i COLOR SORTING SYSTEM WITH ROBOT ARM
YEOW KHANG YUNG
i SMART COLOR SORTING ROBOT
YEOW KHANG YUNG
This report is submitted in partial fulfillment of the requirements for the award of the Bachelor of Electronic Engineering (Wireless Communication)
Faculty of Electronic and Computer Engineering University Technical Malaysia Melaka
ii UNIVERSTI TEKNIKAL MALAYSIA MELAKA
FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER
BORANG PENGESAHAN STATUS LAPORAN
PROJEK SARJANA MUDA II
Tajuk Projek : ………
Sesi
Pengajian :
Saya ……….. (HURUF BESAR)
mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.
2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi
pengajian tinggi.
4. Sila tandakan ( ) :
SULIT*
*(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)
TERHAD** **(Mengandungi maklumat terhad yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
__________________________ ___________________________________
iii “I hereby declare that this report is the result of my own except for quotes as cited in
the references”
Signature :
Author : Yeow Khang Yung
iv “I hereby declare that I have read this report and in my opinions this report is sufficient in terms of the scope and quality for the award of Bachelor of Electronic
Engineering (Wireless Communication)”
Signature :
Author : Madam Nurmala Irdawaty Binti Hassan
v ACKNOWLEDGEMENT
First and foremost, I would like to express my most sincere gratitude to my supervisor, Madam Nurmala Irdawaty Binti Hassan for her guidance, support and encouragement throughout this project. Her vast experience and deep knowledge of the subject proved to be immense help to me. Without her endless support and motivation, this project definitely cannot be done.
Secondly, I would like to say thanks to my parents for their support and understanding in allowing me to focus my attention to this project. They have always been the driving force in pushing us to excel in everything that I do.
Besides that, many thanks are given to my fellow course mates and friends, who have gave me support physically or mentally in which their assistance helped me along the way. I am very grateful for their support, endurance, inspiring spirit and patience they had given throughout my study.
vi ABSTRACT
vii ABSTRAK
viii TABLE OF CONTENTS
CHAPTER TITLE PAGE
TITLE OF PROJECT i
STATUS CONFIRMATION FORM ii
DECLARATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS viii
LIST OF FIGURES ix
LIST OF ABBREVIATION x
LIST OF APPENDICES xi
I INTRODUCTION 1
1.1 Project Background 1
1.2 Objectives 3
1.3 Scope of Work 3
1.4 Problem Statement 4
1.5 Significant of Project 5
1.6 Report Structure 6
ix 2.1 Programmable Interface Controller (PIC) 7
2.2 Infra Red Sensor 12
2.3 Servo motor 14
2.4 Transistor 18
2.5 Voltage Regulator 20
2.6 Color Sensor 21
2.7 C Programming Language 26
2.8 C Language Complier 27
III METHODOLOGY 28
3.1 Project Methodology 29
3.2 The flow chart of project 30
3.3 Apparatus used in the project 31
3.3.1 Enhanced 40 pins PIC start-up kit 31
3.3.2 Complier and Programmer 32
IV RESULT AND DISCUSSION 34
4.1 Result 35
4.1.1 The Overall Colour Sorting System 35
4.1.2 The PIC16F877A Circuit Board 36
4.1.3 The Robot Arm 39
4.1.4 The Control Panel 41
4.1.5 The Manual Controller 42
4.1.6 The C Programming of the System 44
x
V CONCLUSION AND RECOMMENDATION 52
5.1 Conclusion 52
5.2 Recommendation 53
REFERENCES 54
xi LIST OF FIGURES
NO TITLE PAGE
Figure 1.1 The Overview of the Color Sorting System 2
Figure 2.1 The Different Shape, Size and Type of PIC Chip 8
Figure 2.2 The Basic Microcontroller Architecture Inside a PIC Chip.
