output LED.
15
But if a yellow colour light on LDR then input voltage at the comparator is around
0.7 volts at the negative pin of comparator and the output LED doesn’t glow. There are
three LEDs of Red, Blue and Green are arranged along with special LDRs which will just
allow either Red, Blue or Green lights to pass through. The working principle of LDR is
that when a light falls of LDR its resistance reduces and it allows the current to pass
through it. When the light from the LED falls on any of the three coloured object, it will
reflect back on the LDR. These LDR will only allow any one colour to pass through it
and this is how it will sense the colour of the object. There are LEDs placed in order to let
the user know that which coloured object has been sensed by the sensing circuit. There is
a varactor diode which will allow the user to vary the reference voltage in order to
accurately sense the three colours.
The signals from the sensing circuit are sent to the controller circuit consisting of
power circuit, rectifier circuit and micro-controllers.
2.1.2TRANSFORMER:
A transformer is a static device that transfers electrical energy from one circuit to
another through inductively coupled conductors—the transformer's coils. A varying
current in the first or primary winding creates a varying magnetic flux in the transformer's
core and thus a varying magnetic field through the secondary winding. This varying
magnetic field induces a varying electromotive force (EMF) or "voltage" in the secondary
winding. This effect is called mutual induction.
16
secondary winding (Vs) is in proportion to the primary voltage (Vp), and is given by the
ratio of the number of turns in the secondary (Ns) to the number of turns in the primary
(Np) as given in Eq. 1.
(1)
The signals from the micro-controller are then given to the robotic arm through
the switching circuit. These signals will control the arm and gripper movement and will
place the object picked from conveyor belt to three different places in order to segregate
them. The switching circuit gives the option of manual operation of arm movement as
well as gripper operation. The automation switch on the board will operate the system
automatically.
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the supply feeding it. In extreme cases where many rectifiers are loaded onto a power
distribution circuit, it may prove difficult for the power distribution authority to maintain
a correctly shaped sinusoidal voltage curve. The output of the filter circuit is pure DC
which is then supplied to controllers, motors and sensors.
2.1.4 RELAYS:
A type of relay that can handle the high power required to directly control an
electric motor is called a contractor. Solid-state relays control power circuits with no
moving parts, instead using a semiconductor device to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used to
protect electrical circuits from overload or faults; in modern electric power systems these
functions are performed by digital instruments still called "protective relays".
In this system DC Motors for gripper, turn table, robotic arm and conveyor belt
are connected through the relay circuit.
2.1.5 DC MOTORS:
Motor Details
18
The DC motors are used to control the arm and turn table movement are connected to
controller circuit and receives signals from micro-controller. There are IR sensors
installed in order to accurately identify ground and drop places
Gripper: 9V, 60 rpm, DC motor is used to control the gripper movement, for
opening and closing of the gripper. The DC motor receives its signal from the controller
for performing gripping and dropping operations. The gripper has been specially
designed in order to grip rectangular or square objects from the running conveyor and
dropping them at programmed locations.
19
Here, the conveyor motor receives power and signal from the central supply
through rectifier and control circuit. The control circuit consisting of an potentiometer
will allow the user to manually control the speed of conveyor belt by the regulatory knob.
Polyester is used as a belt material.
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A conveyor belt consists of two or more pulleys, with a continuous loop of
material - the conveyor belt - that rotates about them. One or both of the pulleys are
powered, moving the belt and the material on the belt forward. The powered pulley is
called the drive pulley while the unpowered pulley is called the idler. There are two main
industrial classes of belt conveyors; those in general material handling such as those
moving boxes along inside a factory and bulk material handling such as those used to
transport industrial and agricultural materials, such as grain, coal, ores, etc. generally in
outdoor locations.
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CHAPTER 3
EXPERIMENTAL SETUP
3.1 CONVEYOR SYSTEM
3.1.1 FRAMES
Standard gravity conveyor frame widths are 305mm, 460mm and 610mm overall.
