1 PROJECT REPORT ON MICROCONTROLLER BASED HUMANOID ARM Submitted in partial fulfilment of the requirements for the award of the degree Of BACHELOR OF TECHNOLOGY In MECHANICAL ENGINEERING By MUTHAMIZH SELVAN. A (1020940099) NITHIN KUMAR. D (1020940106) SRIRAM. R (1020940168) Under the guidance of Mr E. THAMBIRAN, M.E (Asst. Professor (Sr.G), School of Mechanical Engineering) FACULTY OF ENGINEERING AND TECHNOLOGY SRM UNIVERSITY (Under section 3 of UGC Act, 1956) Ramapuram Campus - Part, Vadapalani Chennai - 600 026 APRIL-2013
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1
PROJECT REPORT
ON
MICROCONTROLLER BASED HUMANOID ARM
Submitted in partial fulfilment of the requirements
for the award of the degree Of
BACHELOR OF TECHNOLOGY In
MECHANICAL ENGINEERING By
MUTHAMIZH SELVAN. A (1020940099)
NITHIN KUMAR. D (1020940106)
SRIRAM. R (1020940168)
Under the guidance of
Mr E. THAMBIRAN, M.E
(Asst. Professor (Sr.G), School of Mechanical Engineering)
FACULTY OF ENGINEERING AND TECHNOLOGY
SRM UNIVERSITY (Under section 3 of UGC Act, 1956)
Ramapuram Campus - Part, Vadapalani
Chennai - 600 026
APRIL-2013
2
BONAFIDE CERTIFICATE
Certified that the project report entitled “MICROCONTROLLER BASED
HUMANOID ARM” Submitted by “MUTHAMIZH SELVAN. A (1020940099),
NITHIN KUMAR. D(1020940106), SRIRAM. R (1020940168)” is a record of
project work done by them under my supervision towards the partial fulfilment of the
requirements for the award of the degree of Bachelor of Technology in Mechanical
engineering in SRM University, Chennai during the year 2012-2013. This project has
not formed the basis for the award of any degree, diploma, associate ship or
fellowship.
Mr E. THAMBIRAN Prof.C.K.LAKSHMYNARAYANAN
PROJECT GUIDE HOD
MECHANICAL ENGINEERING MECHANICAL ENGINEERING
Internal Examiner External Examiner
3
DECLARATION
I do hereby declare that the project report entitled “MICROCONTROLLER BASED
HUMANOID ARM” is a record of original work carried out by MUTHAMIZH
SELVAN. A (1020940099), NITHIN KUMAR. D (1020940106), SRIRAM. R
(1020940168) under the supervision of Mr E. THAMBIRAN, Asst. Professor,
department of Mechanical Engineering, SRM
UNIVERSITY, RAMAPURAM PART – VADAPALANI. This project has not been
submitted earlier in part or full for the award of any degree, diploma, associate ship or
fellowship.
MUTHAMIZH SELVAN. A
NITHIN KUMAR. D
DATE: SRIRAM. R
4
ACKNOWLEGDEMENT
This final year project was the result of the thought process combined with hard work of
not just us, but a group of other people. This thesis would be incomplete without
expressing our heartfelt gratitude to them.
First and foremost we want to thank god or enabling us to complete our project in the
required time. We are extremely grateful to our beloved Dr.R.PACHAMUTHU
(Chancellor, SRM University) for providing us with the quality infrastructure and lab
facilities.
We choose this moment to thank our Dean Dr.N.VASUDEVAN, B.E., M.TECH., PhD
for the support he has rendered throughout OUR educational experience in SRM
University City campus.
We are grateful to our Head of the department Prof.C.K. LAKSHMI NARAYANAN,
B.Sc.Engg., M.E,(Head Of The Department) for his invaluable guidance, motivation,
timely and insightful technical discussions. We are immensely grateful for his constant
encouragement, smooth approach throughout our project and make this work possible.
We wish to express our heartfelt thanks to our guide Asst.Prof .E. THAMBIRAN M.E,
for guiding us in this endeavour throughout the project. We are deeply indebted to him for
his unconditional support and thorough guidance.