9
Figure 2.3 The Electronic Circuit Board for PIC Microcontroller. 9
Figure 2 4 PIC16F877A With Rectangular Shape and 40 DIP Type Pin
10
Figure 2.5 The Function of Each 40 Pins of PIC16F877A 11
Figure 2.6 The Features of PIC16F877A. 11
Figure 2.2.1 The Frequency Spectrum 12
Figure 2.2.2 The Infrared Modulated at 36kHz. 13
Figure 2.2.3 The Modulated Infrared Demodulated At Receiver. 13
Figure 2.2.4 The Schematic Circuit for the Infrared Sensor 13
Figure 2.2.5 The Typical Example of Infrared Component 14
Figure 2.3.1 The Typical Servo Motor. 16
xii Figure 2.3.3 The Block Diagram for Typical Servo Motor 17
Figure 2.3.4 Servo Motor postion and the control signal. 17
Figure 2.4.1 The schemetic for NPN and PNP transistor. 18
Figure 2.4.2 The Transistor Act As Electronic Switch. 19
Figure 2.4.3 The I-V Graph For A Transistor. 19
Figure 2.5.1 The LM7805 Voltage Regulator. 20
Figure 2.6.1 The Operation of Photoresistor 22
Figure 2.6.2 The Photoresistor 22
Figure 2.6.3 The Installation of the LED on the Breadboard 23
Figure 2.6.4 The Surface of the Object Reflect the Light Incident on it. 24
Figure 2.6.5 The Blue Surface Will Reflect More Blue Light 24
Figure 2.7.1 The Trademark Logo for CCS C Compiler 26
Figure 3.3.1.1 The SK40C Enhanced 40 Pins PIC Start-up Kit 31
Figure 3.3.1.2 The Solder SK40C on the breadboard 32
Figure 3.3.2.1 The screenshot of CCS C Compiler 33
Figure 3.3.2.2 The UIC00A USB ICSP PIC Programmer 33
Figure 4.1.1.1 The Overall Colour Sorting System with Robot Arm. 35
Figure 4.1.2.1 The Schematics of the Circuit 36
Figure 4.1.2.2 The PCB Layout Of the Circuit. 37
Figure 4.1.2.3 The 3D Visualization Of The PCB Circuit. 37
Figure 4.1.2.4 The Final Real Circuit Board. 38
xiii
Figure 4.1.3.2 The Robot Arm Moving Up And Down. 40
Figure 4.1.3.3 The Robot Gripper Open and Close. 40
Figure 4.1.4.1 The Control Panel. 41
Figure 4.1.5.1 The Manual Controller. 42
Figure 4.1.5.2 The Input Codes And The Description. 43
xiv LIST OF TABLES
NO TITLE PAGE
Table 2.5.1 The LM Series Voltage Regulator And The Ouput Voltage.
20
1 CHAPTER I
INTRODUCTION
This chapter will briefly discuss on the project overview. The objective, scope, and thesis outline will be presented in this chapter.
1.1 Project Background
Color Sorting System with Robot Arm is based on the placing system with some capability to decide the object according to their color. The object will be defined by determining color of the object while the system will figure which location the object should be located. This system use Programmable Interface Controller (PIC) to control the whole system.
There are four main parts in this system: robot arm
ball tower color sensor
ball collection station
2 differentiating station consists of a Light Dependent Resistor (LDR) which will detect the light reflected by the object. By comparing the reflected light value with the calibrated value stored in the PIC data base, the PIC controller will process the data and determine the color of the object.
After determining the color of the object, the gripper of the system will pick up the ball and move it to the desire color station. There are four three color station in this system, there are red station, green station, and blue station. Depending on the color of the object, the gripper will move the object to the correct destination and place the object inside that station.
Figure 1.1: The Overview of the Color Sorting System
The operation of whole system is as below:
1. The ball tower detects the existence of the ball.
2. The robot arm move it gripper to that ball and pickup the ball. 3. The robot arm sends the ball to the color sensor station. 4. The color sensor station will determine the color of the ball.
5. The robot arm will move the ball to appropriate ball collection station based on the result produce by color sensor station.