Conveyor frames are stocked in both 1.5 metre and 3 metre lengths. Frames are supplied
with either “butting plates” (standard) or hook and bar attachments to secure each
segment together.
Standard frames are supplied in a “hammer tone” blue spray painted finish. Other colours
or finishes are available on request e.g., Powder coated, galvanised finish or stainless
steel.
3.1.2 ROLLERS
Standard rollers for the conveyor frames are 50.8mm diameter. They are available
in PVC (25kg capacity), Black Steel and Galvanised Steel in both Medium Duty (140kg
capacity) and Heavy Duty (200kg capacity) versions to suit varying loads or conditions.
Stainless steel rollers for wash-down or corrosive applications are used.
Spring loaded axles slot into holes along the frame. On PVC and Medium Duty
rollers one end is a D shape whilst the other is round. This allows for easy replacement of
damaged rollers. Heavy Duty rollers are supplied with 12mm shafts. Precision or
stainless steel bearings are available for frame work.
3.1.3 SUPPORTS
Two types of standard supports are available. Both styles provide adjustment from
600 – 1000mm to “Top of Roller”. Other support styles and complete frames are used to
special support.
RHS Supports are bolted to the underside of the conveyor frame via a crescent
(smiley) plate. This plate provides allowance for any angular misalignment.
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Pipe stands are also available for economy or for applications where the conveyor
may be moved on a frequent basis.
Normally, supports are only placed on every conveyor join (3 stands for 2
frames). Curves always require 2 stands for proper stability.
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This style of conveying is ideal in warehouse order picking applications or where
cartooned product is being transported through a manufacturing process. It provides
minimum pressure accumulation, quiet operation and easy installation.
Line shaft conveyors are suitable for transportation of products within warehouse or
manufacturing operations where lighter weight cartons, tote bins and other products need
to be moved, allowing for a variety of situations requiring directional changes. Limited,
minimal pressure accumulation of product can be obtained with this style of conveyor.
Straight modules, curves and merges, slave drive assemblies, under roller brakes,
pneumatic blade stops, personnel gates and many other accessories for this product line.
Due to the nature of line shaft, one drive can power many metres of conveyor, making it
extremely economical.
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3.1.6 CONVEYOR SYSTEM
SENSING
CIRCUIT
ELECTRONIC
CIRCUIT
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3.2 ROBOTIC ARM
Drill a hole in the base 8 cm from the front and to the side so the disk is close to
one side. This will leave room for the piston that moves it on the other side. Cut a 4 cm
dowel and glue it in the base. Slide the disk over the dowel and glue down the 2.5 cm
piece over the disk. This way the disk will rotate, but not come off.
The right side of the support structure has two screw eyes; the one on the inside is
big enough for the syringe tube and is 2.5 cm up from the bottom.
The one on the outside can be smaller since it only will have a wire in it, and it is .
5 of a cm from the bottom and .5 cm from the back (the long side of the base is the back).
One can use a big one on the outside if that is all one have. Screw them in before one glue
the pieces to the disk since it is easier (especially the inside one).
Cut a piece of dowel to fit in the holes 6 cm from the bottom. It should be long
enough to go to the outside edge of the support structure, so the structure is exactly 3.2
cm across. The long arm should be 3.2 cm across, (measure your drying long arm) so the
space here has to Insert pegs in the top holes so they stick in 1 cm, this will hold the long
arm. They don’t need to be glued since there is no motion that will work them loose, and
it’s nice to be able to remove them let this dry and go on to the grabber arms.
26
Do the same for the other side and one are ready for the claws! Place tubing over
the dowels to hold them in place. There should be .5 cm on each side of the arm
for the tubing.
