Implementation of an Automated Sorting System with a 2-Link Robotic Arm

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1 Implementation of an Automated Sorting System with a 2-Link Robotic Arm Thomas Carlone, Frederik Clinck le, Raymond Short Worcester Polytechnic Institute, Worcester, MA, USA tomcarlone@wpi.edu, fclinck@wpi.edu, rayshort@wpi.edu Abstract Many manufacturing applications could benefit from an automated sorting system. The ability to accommodate a variety of objects and sort them by weight could have many possible advantages over traditional sorting methods. The repeatability of robots and the possible cost reduction associated with replacing human sorters are two such advantages. The idea of this project is to use a 2-link robotic arm in combination with a conveyer to sort objects by weight. The conveyer belt is used to simulate a production line and is essentially the mechanism that carries the objects to be sorted. The systems sensing capability allows the object to be anywhere on the conveyer belt allowing for increased flexibility. The goal of this project is to create a complete system to demonstrate the objective of sorting objects from a conveyer belt. The focus is on integrating hardware and sensor systems with software that can be used as a basis to determine the feasibility of this type of automated sorting system. The result is a fully completed system that is successfully used to sort objects by weight. It is tested for repeatability, which revealed concerns about the use of the IR range sensor in determining the location of the object. With that exception, the system proved to work very well in many other aspects and showed that this type of system may have some potential uses where automated sorting is desired. I. INTRODUCTION The concept of automated sorting is not new and has already found several applications in industrial manufacturing settings. The system used here focused on the use of a 2-link arm to sort objects by weight. Such an arm might have distinct advantages over conventional systems such as an increased workspace or ability to place objects in a variety of different places. In addition, a modular gripper can be used to make this type of system helpful in more than one specific application. In implementing this system there were four major components to consider. One is the mechanical aspect and system hardware. This will be briefly reviewed; however, it is not a central part of the project. In addition, electrical hardware was not a priority as it was supplied along with all mechanical components. The next major component was sensing. Sensing strategies will be reviewed in detail and can be broken down into three main categories. One aspect was finding a way to sense the position of the block on the conveyer belt. Because the conveyer belt is often much wider than the object, there are a number of different places the object can be along the width of the conveyer. To sense this position an IR range sensor is used. The next major area of sensing is proprioceptive and has to do with measuring the joint angles of each link of the arm. Inverse kinematics are used to control the arm to different locations, and knowing the joint angles of each link is essentially for getting feedback for the PID controller. Potentiometers are built into each joint and are used to get joint angle feedback. The last aspect of sensing is in determining the weight of the object. For testing purposes, two weights are used meaning the robot must be able to tell if it has picked up a heavy weight (140grams), light weight (40grams), or no weight in the case it misses the object or has the object removed before it is grabbed. To accomplish this several different methods of current sensing are explored in an effort to find the most reliable and accurate solution. The last component, and the focus of this project, is the software portion of the system. Software needed to be developed for a wide range of functions from low-level activities like SPI communication with DACs to higher-level functions such as PID control. The main low-level tasks in software were establishing SPI communications with the DAC, configuring the ADC to use analog sensors, and configuring a timer. Other tasks involved implementing and

2 tuning a PID controller, creating functions to solve the forward and inverse kinematics, developing functions to control the position of the arm, and linearizing the IR sensor. Eventually these sorts of functions are used in developing the main program used in the final system. II. DESIGN REQUIREMENTS The objective of this project was to create a multiple-link serial manipulator for use in an automated industrial sorting application. This requires the use of ranging and non-ranging sensors to perform inverse position kinematics and position the end-effector of the arm at the location of the object. A. Overview of System Hardware For this application, all of the hardware was provided, but modifications could be performed if necessary. The hardware consists of a two-link serial manipulator with a parallel-plate gripper as the end-effector, a conveyor belt driven at a constant speed, and an infrared rangefinder attached to the beginning of said conveyor belt. A side view of the system with important dimensions labeled is shown in Figure 1, along with a top view showing other important features in Figure 2. The IR rangefinder is attached to the conveyor belt via a standoff (15 cm) in order to optimize the operative space as being in the effective range of the sensor. The arm is attached to the other end of the conveyor belt by its own standoffs in order to provide a common ground for stability purposes. The necessary workspace for the end-effector is from the close edge of the conveyor belt to the far edge, a width of 8.8 cm. This was combined with the known distance of 21 cm from the origin of the arm to the edge of the conveyor belt to obtain a necessary displacement along the x-axis of the manipulator. This range is between 21 and 29.8 cm from the arm, which is fully obtainable, given the configuration of 19 cm for the first link and 15 cm for the length of the second link to the center of the end-effector. The control for the y-axis of the manipulator was determined by a distance of 10 cm from the conveyor belt to the origin of the arm, along with the height of each block being 6.5 to 7 cm in height. This resulted in a normal y-axis adjustment of 3 to 3.5 cm. Finally, there is the Fig. 1. Side view of the conveyor belt and arm system, with important dimensions labeled. Fig. 2. Top view of the conveyor belt and arm system, with important dimensions labeled. consideration of travel distance from being sensed to being picked up by the arm, which is a 15 cm length from IR to arm center. B. System Objectives The objectives and set of boundaries for this application were provided upfront as a means of guiding the design process of the software and sensor implementation. The first requirement for the solution is to use the provided motor-driven conveyor belt and keep it in continuous motion. The second objective is to use the provided parallel plate gripper to manipulate the objects on the conveyor belt. This contains another objective, which is shared with the first, of using the coprocessor of