Our Sincere thanks to Asst.Prof.E. SANKAR, M.E, (Project Coordinator) who shared
his valuable information that helped in the successful completion of this project.
We also express our sincere thanks to Mr SANTHOSH Diploma in A.M.I.E, technical
assistant, Automation laboratories helping and rendering his valuable help to us in our
research.
We are very grateful to Mr PRAKASH (Simple Labs) and Mr BASKAR (Mercy
Electronics) for dealership of all the required components for this project at a reasonable
price and also for his whole hearted support during the entire project.
We also take this opportunity to thank all our colleagues and other teaching faculty, whose
valuable suggestion and motivation, without which we could never have completed this
work.
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ABSTRACT
This Paper gives a clear-cut idea about design, manufacturing, theory and application of
Humanoid Robotic Hand. The task was to develop a prototype of a Wireless operated -
Humanoid hand, This Five-Fingered Humanoid hand has the capability of replicating
complex actions of an actual human hand operated from distance of up to 300-400 ft in
the line of sight outdoor and 100ft indoors.
The focus of this thesis within the project lied on to improve the function and wireless
application of the robotic hand. From Mechanical point of view and interest in addition
to the control system, a Conceptual design & 3D-Model should be developed and NX-
CAM code for milling the prototype has to be generated.
Simultaneously a developing the control interface of the hand glove using Flexible
sensor and Arduino Uno was also made. To reduce the cost of the hand, working model
was made as simple as possible. To keep the manufacturing costs down is also an
important issue developing the new Prototype. Several different concepts where analysed
before the final Prototype was built. To designing and rendering the hand Solid Works
was used. CAM codes were generated using NX-CAM. This project revolves around
applications from subjects such as Mechatronics, Fluid Power Control and Engineering
Design etc…. from our undergraduate study.
6
TABLE OF CONTENT
CHAPTER TITLE PAGE No.
NUMBER
1 INTRODUCTION 8
1.1 ABOUT OUR PROJECT 8
1.2 ROBOTICS 9
1.3 BIO INSPIRED TECHNOLOGY 9
1.4 STUDY ON HUMAN HAND 10
1.5 HUMANOID HAND 10
1.6 APPLICATION OF HUMANOID HAND 13
2 MECHANICAL DESIGN 15
2.1 SOLIDWORKS 16
2.2 PART MODELING 16
2.3 ASSEMBLY MODELING 17
2.4 RENDERING 19
2.5 DRAWING AND DETAILING 19
3 ANALYSIS 21
4 COMPUTER AIDED MANUFACTURING 26
5 MICROCONTROLLER BOARD AND
WIRELESS COMPONENTS 34
5.1 ARDUINO UNO 34
5.2 WIRELESS CAPABILITIES 36
6 ACTUATOR AND SENSOR USED 38
6.1 SERVO MOTOR 38
6.2 FLEX SENSOR 39
7 COMPONENTS PURCHASE QANTITY 41
7
8 EXPERIMENTS CONDUCTED 42
9 PROGRAMMING THE ARDUINO 43
9.1 SENDING ARDUINO CODE 43
9.2 RECEVING ARDUINO CODE 44
10 FINAL ASSEMBLY 46
10.1 CONTROL GLOVE 46
10.2 HUMANOID HAND ASSEMBLY 47
11 WORKING 48
12 RESULTS AND DISCUSSIONS 50
13 CONCLUSION 51
14 BIBLIOGRAPHY 52
8
1. INTRODUCTION
In this chapter, the sole purpose of this project and theory behind this project will be
described. It will also be mentioned why it is important to develop Humanoid hand and
what was important to achieve within this project.