There are two ways one can attach them. The researchers have decided that they
are both fine and one can use whichever technique one want (in a vote 42 to 5) .Either
ways, one need a wooden spacer on the arm on the right. On these pieces the dowel
doesn’t need a rubber holder since they are going to be gluedand the dowel should be flat
on the claw. Trim the dowel with a pair of small wires nippers if they are too long. Move
the linkage in and out with your hands and adjust the claws so they are at the correct
angle, and they don’t bind with each other. If they hit each other and don’t nicely mesh
then take them off and sand them so they slide together. Once they are smoothly meshing
and at an angle that one like, put glue on the dowels and push them in.
1. The cardboard robotic arm must have a sturdy base. If it is not secured it will
topple over when it attempts to pick up the object.
2. The cardboard robotic arm must have at least two parts to the limb. These are
generally referred to as the biceps and the forearm. Some cardboard robotic arms
also have hands or fingers.
3. The cardboard robotic arm must have at least two joints. The elbow joint enables
it to bend over to the object. The wrist or finger joints allow it to pick up the
object. Some cardboard robotic arms also have a third joint at the shoulder near
the base.
4. The cardboard robotic arm must have a muscle system. This powers it through its
motions. This can be human muscle pulling strings, hydraulics pushing liquid or
electricity sending impulses to motors.
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3.2.2 ROBOTIC ARM
GRIPPER
COLOUR
SHOULDER TURN TABLE SENSING
WOODEN BASE
CIRCUIT
3.1.3 GRIPPER
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Figure 3.3 shows the gripper design that can grip square and rectangular objects.
GRIPPER MOTOR
Fig.3.3 Gripper
GRIPPER CHAPTER 4
CAPACITOR
ELECTRONIC CIRCUITS
4.1 ELECTRONIC MODULE
Figure.4.1 represents Electronic Module contains Microcontroller circuit, Relay Circuit,
Infrared Sensors and Voltage Converting Circuits.
AC TO DC
CONVERTOR
CIRCUIT
TRANSFORMER
FOR GRIPPER
MOTOR 29
RELAY CIRCUIT
TRANSFORMER
12-0-12
SPEED CONTROL OF
AC TO DC MICROCONTROLLER
CONVEYOR
CONVERTOR CIRCUIT
CIRCUIT CONTROL BOARD
4.2 INTERFACING OF MICROCONTROLLER TO RELAY
CIRCUIT BY DARLINGTON array (ULN DRIVER)
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switch closure gives logic 1. But this is not a matter because it is easy to handle
in software.
The ULN2003 is a monolithic high voltage and high current Darlington transistor
arrays. It consists of seven NPN Darlington pairs that feature high-voltage outputs with
common-cathode clamp diode for switching inductive loads. The collector-current rating
of a single Darlington pair is 500mA. The Darlington pairs may be paralleled for higher
current capability. Applications include relay drivers, hammer drivers, lamp drivers,
display drivers (LED gas discharge), line drivers, and logic buffers. The ULN2003 has a
2.7kW series base resistor for each Darlington pair for operation directly with TTL or 5V
CMOS devices. The ULN driver details are shown in Fig. 4.2.
4.2.1
FEATURES
* 500mA rated collector
current (Single output)
* High-voltage outputs:
50V
* Inputs
compatible with various
types of logic.
* Relay driver
application
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Fig. 4.2 ULN 2803
This project uses relay circuit board to control various parameters of project. It
uses 8 relay board. The relay acts as a switch for parameters like turn table, shoulder of
robot and gripper.
All relays contain a sensing unit, the electric coil, which is powered by AC or DC current.
When the applied current or voltage exceeds a threshold value, the coil activates the
armature, which operates either to close the open contacts or to open the closed contacts.
When a power is supplied to the coil, it generates a magnetic force that actuates the
switch mechanism. The magnetic force is, in effect, relaying the action from one circuit
to another. The first circuit is called the control circuit; the second is called the load
circuit. Figure 4.3 gives the internal detail of relay circuit and Fig 4.4 shows eight relay
circuit diagram with ULN driver which drives the various motors of Robotic Arm.
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There are three basic functions of a relay: On/Off Control, Limit Control and Logic
Operation.