3 the RBE Development Board to control the servos of the conveyor belt and gripper. The next objective is multi-faceted and describes the desired process for sorting with the robotic arms. The process is as follows: detect the relative position of each object on the belt with respect to robot base; use inverse kinematics to determine the corresponding joint positions of the arm; determine the correct timing for pick up; pick up the object; identify the object based on weight (using motor torques); and sort the objects by placing them in two different bins. There is also the allowance to use Vex sensors that are not explicitly stated in earlier sections in addition to the sensors already placed in and on the system. Finally, documentation and a demonstration of the automation process are required. III. SYSTEM DESIGN The robot design created in this lab was capable of detecting and picking up objects from a conveyer belt. The robot could also differentiate between the weights of different blocks and position them in different places depending on those weights. Here is a thorough analysis of the different parts involved in the design of the robot. A. System Architecture To achieve this goal, the design made use of an infrared sensor connected to one end of the conveyer belt. Once the infrared sensor detected the block, it was picked up at the other end of the conveyer belt by a gripper connected to the end of a two-link arm. The double link arm was controlled using Proportional Integral Derivative Controllers on the joint angles. The desired arm angles values are calculated using the Infrared Sensor value to figure out the desired gripper position. This position can then be translated in corresponding angle values using inverse Kinematics. The process for weighing the block made use of the Digital-to- Analog Converter (DAC) found on the RBE Development Board. The RBE Development Board made use of the Atmel ATmega644P microprocessor. The Vex interface on the board was used to run the Vex motors in the conveyer belt and the gripper. The board also controlled the arm links and analyzed the output of the IR sensor and the potentiometers found at the arm links. Initially, the robot was designed to use a current sensing circuit to calculate the torque on the arm. This value would result in a measure of the weight of the blocks. Instead, it was decided that it would be easier to use the values sent to the motor as read on the DAC. Weighing the block using this method becomes very trivial. The current of the arm was slowly increased until the potentiometers notice a change in the arm position. A heavier block would cause the DAC value when the arm moves to be higher than a lighter block. B. Sensing Strategies As previously discussed establishing a sensing strategy is an essential part of the automated sorting system. The three main parts of the sensing system include a method of determining the objects location, a way to sense joint angles of the arm, and a way to measure the weight of the object that has been picked up. In trying to sense where the block is located along the width of the conveyer belt, a GP2D12 Sharp IR Sensor is used. Based on its specifications it has the required range and an adequate resolution for the application. As seen in the review of system hardware the IR sensor is positioned on the same side of the conveyer as the arm and more than 10cm away from the edge of the conveyer belt. Since the IR range finder cannot measure distances less than 10cm that offset is required for the use of this particular sensor. With the IR sensor producing an analog voltage as its output the only step required after configuring the ADC is to linearize the data. This was done using a combination of experimentation and the suggested function provided in the data sheet. The resulting equation is seen below in Eq. (1). 1 D = 10 ( 0.42) (1) V Where D is the distance in mm and V is the output of the IR sensor in volts. With this equation established and tested, the exact position of the block can be calculated. Because there is a known offset between the origin of the arm and where the IR sensor is mounted, knowing the distance from the object to the IR sensor also gives you the distance from the object to the origin of the arm. In addition, the width of the object can be taken into account assuming it is symmetrical. In our case block were used as objects so there was a