3 1.2 OBJECTIVE
This project is developed with the purposed to optimizing the productivity, minimizing the cost of the project and make no human mistakes. The main thing of this project is to study how to use the programming language to communicate with the PIC controller. After determining the color of the object, the robot arm system will make its own decision to the station that been programmed. The objective can be summarized as below:
i. To sort the object according to their color.
ii. To sort the object to the station accordingly.
iii. To make the system run continuously with less rest.
iv. To make an interface between the programming of robot arm and the sensors.
v. To make the robot’s gripper has the function of pick and place.
vi. To make the robot capable to stop at the desire location accurately.
1.3 SCOPE OF PROJECT
This project is subjected to several scope and limitations that are narrowed down to the study. There are a few scopes and guidelines listed to ensure the project is conducted within its intended boundary. This is to ensure the project is heading in the right direction to achieve its intended objectives. The objectives are:
i. Research and study on the Programmable Intelligence Computer, PIC16F876A microcontroller and the control system of the circuit. ii. Research and study on C programming language to communicate with the
microcontroller.
iii. Research and study on the Light Dependent Resistor for color sensor. iv. Research and study on the Infra Red transmitter and receiver for proximity
sensor.
4 vi. To fabricate a PCB circuit board for the overall system.
vii. To develop the program that can integrate and control the overall system. viii. To construct the model and test either the robot is function or not.
1.4 PROBLEM STATEMENT
The problems which often occurred in the industrial that can be solved by this project are:
i. The speed of color sorting process by an operator is very slow. This is due to the limitation of response time for a human eye. The eye will always take some time to see an image and project this to the brain to initiate visual sensation. After the brain has received the image, it will take some time for the brain to determine the color of the object too. However, this limitation can be covered by using a computer. In this project, a PIC microcontroller is used to increase the speed of color sorting.
ii. The accuracy of color sorting process by an operator is very slow. This is because an operator will need to handle hundred or thousand of object each day, they will feel boring and their eyes are tired after a long day working. It was a very common case for an operator to give wrong result. However, a machine will not have this problem. A machine will give accurate result even after it has repeated a process for billions of times. In this project, a PIC microcontroller was used to substitute the operator and thus increase the accuracy of color sorting
5 and cut-down the cost of process of color sorting. This project should overall optimize the productivity of an industrial
1.5 SIGNIFICATION OF THE PROJECT
i. This project will increase the speed of color sorting process.
ii. This project will increase the accuracy color sorting process.
iii. This project will cut-down the cost of color sorting process.
iv. This project will overall optimize the productivity of an industrial
v. This project will have a robot arm which can perform an action which is closer to human action.
1.6 REPORT STRUCTURE
Chapter one briefly introduces he overall of the project title Smart Color Sorting Robot. The introduction consists of overview, objective, problem statement, scope of work, methodology and structure report.
Meanwhile chapter two discuss the literature review about the Color Sorting System with Robot Arm. Literature review will produce overall structure of the system which shows the relationship between project research and theoretical concept.
Chapter three will explain about the project methodology. Project methodology give details about the method used to solve the problem to complete the project. The method used such as collecting data method, process and analysis data method, modeling and etc.
7 CHAPTER II
LITERATURE REVIEW
This chapter is to discuss some fundamental ideas of Color Sorting System with Robot Arm. The features of this project are also included. All components using for this project will be explain as well.
2.1 PROGRAMMABLE INTERFACE CONTROLLER (PIC)
Microcontrollers were introduced when the skills of the semiconductor industry allowed several functions such as CPU, memory and I/) to be integrated onto one piece of silicion [4].. The advantage of designing around a microcontroller is that a large amount of electronics needed for certain applications can be eliminated. This makes it the ideal device for use with mobile robots and other applications where computing power is needed. The microcontroller is popular because the chip can be reprogrammed easily to perform different functions, and is very inexpensive.
8 PICs are popular with both industrial developers and hobbyists a like due to:
low cost
wide availability large user base
extensive collection of application notes and diagrams availability of low cost or even free development tools serial programming capability
reprogrammable with flash memory
9 Figure 2.2: The Basic Microcontroller Architecture Inside a PIC Cchip.
Figure 2.3: The Electronic Ccircuit Board for PIC Microcontroller.