On/Off Control: Example: Air conditioning control, used to limit and control a “high
power load”, such as a compressor
Limit Control: Example: Motor Speed Control, used to disconnect a motor if it runs
slower or faster than the desired speed
Logic Operation: Example: Test Equipment, used to connect the instrument to a number
of testing points on the device under test.
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Fig. 4.3 Eight relays circuit
35
Fig. 4.4 Eight relay circuit diagram with ULN driver
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4.4 COLOUR SENSING CIRCUIT
The colour sensing circuit of the project contains three different coloured LED
emitter and three separate receivers. The light is reflected off of the target such as a blue
piece of paper and returns to the sensor. The receivers are tuned to look for a specific
wavelength of light working out its RGB or Red, Green and blue values.
The light sensors are able to record the components of the reflected light and its
intensity. The sensor then compares these values to the settings on the computer to
determine the necessary action. Many of the colour sensors today have the ability to
recognize Red, Blue, Green (RGB) or primary. Figure 4.5 shows the colour sensing
circuit.
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when sorting or matching objects of similar colour. The more exact the required match,
the more tight the colour tolerance level is set.
Fig. 4.5 Colour sensor
LDRs or Light Dependent Resistors are very useful especially in light/dark sensor
circuits. Normally the resistance of an LDR is very high, sometimes as high as 1000 000
ohms, but when they are illuminated with light resistance drops dramatically. When a
light level of 1000 lux (bright light) is directed towards it, the resistance is 400R (ohms).
When a light level of 10 lux (very low light level) is directed towards it, the resistance
has risen dramatically to 10.43M (10430000 ohms).
When the light level is low the resistance of the LDR is high. This prevents
current from flowing to the base of the transistors. Consequently the LED does not light.
Figure 4.6 shows LED based LDR Sensor
However, when light shines onto the LDR its resistance falls and current flows
into the base of the first transistor and then the second transistor. The LED lights.
38
The LEDs are water clear when turned off. Black electrical tape surrounds the
photocell in the center of the LEDs. The tape blocks the direct light from the LEDs from
reaching the photocell, thus detecting only reflected light.
After the amount of red light, green light, and blue light is measured, each
component is individually scaled based on minimum and maximum values obtained at
calibration. One-time calibration consists of aiming the completed sensor first at a white
piece of paper and then at a piece of black conductive foam. The maximum and minimum
values are plugged into the EEPROM of the microcontroller. Scaling based on actual data
allows the individual attributes of that particular sensor and set of LEDs to be accounted
for.
Alternatively, one can adjust the balance of the colours in hardware by using with
three separate trimpots (trimmer potentiometers). Dialing a trimpot changes the
brightness of a particular LED. For example, if there is too much red light being sensed,
simply increase the resistance to decrease the LED brightness by turning the trimpot
attached to the red LED.
Include a minimum fixed resistor value (100 ohms to 150 ohms) in series with each
trimpot so that if one accidentally dial the trimpot to 0 ohms the LED won't be damaged.
The object whose colour is required to be detected should be placed in front of the
system. The light rays reflected from the object will fall on the three convex lenses which
are fixed in front of the three LDRs. The convex lenses are used to converge light rays.
This helps to increase the sensitivity of LDRs. Blue, green and red glass plates (filters)
are fixed in front of LDR1, LDR2 and LDR3 respectively. When reflected light rays from
the object fall on the gadget, the coloured filter glass plates determine which of the LDRs
would get triggered.
When a primary coloured light ray falls on the system, the glass plate corresponding to
that primary colour will allow that specific light to pass through Fig 4.7. But the other
two glass plates will not allow any light to pass through. Thus only one LDR will get
triggered and the gate output corresponding to that LDR will become logic 1 to indicate
39
which colour it is. Similarly, when a secondary coloured light ray falls on the system, the
two primary glass plates corres- ponding to the mixed colour will allow that light to pass
through while the remaining one will not allow any light ray to pass through it. As a
result two of the LDRs get triggered and the gate output corresponding to these will
become logic 1 and indicate which colour it is.
