This document is a lab report submitted by two students, B. Haridhar and G. Akhil, for their Bachelor of Technology degree. It describes the design of a pick and place robot for loading and packing lead battery cells. The report provides background on industrial robots and pick and place robots. It discusses the classification of robots, key components of pick and place robots like actuators and sensors, and how basic pick and place robot movement works through rotary joints. The overall aim is to analyze problems in automated battery loading and design a robot solution.

1. A
PROJECTBASED LAB REPORT
On
PICK AND PLACE ROBOT
Submitted in partial fulfilment of the
Requirements for the award of the Degree of
Bachelor of Technology
In
Electronic and Communications Engineering
BY
B.HARIDHAR(14004561 )
G.Akhil(14004337)
DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING
K L University
Green Fields, Vaddeswaram, Guntur District-522 502
2016-2017

2. K L University
DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING
(DST-FIST Sponsored Department)
This is to certify that this project based lab report entitled “PICK AND PLACE
ROBOT” is a bonafide work done by B.HARIDHAR (14004561)
G.AKhil(14004337)in partial fulfillment of the requirement for the award of degree
in BACHELOR OF TECHNOLOGY in Electronics and Communication
Engineering during the academic year 2015-2016.
Faculty In Charge Head of the Department
CERTIFICATE

3. K L University
DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING
(DST-FIST Sponsored Department)
We hereby declare that this project based lab report entitled “PICK AND
PLACE ROBOT” has been prepared by us in partial fulfillment of the
requirement for the award of degree“ BACHELOROF TECHNOLOGY in
ELECTRONICS AND COMMUNICATION ENGINEERING” during the
academic year 2015-2016.
I also declare that this project based lab report is of our own effort and it has
not been submitted to any other university for the award of any degree.
Date:
B.HARIDHAR(14004561)
G.Akhil(14004337)
DECLARATION

4. Abstract
Mankind has always strived to give life like qualities to its artefacts in an
attempt to find substitutes for himself to carry out his orders and also to work
in a hostile environment. The popular concept of a robot is of a machine that
looks and works like a human being.
The industry is moving from current state of automation to Robotization, to
increase productivity and to deliver uniform quality. The industrial robots of
today may not look the least bit like a human being although all the research is
directed to provide more and more anthropomorphic and humanlike features
and super-human capabilities in these.
One type of robot commonly used in industry is a robotic manipulator or
simply a robotic arm. It is an open or closed kinematic chain of rigid links
interconnected by movable joints. In some configurations, links can be
considered to correspond to human anatomy as waist, upper arm and forearm
with joint at shoulder and elbow. At end of arm a wrist joint connects an end
effectors which may be a tool and its fixture or a gripper or any other device
to work.
Here how a pick and place robot can be designed for a workstation where
loading and packing of lead batteries is been presented. All the various
problems and obstructions for the loading process has been deeply analyzed
and been taken into consideration while designing the pick and place robot.

5. Introduction
Robotics is the branch of engineering science & Technology related to robots,
and their design, manufacture, application, and structural disposition. Robotics
is related to electronics, mechanics, and software. Robotics research today is
focused on developing systems that exhibit modularity, flexibility,
redundancy, fault-tolerance, a general and extensible software environment
and seamless connectivity to other machines, some researchers focus on
completely automating a manufacturing process or a task, by providing sensor
based intelligence to the robot arm, while others try to solidify the analytical
foundations on which many of the basic concepts in robotics are built.
In this highly developing society time and man power are critical constrains
for completion of task in large scales. The automation is playing important
role to save human efforts in most of the regular and frequently carried works.
One of the major and most commonly performed works is picking and placing
of jobs from source to destination.
Present day industry is increasingly turning towards computer-based
automation mainly due to the need for increased productivity and delivery of
end products with uniform quality. The inflexibility and generally high cost of
hard-automation systems, which have been used for automated manufacturing
tasks in the past, have led to a broad based interest in the use of robots capable
of performing a variety of manufacturing functions in a flexible environment
and at lower costs. The use of Industrial Robots characterizes some of
contemporary trends in automation of the manufacturing process. However,
present day industrial robots also exhibit a monolithic mechanical structure
and closed-system software architecture. They are concentrated on simple
repetitive tasks, which tend not to require high precision. The pick and place
robot is a microcontroller based mechatronic system that detects the object,
picks that object from source location and places at desired location. For
detection of object, infrared sensors are used which detect presence of object
as the transmitter to receiver path for infrared sensor is interrupted by placed
object.

