COLOR SORTING SYSTEM WITH ROBOT ARM YEOW KHANG YUNG May 2011 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 May 2011 i
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 syaratsyarat 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: (TANDATANGAN PENULIS) (COP DAN TANDATANGAN PENYELIA) ii
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 Date : iii
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 Date : iv
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. Finally, I would also like to extend our utmost gratitude to all the lecturers of University Technical Malaysia Malacca (UTeM) for their guidance and patience. Their teachings have thought me that education and knowledge are vital in life if we wish to succeed. v
ABSTRACT Color sorting system is one of the useful systems in Industrial. It can be used to differentiate item based on the color of the item itself. This system is implemented to improve the process of the industrial. Traditionally, the color sorting process is done by the operator manually. However, this method has some shortage such as increase the cost of the product, slow, and inaccuracy due to the human mistake. Color Sorting System with Robot Arm is a solution to this problem. Color Sorting System with Robot Arm will be operated using Programmable Interface Controller (PIC). For the color detecting part, it will use the Light Dependent Resistor (LER) as a sensor to detect the color of the object. The most significant part of this project is to have a robot arm. This robot arm is function to pick and place, and its gripper can move in a circular path. Since this system is mainly controlled by the PIC microcontroller, the result of the sorting process will be more reliable and faster. vi
ABSTRAK Sistem pembezaan warna merupakan satu sistem yang amat berguna dalam industri. Sistem ini boleh digunakan untuk membezakan object berdasakan warna object itu sendiri.sistem ini digunakan untuk menambah baik proses industri. Biasanaya, process pembezaan warna ini dijalankan oleh operator secara bertangan.namun, cara ini mempunyai keburukan seperti meningkatkan kos, lambat, dan mudah salah disebabkan kecuaian manusia. "Color Sorting System With Robot Arm" merupakan penyelesaian kepada masalah ini. Sistem ini beroperasi menggunakan Programmable Interface Controller, atau yang lebih dikenali sebagai PIC teknologi.perintang bergantung cahaya akan digunakan untuk mengesan warna sesuatu objek itu. Bahagian terpenting dalam sistem ini ialah sistem ini mempunyak satu tangan jentera yang mampu mengutip dan melepas, dan tangan jentera ini mampu bergerak dalam satu bulatan. Disebabkan sistem ini dikawal oleh PIC teknologi, keputusan yang diberi oleh sistem ini adalah sangat tepat dan cepat. vii
TABLE OF CONTENTS CHAPTER TITLE PAGE TITLE OF PROJECT STATUS CONFIRMATION FORM DECLARATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF FIGURES LIST OF ABBREVIATION LIST OF APPENDICES i ii iii iv v vi viii ix x 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 II LITERATURE REVIEW 7 viii
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 4.2 Discussion 49 ix
V CONCLUSION AND RECOMMENDATION 52 5.1 Conclusion 52 5.2 Recommendation 53 REFERENCES 54 APPENDIX 55 x
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 Figure 2.3.2 Servo Motor Part 16 xi
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 Figure 4.1.3.1 The Robot Arm. 39 xii
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 Figure 4.1.5.3 The Controller with input code of 110. 43 xiii
LIST OF TABLES NO TITLE PAGE Table 2.5.1 The LM Series Voltage Regulator And The Ouput Voltage. 20 Table 4.1.2.1 The Basic Component In The Circuit. 35 xiv
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 Firstly, a manually feed object will be determined by the robot. The gripper of the robot will pick up the object and place it to a color differentiating station. The color 1
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. 6. The robot arm returns to its original place, and repeat the whole process if there is another ball in the ball-tower station. 2
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. iii. iv. To sort the object to the station accordingly. To make the system run continuously with less rest. 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. v. To design circuitry for the overall system. 3
vi. vii. viii. To fabricate a PCB circuit board for the overall system. To develop the program that can integrate and control the overall system. 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 iii. The implementation cost for a color sorting process using the operator is very high. This is because the work load for an operator is very low. If an industry needs to sort a bulk quantity of product, they have to recruit many workers, implement shift and overtime system for the workers. This will definitely increase the cost of a product. In this project, a color sorting system was designed so that to increase the process time, increase the process accuracy, 4
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. iii. iv. This project will increase the accuracy color sorting process. This project will cut-down the cost of color sorting process. 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. Chapter four consists of result and discussion of the project, finding and analysis throughout the research and project development. 5
Lastly, chapter five is the project conclusion. This chapter rounds up the attained achievement of the whole project and reserves suggestions for possible future researches. 6
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. The microcontroller contains all the basic components that make up a computer. It contains all the basic components that make up a computer. It contains a central processing unit (CPU), read-only memory, random-access memory (RAM), arithmetic logic unit, input and output lines, timers, serial and parallel ports, digitalto-analog converters, and analog-to-digital converters. The name PIC denotes several families of microcontrollers manufactured by Microchip Technology [6]. 7
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 Figure 2.1: The different shape, size and type of PIC chip 8
Figure 2.2: The Basic Microcontroller Architecture Inside a PIC Cchip. Figure 2.3: The Electronic Ccircuit Board for PIC Microcontroller. PIC16F877A is one of the PIC chip in PIC family. The package type of this chip is DIP package. DIP stand for Dual Inline Package and it is an electronic device package with a rectangular housing and two parallel rows of electrical connecting pins. 9