When all the LDRs get triggered or remain untriggered, one will observe white and black
light indications respectively. Following points may be carefully noted:
1. Potmeters VR1, VR2 and VR3 may be used to adjust the sensitivity of the LDRs.
2. Common ends of the LDRs should be connected to positive supply.
3. Use good quality light filters.
The LDR is mounded in a tube, behind a lens, and aimed at the object. The coloured glass
filter should be fixed in front of the LDR as shown in the figure. Make three of that kind
and fix them in a suitable case. Adjustments are critical and the gadget performance
would depend upon its proper fabrication and use of correct filters as well as light
conditions. Figure 4.8 shows LDR with cellophane filter.
40
4.4.1 COLOUR
SENSING
CIRCUIT
LEDs
GREEN LDR
POTENTIOMETER
Volta
BLUE LDR 41 RED LDR
Voltag
Volt
Voltage Com
Fig 4.8 Colour sensing circuit
It is the same principle in ALL Infra-Red proximity sensors. The basic idea is to send
infra red light through IR-LEDs, which is then reflected by any object in front of the
sensor.
Then all one have to do is to pick-up the reflected IR light. For detecting the reflected IR
light that was emitted from another led of the exact same type!
This is an electrical property of Light Emitting Diodes (LEDs) which is the fact that a led
Produce a voltage difference across its leads when it is subjected to light(Fig 4.9). As if it
was a photo-cell,
but with much lower
output current. In
other words, the
voltage generated by
the leds can't be - in
any way - used to
generate electrical
power from light, It
can barely be
detected.
42
that's why as one will notice in the schematic, Op-Amp (operational Amplifier) will
accurately detect very small voltage changes. Both the sender and the receiver are
constructed on the same board.
The sender is composed of an IR LED (D2) in series with a 470 Ohm resistor, yielding
a forward current of 7.5 mA.
The receiver part is more complicated, the 2 resistors R5 and R6 form a voltage divider
which provides 2.5V at the anode of the IR LED (here, this led will be used as a sensor).
When IR light falls on the LED (D1), the voltage drop increases, the cathode's voltage of
D1 may go as low as 1.4V or more, depending on the light intensity. This voltage drop
can be detected using an Op-Amp (operational Amplifier LM358). One will have to
adjust the variable resistor (POT.) R8 so the the voltage at the positive input of the Op-
Amp (pin No. 5) would be somewhere near 1.6 Volt. if one understand the functioning of
Op-Amps, one will notice that the output will go High when the volt at the cathode of D1
drops under 1.6. So the output will be High when IR light is detected, which is the
purpose of the receiver(Fig 4.10).
43
Fig 4.10 I.R. Sensor
The op-amp has 2 input, the +ve input, and the -ve input. If the +ve input's voltage is
higher than the -ve input's voltage, the output goes High (5v, given the supply voltage in
the schematic), otherwise, if the +ve input's voltage is lower than the -ve input's voltage,
then the output of the Op-Amp goes to Low (0V). It doesn't matter how big is the
difference between the +ve and -ve inputs, even a 0.0001 volts difference will be
detected, and the the output will swing to 0v or 5v according to which input has a higher
voltage.
All objects above absolute zero emit energy in the form of radiation. Usually
infrared radiation is invisible to the human eye but can be detected by electronic devices
designed for such a purpose. The term passive in this instance means that the PIR device
does not emit an infrared beam but merely passively accepts incoming infrared radiation.
“Infra” meaning below the ability to detect it visually, and “Red” because this colour
represents the lowest energy level that ones eyes can sense before it becomes invisible.
44
Thus, infrared means below the energy level of the colour red, and applies to many
sources of invisible energy.
This sensor can be used for most indoor applications where no important ambient
light is present. For simplicity, this sensor doesn't provide ambient light immunity, but a
more complicated, ambient light ignoring sensor should be discussed in a coming article.