6. Classification Of Robot
Industrial robots are found in a variety of locations including the automobile
and manufacturing industries. Robots cut and shape fabricated parts, assemble
machinery and inspect manufactured parts. Some types of jobs robots do: load
bricks, die cast, drill, fasten, forge, make glass, grind, heat treat, load/unload
machines, machine parts, handle parts, measure, monitor radiation, run nuts,
sort parts, clean parts, profile objects, perform quality control, rivet, sand
blast, change tools and weld. Outside the manufacturing world robots perform
other important jobs. They can be found in hazardous duty service,
CAD/CAM design and prototyping, maintenance jobs, fighting fires, medical
applications, military warfare and on the farm.
TYPES OF ROBOTS AS PER APPLICATIONS:
Nowadays, robots do a lot of different tasks in many fields. And this number
of jobs entrusted to robots is growing steadily. That's why one of the best
ways how to divide robots into types is a division by their application.
INDUSTRIAL ROBOTS: Robots today are being utilized in a wide variety of
industrial applications. Any job that involves repetitiveness, accuracy,
endurance, speed, and reliability can be done much better by robots, which is
why many industrial jobs that used to be done by humans are increasingly
being done by robots.
MOBILE ROBOTS: Also known as Automated Guided Vehicles, or AGVs, these
are used for transporting material over large sized places like hospitals,

7. container ports, and warehouses, using wires or markers placed in the floor, or
lasers, or vision, to sense the environment they operate in. An advanced form
of the AGV is the SGV, or the Self Guided Vehicle, like PatrolBot Gofer,
Tug, and Specie-Minder, which can be taught to autonomously navigate
within a space.
AGRICULTURE ROBOTS: Although the idea of robots planting seeds, ploughing
fields, and gathering the harvest may seem straight out of a futuristic science
fiction book, nevertheless there are several robots in the experimental stages
of being used for agricultural purposes, such as robots that can pick apples.
TELEROBOTS: These robots are used in places that are hazardous to humans,
or are inaccessible or far away. A human operator located at a distance from a
telerobot controls its action, which was accomplished with the arm of the
space shuttle. Telerobots are also useful in nuclear power plants where they,
instead of humans, can handle hazardous material or undertake operations
potentially harmful for humans.
SERVICE ROBOTS: The Japanese are in the forefront in these types of robots.
Essentially, this category comprises of any robot that is used outside an
industrial facility, although they can be sub-divided into two main types of
robots: one, robots used for professional jobs, and the second, robots used for
personal use. Amongst the former type are the above mentioned robots used
for military use, and then there are robots that are used for underwater jobs, or
robots used for cleaning hazardous waste, and the like.

8. Parts of a Pick N Place Robot
Let us see what the pick and place robot actually consists of
A Rover: It is the main body of the robot consisting of several rigid bodies
like a cylinder or a sphere, joints and links. It is also known as a manipulator.
End Effector: It is the body connected to the last joint of the rover which is
used for the purpose of gripping or handling objects. It can be an analogy to
the arm of a human being.
Actuators: They are the drivers of the robot. It actually actuates the robot. It
can be any motor like servo motor, stepper motor or pneumatic or hydraulic
cylinders.
Sensors: They are used to sense the internal as well as the external state to
make sure the robot functions smoothly as a whole. Sensors involve touch
sensors, IR sensor etc.
Controller: It is used to control the actuators based on the sensor feedback
and thus control the motion of each and every joint and eventually the
movement of the end effector.