1.1 ABOUT OUR PROJECT
The task was to develop a prototype of a Wireless operated -Humanoid hand, This Five-
Fingered Humanoid hand has the capability of replicating complex actions of an actual
human hand. The focus of this thesis within the project lied on to improve the function and
wireless application of the robotic hand. In addition to that a Conceptual design & 3D-
Model should be developed and NX-CAM code for milling the prototype has to be
generated. Simultaneously a developing the control interface of the hand glove using
Flexible sensor and Arduino Uno was also made. To reduce the cost of the hand, working
model was made as simple as possible. To keep the manufacturing costs down is also an
important issue developing the new Prototype. Several different concepts where analyzed
before the final Prototype was built. To designing and rendering the hand Solid Works was
used. CAM codes were generated using NX-CAM. This project revolves around
applications from subjects such as Mechatronics, Fluid Power Control and Engineering
Design etc…. from our undergraduate study.
WIRELESS
TECHNOLOGY
MECHATRONICS
ENGINEERING DESIGN
9
1.2 ROBOTICS
Robotics is the branch of technology that deals with the design, construction,
operation, and application of robots. The study of robots involves various aspects of
Mechanical Engineering, Electrical Engineering and control Theory. Robotics deals
with automated machines that can take the place of humans in dangerous
environments or manufacturing processes, or resemble humans in appearance,
behaviour, and cognition. These definitions are also not enough or not very close to
defining Robotics, as it’s a vast, rapidly growing and multidisciplinary field.
Many robots do jobs that are hazardous to people such as defusing bombs, exploring
shipwrecks, and mines. They are also employed in jobs which are too dirty 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. Japan and
Germany are the leading nations in the
field of robotics, which has substantially
helped those countries to become
Industrial super powers of this field.
Robots are mainly used in
manufacturing firm especially
Automobile manufacturing plants. Japan
and Germany are leaders in Advanced
Robotic research and development; this
has substantially paid of them by making
contributing to manufacturing sector.
Now Japan and Germany are two
Industrial super powers of the world. Figure 1.1
1.3 BIO INSPIRED TECHNOLOGY
Biologically inspired technology is a power full tool for advanced research in Mechanical
Engineering especially in the field of robotic locomotion and object handling. Bio-inspired
robotics is about studying biological systems, and look for the mechanisms that may solve
a problem in the engineering field. The designer should then try to simplify and enhance
that mechanism for the specific task of interest. It is about observing the nature and
learning from it, later the principles or the mechanism devised is applied to the real world
engineering systems. More specifically, this field is about making robots that are inspired
10
by the biological systems. As a product designer and developer we can refine our product
for better looks and performance maximum 15-20 iterations, but nature has course of
thousands of years evolution and infinite number of iterations.
Figure 1.2
1.4 STUDY ON HUMAN HAND Developed under many years of evolution the human hand has made us to what we are today.
The human hand is composed by 27 different bones and the opposing thumb is characteristic
For the human. The opposing thumb enables the precision grasp between the long finger and
The thumb which enables us to write or to perform precision work. Further the hand has 20
DOF and the most muscles are placed in the forearm and transmit their developed force via
tendons to the fingers. The bigger muscles in the hand are the thenar muscle on the thumb
side and the Hypothenar muscle on the side of the little finger.
1.5 HUMANOID HAND
In our project we have the inspiration from the Human hand, a microcontroller based
humanoid arm with wireless capabilities. Our design and mechanism are very much
similar to an actual human arm. The very word Humanoid means human like , A humanoid
is something that has an appearance resembling a human being.
11
1.5.1. TWO TYPES OF HUMANOID HANDS
MODULAR HAND They are autonomous units with all the components required to function that includes
actuator, sensor etc ...They are more of an end effector that connects to the robot's arm
kinematics to execute their functions An overall complex design is required , still in
research and development level. Slightly lower gripping is achieved that the integrated
hand , and slightly bigger in size compared to human hand.
**The code was very lengthy, hence it was cut shorted.
34
5. MICROCONTROLLER BOARD AND WIRELESS COMPONENTS
5.1 ARDUINO UNO (MICROCONTROLLER BOARD)
The Arduino Uno is a microcontroller board based on the ATmega328 .It has 14
digital input/output pins ,6 Analog inputs, a 16 MHz ceramic resonator, a USB
connection, a power jack, an ICSP header, and a reset button. It contains everything
needed to support the microcontroller; simply connect it to a computer with a USB
cable or power it with a AC-to-DC adapter or battery to get started.