However, this sensor can be used to measure the speed of object moving at a very high
speed, like in industry or in tachometers. In such applications, ambient light ignoring
sensor, which rely on sending 40 Khz pulsed signals cannot be used because there are
time gaps between the pulses where the sensor is 'blind'...
The solution proposed doesn't contain any special components, like photo-diodes,
photo-transistors, or IR receiver ICs, only a couple if IR leds, an Op amp, a transistor and
a couple of resistors (Fig. 4.11). In need, as the title says, a standard IR led is used for the
purpose of detection. Due to that fact, the circuit is extremely simple, and any novice
electronics hobbyist can easily understand and build it.
45
4.6 VOLTAGE CONVERTOR CIRCUIT
Many electronic devices, from computers to TVs to cell phone chargers, require
various DC (direct current) voltages to supply power to their circuitry. For those
appliances and devices that get their power by plugging them into an electrical wall
outlet, a circuit must be designed to convert the 120 volt AC power to a desired DC
voltage.
46
voltage through. Thus, the "output" on the cathode side of the diode will always be
positive. While this simple "rectifier" or "AC to DC converter" circuit helps explain how
a diode works as a rectifier, the circuit only recovers half of the AC voltage cycle. Also,
although the circuit's output is only positive, there is no output during the negative half of
the input cycle.
Connect two diodes to the output of a transformer that has a "center tap" such that
both the positive and negative part of the AC cycle are converted. Often, a step-down
transformer is used to change the 120 volts from the wall outlet down to a voltage needed
by the device. Transformers and diode combinations are used in "wall warts" or power
adaptors, many of which are probably around your home for cell phone chargers and
phone answer machines. In a two-diode configuration, connect the anode end of a diode
on one leg of the transformer and also connect the anode end of a second diode to the
other transformer leg. The transformer must have a "center tap" connection. This will be
the "ground" or negative connection. Connect the cathode end of both diodes together.
This will be the positive DC output connection.
Place an electrolytic capacitor across the DC output of the rectifier circuit --using
either the two-diode or four-diode configuration--to further smooth out the DC voltage
created by the full wave rectifier. Observe the polarity of the capacitor, connecting the
positive end to the positive output of the rectifier circuit, and the negative end to the
ground, or minus, connection--which is the transformer's center tap in the case of a bridge
rectifier. The voltage rating on the capacitor must be higher than the DC output voltage--
with no "load" connected. Formulas have been devised to calculate the best capacitance
value, but generally, a large capacitor value will reduce ripple significantly. Start by
experimenting with a value of 100 microfarads for a circuit with a 12 volt output. An
oscilloscope can be used to see the effect of a capacitor on ripple smoothing. Figure 4.12
shows voltage convertor circuit which converts 220V to 35V.
47
Fig 4.12 Voltage convertor circuit
48
CHAPTER 5
$MOD51
49
START_SW BIT P0.0
;.......................................................................................
ORG 00H
JMP START
ORG 030H
START:
MOV P1,#0FFH
MOV P3,#0FFH
MOV P2,#00H
MOV P0,#0FFH
N4: JB CONVEYOR_SW,N5
CPL CONVEYOR
50
N5: JB SHOULDER_DN_SW,N6
CALL SHOULDER_DOWN
N6: JB SHOULDER_UP_SW,N7
CALL SHOULDER_UP
N7: JB GRIPPER_OPEN_SW,N8
CALL GRIPPER_OPEN
N8: JB GRIPPER_CLOSE_SW,N9
CALL GRIPPER_CLOSE
N9: JB T_TABLE_SW_L,N10
CALL TURNTABLE_LEFT
N10: JB T_TABLE_SW_R,N11
CALL TURNTABLE_RIGHT
N11: JB START_SW,N12
CALL DELAY2
CALL DELAY2
CALL AUTOMATION
51
N12: CALL DEBOUNCE
JMP N4
;...............................................................
DEBOUNCE:
MOV R1,#20
DJNZ R2,$
DJNZ R1,K1
RET
;..............................................................