9. Working of a Basic Pick N Place Robot
The basic function of a pick and place robot is done by its joints. Joints are
analogous to human joints and are used to join the two consecutive rigid
bodies in the robot. They can be rotary joint or linear joint. To add a joint to
any link of a robot, we need to know about the degrees of freedom and
degrees of movement for that body part. Degrees of freedom implement the
linear and rotational movement of the body and Degrees of movement imply
the number of axis the body can move.
A simple pick and place robot consists of two rigid bodies on a moving base,
connected together with rotary joint. A rotary joint is a one which provides
rotation in 360 degrees around any one of the axes.
 The bottom or the base is attached with wheels which provide linear
movement.
 The 1st rigid body is fixed and supports the second rigid body to
which the end effector is provided.
 The 2nd rigid body is provided with movement in all 3 axes and has 3
degrees of freedom. It is connected to the 1st body with a rotational
joint.

10.  The end effector should accommodate all 6 degrees of freedom, in
order to reach all sides of the component, to take up position to any
height.
On a whole, the basic pick and place robot works as follows:
 The wheels underneath the base help to move the robot to the desired
location.
 The rigid body supporting the end effector bends or straightens up to
reach the position where the object is placed.
 The end effector picks up the object with a strong grip and places it at
the desired position.
Now that we have got a brief idea of the pick and place robot, the basic
question is how it is actually controlled. A simple pick and place robot can be
controlled by controlling the movement of its end effector. The motion can be
using hydraulic motion, i.e. using hydraulic fluid under pressure to the drive
the robot, or using pneumatic motion, i.e. using pressurized air to cause
mechanical motion. However the most effective way is using motors to
provide the required motion. The motors have to be controlled in order to
provide required motion to the robot and the end effector.
Working Example of Controlling a Pick N Place Robot
How about controlling the robot with a just a few buttons on the keypad? Yes,
it is possible! Just pressing the required button, we can transmit command to
the robot to make it move in any direction to achieve our task. Moreover this
can be achieved using simple wireless communication.
Let’s see how this actually works:
The transmitter part consists of the keypad interfaced to the microcontroller.
Any button number in decimal format is converted to 4 digit binary by the
microcontroller and the parallel output at one of its port is applied to the
encoder. The encoder converts this parallel data to serial data and this is fed to
the transmitter, fitted with an antenna to transmit the serial data.

11. The receiver side consists of a decoder interfaced to the microcontroller. The
decoder converts the received command in serial format to the parallel form
and gives this data to the microcontroller. Based on this command the
microcontroller sends the appropriate input signals to the motor drivers to
drive the respective motors.

12. The system consists of two motors for providing motion to the whole robot
and two other motors to provide the arm motion. The end effector or the
gripper needs to be controlled to apply proper pressure on the object to handle
it effetely, to give it a soft grip. This is ensured by controlling the arm motors
through proper command. The output from the arm motors is connected to a
10Ohms/2W resistor and at the time of motor over load or locked condition, a
high voltage is developed across the resistor, which causes a logic high level
at the output of the opt isolator and the interrupt pin of the microcontroller
connected to the opt isolator output through a pnp transistor gets logic low
signal, which halts all other operations of the gripper.
Practical Applications of Pick and Place Robot
Defence Applications: It can be used for surveillance and also to pick up
harmful objects like bombs and diffuse them safely.
Industrial Applications: These robots are used in manufacturing, to pick up
the required parts and place it in correct position to complete the machinery
fixture. It can be also used to place objects on the conveyer belt as well as
pick up defective products from the conveyer belt.
Medical Applications: These robots can be used in various surgical
operations like in joint replacement operations, orthopedic and internal
surgery operations. It performs the operations with more precision and
accuracy.
Advantages
 Reducing man power
 Fast production
 Time management
 Reducing damages for objects
 They are accurate.
 They increase the safety of the working environment and actually
never get tired