Reasonably price and reliable quality were the deciding factors for choosing this
microcontroller board for our project. Added advantage of using an Arduino is that it
is Open-source hardware and supporting software provided. Working with Arduino
can be fun and easy, at the same time one can learn a lot about electronics and
robotics. Especially when Mechanical Engineering students and other disciplinary
students getting started with electronics can explore the amazing world of robotics
control with Arduino Uno.
DETAILS- ARDUINO UNO
Microcontroller ATmega328
Operating Voltage 5V
Input Voltage (recommended) 7-12V
Input Voltage (limits) 6-20V
Digital I/O Pins 14 (of which 6 provide PWM output)
Analog Input Pins 6
DC Current per I/O Pin 40 Ma
DC Current for 3.3V Pin 50 Ma
Flash Memory 32 KB (ATmega328) of which 0.5 KB used by boot loader
SRAM 2 KB (ATmega328)
EEPROM 1 KB (ATmega328)
Clock Speed 16 MHz
35
AT MEGA-328
(MICROCONTROLLER)
The ATmega328 is a single chip
micro-controller created by Atmel
and belonging to the megaAVR
series. In our case it comes along
with Arduino Uno board which
makes our work easy.
SERVO MOTOR SHIELD
The Simple Labs' Servo Shield is
a custom designed Shield to drive Servo Motors. The Shield Can drive up to 10 servo
motors at a time. It was originally designed for our Quadbot Robot Kit (8 Servos) +
Mini Pan and Tilt Kit (2 Servos). In addition to this, the servo shield has suitable pin
outs to be able to connect the Compound Eye IR Sensor.It has a screw terminal for
external supply to be connected to power the servos. We can use 6V battery to Power
these up.
The servo shield has Servo control pins on Arduino Digital Pins D2, D3, D4, D5, D6,
D9, D10, D11, D12 & D13. Refer to the TOP Legend on the board "D + - " for the
Orientation of the Servo Connector Connection. We used five outputs from this motor
shield, maximum ten servo motors can be operated using this servo shield. We were
very fortunate to find this board as it made our control system very compact and neat.
The pins are designed in such a way it mounts directly into the Arduino Uno-Wireless
setup shield.
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5.2 WIRELESS CAPABILITIES
Our project the Humanoid Hand or the Robotic Hand has the capability of replicating
figure flex and gestures of Human Hand with the help of Control Glove. We later
included the wireless control in this setup , It would greatly enhance the project in its
application area. Wireless control of our Robotic Hand helped us break into the world
of communication and expand our horizon to Military ,Defence Bomb defusing and
Nuclear Facility applications. Working with wireless can be hard and frustrating,
especially when you are a Mechanical student. We have found an easier and cost
effective solution for these problems. Just buy the following components in pair , we
will need one as a sender(master) and other as receiver(Slave).
5.2.1 XBEE SERIES-2 MODULE
The XBee XB24-Z7WIT-004 Series 2 improves on the power output and data
protocol. XBee Series 2 modules allow a very reliable and simple communication
between microcontrollers, computers, systems, really anything with a serial port!
Point to point and multi-point networks are supported. We just need to create
communication between two Arduino Uno Boards. The Series 2 requires considerable
setup and configuration but there are tons of tutorials out there in Internet. To create a
network pair we must configure using X-CTU Software. One must be configured as
Co-ordinator and other must be Router device. Indoor/Urban range up to 133 ft.
(40m) , Outdoor RF line-of-sight rang up to 400 ft. (120m)
5.2.2 ITEAD XBEE SHIELD
XBee Shield is an enhanced Zigbee XBee Series modules breakout board for Arduino,
it can directly plug in with Arduino Uno Board. It Protects the XBee modules from
damage due to higher voltage and has a 3.3 V regulator for this purpose. The XBee
Shield simplifies the task of interfacing an XBee with your Arduino. This board mates
directly with an Arduino Pro or USB board, and equips it with wireless
communication capabilities using the popular XBee module. This unit works with all
XBee modules including the Series 2 (and 2.5), standard and Pro version. There was
no need of soldering in wireless system, they are easy to assemble, just place the
wireless shield on Arduino make sure the pins are correctly matched and gently press,
same applies for Servo motor shield and XBee module.