TURNTABLE_RIGHT:
SETB TURNTABLE_A
CLR TURNTABLE_B
JNB T_TABLE_SW_R,$
CALL STOP
RET
;..............................................................
TURNTABLE_LEFT:
CLR TURNTABLE_A
SETB TURNTABLE_B
JNB T_TABLE_SW_L,$
CALL STOP
RET
52
;..............................................................
SHOULDER_UP:
SETB SHOULDER_A
CLR SHOULDER_B
JNB SHOULDER_UP_SW,$
CALL STOP
RET
;................................................................
SHOULDER_DOWN:
CLR SHOULDER_A
SETB SHOULDER_B
JNB SHOULDER_DN_SW,$
CALL STOP
RET
;...............................................................
GRIPPER_OPEN:
SETB GRIPPER_A
CLR GRIPPER_B
JNB GRIPPER_OPEN_SW,$
CALL STOP
RET
;...............................................................
53
GRIPPER_CLOSE:
CLR GRIPPER_A
SETB GRIPPER_B
JNB GRIPPER_CLOSE_SW,$
CALL STOP
RET
;...............................................................
STOP:
MOV P2,#00
RET
;...............................................................
AUTOMATION:
call pos1
call pos2
call pos3
J4: JB START_SW,J1
54
call delay2
call delay2
call delay2
RET
;.............................................
DOWN_FUNCTION:
CALL SHOULDER_DOWN2
CALL DELAY2
CALL DELAY2
CALL DELAY2
JB Y_SENSOR,$
CALL STOP
CALL DELAY2
RET
;..........................................
UP_FUNCTION:
CALL SHOULDER_UP2
CALL DELAY2
CALL DELAY2
CALL DELAY2
JB Y_SENSOR,$
CALL STOP
RET
55
;.........................................
X_LEFT_FUNCTION:
CALL TURNTABLE_LEFT2
CALL DELAY2
CALL DELAY2
CALL DELAY2
CALL DELAY2
JB X_SENSOR,$
CALL STOP
RET
;........................................................................
X_RIGHT_FUNCTION:
CALL TURNTABLE_RIGHT2
CALL DELAY2
CALL DELAY2
CALL DELAY2
CALL DELAY2
JB X_SENSOR,$
CALL STOP
RET
;........................................................................
SHOULDER_DOWN2:
SETB SHOULDER_A
56
CLR SHOULDER_B
RET
;................................................................
SHOULDER_UP2:
CLR SHOULDER_A
SETB SHOULDER_B
RET
;...............................................................
GRIPPER_OPEN2:
SETB GRIPPER_A
CLR GRIPPER_B
CALL DELAY2
CALL DELAY2
CALL DELAY2
CALL DELAY2
CALL STOP
RET
;...............................................................
GRIPPER_CLOSE2:
CLR GRIPPER_A
SETB GRIPPER_B
CALL DELAY2
CALL DELAY2
57
CALL DELAY2
CALL DELAY2
CALL STOP
RET
;...............................................................
TURNTABLE_RIGHT2:
SETB TURNTABLE_A
CLR TURNTABLE_B
RET
;..............................................................
TURNTABLE_LEFT2:
CLR TURNTABLE_A
SETB TURNTABLE_B
RET
;..............................................................
DELAY2:
MOV R1,#2
KK11:MOV R2,#250
KK12:MOV R3,#250
DJNZ R3,$
DJNZ R2,KK12
DJNZ R1,KK11
RET
58
;............................................................
djnz r7,bk1
call gripper_close2
call up_function
call x_left_function
call down_function
call gripper_open2
call up_function
call x_right_function
call down_function
ret
;..............................................................
pos2:
mov r7,#10
djnz r7,bk2
call gripper_close2
call up_function
call x_right_function
call down_function
call gripper_open2
59
call up_function
call x_left_function
call down_function
ret
;................................................................
djnz r7,bk3
call gripper_close2
call up_function
call x_right_function
call x_right_function
call down_function
call gripper_open2
call up_function
call x_left_function
call x_left_function
call down_function
ret
;................................................................