37
38
6. ACTUATOR AND SENSOR USED
6.1 SERVOMOTOR:
Servomotor is a mechanical actuator that gives highly precise angular motion using
closed loop position feedback. Servomotors are used in applications such as robotics,
CNC machinery or automated manufacturing.
MODELS PURCHASED
V 3006 Servomotor It is a heavy duty plastic geared economy hobby servo motors for general purposes. Specification: Operating Voltage: 4.8-6.0V Stall Torque: 6 kg-cm at 4.8V, 7.1 Kg-cm at 6V Operating Speed: 0.18 sec/ 60° at 4.8V, 0.16 sec/ 60° at 6V at no load Weight: 40g Size: 41.3*20.3*38.7 Connector wire length: 30cm
TowerPro SG5010 TowerPro SG5010 is a high quality but really low-cost servo for all your mechatronic
needs. It comes with a 3-pin power and control cable, even a dozen of hardware as
shown.
Features: 3 pole ferrite, all nylon gear, Top ball bearing.
Operating
Voltage:
4.8V~6.0V
Operating
speed:,
0.16sec/60deg
(6.0V)
Stall torque:
6.5kg*cm
(6.0V)
Dimension:
41 x 20 x
38mm
Weight: 41g
Connector wire
length: 30cm
39
6.2 FLEX SENSOR
Description: A simple flex sensor 4.5" in length. As the sensor is flexed, the
resistance across the sensor increases. Patented technology by Spectra Symbol - they
claim these sensors were used in the original Nintendo Power Glove which was used
as control glove for gaming.. The resistance of the flex sensor changes when the metal
pads are on the outside of the bend (text on inside of bend).Connector is 0.1" spaced
and bread board friendly. It can bend and flex physically with motion device.
Possible Uses
• Robotics
• Gaming (Virtual Motion)
• Medical Devices
• Computer Peripherals
• Musical Instruments
Mechanical Specifications:
• Life Cycle: >1 million
• Height: 0.43mm (0.017")
• Temperature Range: -35°C to +80°C
40
6.2.1 CONNECTING FLEX SENSOR WITH ARDUINO UNO
Flex sensor has two terminals one is for 5v and other must be connected to Analog pin
resistor (10K or 22K) which acts as a voltage divider, then grounded. In order to
connect five Flex sensor to Arduino a separate PCB board has to be made. This board
is mounted on the Control Glove, ready for acton.
41
7. COMPONENTS PURCHASE-QANTITY
Major components like Servo motors, Arduino Uno( microcontroller ),Custom
We had written like number of codes for this project, First few didn’t work well, thank god this pair worked for us. We were not specialist in programming, just learned it from tutorials in Arduino support sites.
46
10. FINAL ASSEMBLY
In order to obtain fully functioning model final assembly must be made, power supply
from USB or battery must be connected. Both Arduinos must be programmed and
shields must be mounted.
10.1 CONTROL GLOVE
The control glove is ready to be worn only when all five Flex sensors are sewed to the
glove and connected with the PCB and Arduino Uno. Flex sensor is very sensitive at
the base hence nice padding must be given so that when flexi is bent the base is not
damaged or disturbed. In our Glove the Arduino is also stitched neat and tidy way.
The Arduino can be powered by battery or USB based on the need.
47
10.2 HUMANOID
HAND ASSEMBLY
Servo motors are
rigidly mounted using
nuts and bolts on to the
robotic chassis, All the
fingers with end caps
with fishing tackles
tied to it internally are
mounted or attached to
the palm. The palm in
turn is attached to the
Servo chassis. All the electronics components are mounted to the Hand using proper
spacers.