END
60
CHAPTER 6
FUTURE WORKS
This project involves the sorting of objects through colour sensors the future
advancements can be done by increasing the efficiency of the colour sensor. The sensor is
key component of project which aides in distinguishing the objects. Failing of which may
result in wrong material handling. Thus it becomes vital that the sensor had a very high
sense of sensitivity and ability to distinguish between colours.
61
access to real robotic and automation (R&A) equipment from the Matlab shell. If used in
conjunction with a robotics toolbox it will extend significantly their application, i.e.,
besides robotic simulation and data analysis the user can interact on-line with the
equipment. Personal experience with this tool shows its usefulness for research
applications, but also for teaching projects. With students, using Matlab means taking
advantage of the reduced training required to start using it, if compare with other
programming environments and languages that can also be used (Microsoft Visual C++
or Visual Basic).
Existing sorting method uses a set of inductive, capacitive and optical sensors do
differentiate object colour. Advanced mechatronics colour sorting system solution with
the application of image processing. Supported by OpenCV, image processing procedure
senses the circular objects in an image captured in realtime by a webcam and then
extracts colour and position information out of it. This information is passed as a
sequence of sorting commands to the manipulator that does pick-and-place mechanism.
Extensive testing proves that this colour based object sorting system works 100%
accurate under ideal condition in term of adequate illumination, circular objects’ shape
and colour. The circular objects tested for sorting are silver, red and black. For non-ideal
condition, such as unspecified colour the accuracy reduces to 80%.
62
CHAPTER 7
CONCLUSION
The project works successfully and separates different coloured objects using
colour sensor. The colour sensor result was converted chiefly to the command that drive
the handling systems which drive the pick and place robot to pick up the object and place
it into its designated place. There are two main steps in colour sensing part, objects
detection and colour recognition. The system has successfully performed handling station
task, namely pick and place mechanism with help of colour sensor.
Thus a cost effective Mechatronics system was designed using the simplest
concepts and efficient result was being observed. This system is a depicting the prototype
of sorting systems which are used in industries.
63
CHAPTER 8
REFERENCES
[1] Tsalidis, S., S., Dentsoras, A., J., “Application of design parameters space search for
belt conveyor design” Journal of Plant Science, Vol. 10, No. 6, pp. 617-629, 2010.
[2]. Huang, T, Wang, P.F., Mei, J.P., Zhao, X.M.,“Time Minimum Trajectory Planning of
a 2-DOF Translational Parallel Robot for Pick-and-place Operations” IEEE Computer
Magazine, Vol. 56, No. 10, pp. 365-368, 2007.
[3]Sahu, S., Lenka, P.; Kumari, S.; Sahu, K.B.; Mallick, B.; “Design a colour sensor:
Application to robot handling radiation work”, Industrial. Engineering, Vol. 11, No. 3,
pp. 77-78, 2010.
[4]. Khojastehnazhand, M., Omid, M., and Tabatabaeefar, A., “Development of a lemon
sorting system based on colour and size” Journal of Plant Science, Vol. 4, No. 4, pp. 122-
127, 2010.
64
CHAPTER 9
APPENDIX
TOPIC PAGE
NO.
• METHODOLOGY
Fig. 2.1
6
• CONVEYOR SYSTEM
Fig 3.1 16
• ROBOTIC ARM
Fig3.2 19
• GRIPPER
Fig 3.3 20
• ELECTRONIC MODULE
Fig 4.1 21
Fig 4.2 23
• RELAY CIRCUIT
Fig 4.3 26
Fig 4.4 27
• COLOUR SENSOR
Fig 4.5 28
65
• LED BASED LDR SENSOR
Fig 4.6 29
Fig 4.7 31
Fig 4.8 32
Fig 4.8 33
Fig 4.10 34
Fig 4.11 36
Fig 4.12 38
66