48
11. WORKING
Operator wears the Control Glove (practically anyone can wear the glove, its elastic
and comfortable). The control glove and Humanoid Hand setup are placed within the
working range of wireless communication of XBee series-2. Final assembly is
complete.
Servomotors are connected to the Servomotor shield powered by 6V Rechargeable or
four ordinary 6v batteries. Arduinos are powered up either by USB or battery.
When the communication begins all the fingers come to the fully extended state, when
a finger is bent the flex sensor senses the bend and the angle is obtained and processed
by the Arduino.
According to the programme we written the obtained angle value is transmitted via
XBee module (Sending) to other XBee module (Receiving).
Subsequently the Receiving Arduino processes the signal and corresponding
Servomotor is actuates and the same figure is flexed exactly to the angle of finger
bend.
All five fingers can be flexed at the same time, and the corresponding Humanoid hand
finger will respond immediately.
By the above mentioned steps , Humanoid hand will be able to replicate any gestures
of the operator from distance of upto 300-400ft in line of sight.
Flex sensor senses the angle of finger
bend
Value obtained is processed by
Arduino Uno on Control Glove
Value is sent wirelessly by XBee
module
Value is received by XBee module
on the Humanoid Hand
The received value is processed by
Arduino Uno
Servomotor is actuated and
rotates the precise angle of fingure
49
PICTURES OF THE WORKING MODEL
HUMANOID HAND SHOWING GERSTURES
50
12. RESULT AND DISCUSSION:
Thus a Wirelessly controlled Humanoid hand is designed and fabricated and testing is
done under supervision of our Project guide..
The Design can be improved to produce variety of movements that include wrist
movement and opposing thumb.
Two microcontrollers are successfully made to communicate with each other using
Wireless system.
Using computer we can monitor the sensor values of the glove to iterate and improve
the sensor value give in the code.
This Humanoid Hand being modular type can be integrated with any Robotic
Kinematic Arm. As it has all the actuators and power supply housed in it.
This programme (codes) can be modified and changed for higher resolution and
accurate bend of fingers.
Material property and manufacturability has to be improved.
In order to use the fullest potential of our motor the fishing tackle used to connect
Servomotor horn must be replaced by alternative line which can withstand higher load
and friction.
It will be great if this Mechatronic system is made closed loop feedback system,
presently our project is a open loop system.
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13. CONCLUSION
The hand prototype is working fine but some improvements could be made. Also the
Design of the hand can be improved by including a stronger material and higher
mechanisms and additional motions.
The Ultimate goal to develop a functioning prototype and a wireless control glove
which was fulfilled, the Humanoid hand can replicate the complex gestures of an
actual Human hand. It can perform grasps using the palm and can grasp objects in a
better way. Also the assembly properties and cable routing is well planned.
As it’s a Bio- inspired technology the Humanoid hand has dimensions close to the
human ones and looks humanlike. The process is made wireless using XBee, Which is
used to send and receive signals.
A Five finger robot hand could be developed at a total project cost of Rs.18,000.
This project can be further developed in many aspects and futuristic ideas can be
implemented. The resolution, mechanism, degree of freedom (D.O.F), precision can
be improved considerably. Hence the system will be more flexible and can be used in
Advanced functions like Nuclear facility, Bomb defusing and defence research.
52
14. BIBLIOGRAPHY:
LITRATURE
“THEORY OF MACHINES”.. R.S.KHURMI..
“ENGINEERING DESIGN”.. R.S.KHURMI..
“MICROPROCESSOR, ARCHITECTURE, PROMMING AND APPLICATIONS”..
RAMESH S.GAONKAR, PENRAM INTERNATIONAL
“MECHATRONICS”.. W.BOLTON.. PEARSON EDUCATION.
“ARDUINO - A QUICK START GUIDE QUICK START GUIDE”..MAIK
SCHMIDT..THE PRAGMATIC BOOKSHELF
“ARDUINO COOKBOOK 2011”..JEREMY BLEM..OREILLY
“ARDUINO_ROBOTIC_EBOOKAMZ”..JOSH ADAMS..TECHNOLOGY IN