4 known distance from where the IR sensor saw the block to where the center of the block is located which is account for in calculating the x-position. After the x-position is known, the y-position is found simply by measuring the blocks height and would vary depending on what is being picked up by the arm. In addition to providing information about where the block is the IR sensor is also used to determine when the block is in front of the arm. The idea here is that as soon as the IR sensor loses sight of the block a timer is reset and begins counting at a rate of one every hundredth of a second. With the assumption that the conveyer belt operates at a constant velocity the location of the block to the arm along the conveyer belt is simply a function of time. Based on the speed of the conveyer belt this time was found to be 6 seconds from when the IR sensor lost sight of the block to when it was directly in front of the arm. This combination of timing and range finding allows means the IR sensor is solely responsible for locating the block on the conveyer relative to the arm. Measuring the joint angles is another area that required sensors. In order to implement PID control there needed to be some form of position feedback of the arms joint angles. This was accomplished using two potentiometers in combination with the ADC. The additional requirement was to calibrate the potentiometers so that it is possible to relate an analog value to an angle in degrees, something that was necessary when using inverse kinematics. This was done by finding the ADC value at 0 and 90 degrees and then using software to generate the resulting calibration functions. The last main sensing component of the system involved finding a way to sense the weight of the object. The original idea was to sense the current in the motor that operated the first link of the arm. Since the torque on the motor is proportional to the weight of the arm and the current is directly related to the torque of the motor, the weight of the object should be proportionally related to the measured current. The current was sensed using an AD8210 in combination with a sense resistor. The AD8210 shifted the voltage over the sense resistor to ensure it could be measured in both directions and amplified it by 20 so that it could be more easily interpreted through the ADC. This system was tested and found to work marginally well. One problem was that the torque generated by the weight of the arm was not directly going to the motor but actually went through a belt and several gear stages before reaching the motor. This factor somewhat removed the relationship between the weight of the arm and the torque on the motor and made it difficult to accurately determine the weight from the current. An alternative method, called DAC counting, was tested and found to be much more accurate and repeatable in measuring weights. The idea is that after the arm grabs a weight it extends itself fully into the horizontal configuration, putting the most torque on the first motor. From here, the DAC is used to control the voltage being sent to the motor. It starts at a value of 2000 and increased by five every 10ms. This continues until the potentiometer detects a change in the angle meaning the arm is beginning to lift and overcome the torque caused by the weight. At that instant the process stops and the current DAC value, or motor voltage, is used in determining the weight. This method works because the motor is essentially stalled just before it starts moving and the voltage value obtained represents the voltage that was just enough to break the stall point. Since the arm motor requires more voltage to overcome more toque caused by a heavier weight this simply relationship is used to determining the weight of that arm and the object it is holding. C. Robot Controller Hardware The main electrical components used in this system are the IR sensor, DAC, ADC, amplifiers, and microprocessors. A picture of the board used with all the relevant electrical components notes is shown below in Figure 3. The microcontroller and co-processor are both ATmega644PAs. The main processor is where the program is stored and executed and it contains a built in ADC used with several analog sensors. The co-processor is used in generating PWMs needed to control servos both for the gripper and conveyer belt. The DAC and amplifiers are used together to control the two motors. The DAC is a LTC2634 and the linear amplifiers are OPA548s. The DAC is 12bits and takes a number between 0 and 4095, outputting the corresponding voltage from 0 to 2.5V. This signal

5 Fig. 3. View of the RBE Development Board with key components labeled. is multiplied by a factor of 6.1 before being sent to drive the motor. There is a DAC and amplifier combination on each side of the motor so that it can be controlled in both directions. D. Software Implementation After having examined the hardware involved in the design of this robot in previous section, this section will analyze the software controlling that hardware. Figure 4 shows the flowchart of the program used to sense, pick up, and sort the blocks. As the flow chart demonstrates, the program started by waiting for the block to appear on the IR sensor. Once it does, the program approximates the position of the block by averaging all IR readings during which the block was noticed. To get the Infrared sensor to read the distances properly, it first had to be linearized. This was done by testing IR readings with known distances and deriving an equation that would obtain the proper distances from the Infrared output. After finishing that process, the formula shown in Eq. (1) above was found. Once the block disappeared from the sight of the Infrared sensor, the program moved the gripper so that it was just above where the block would pass by to make grabbing the block an easier task. This was achieved by using the function calc angles() from kinematics.c to calculate the desired joint angles using inverse kinematics. The program then waits a set amount of time, 645 ms in this case, until the block is right below the gripper. Once that time has passed, the gripper was lowered and closed to grab the object. Fig. 4. Flowchart of the Program Controlling the Robot. The program then entered its weight-measuring phase. There, it the arm was moved so that it was horizontal. The weight was then measured by incrementing the DAC output value until the arm moved. This final DAC value was higher if the big block was in the gripper. As such, if the final DAC value was over 3800, the block was deemed heavy. If it was between f it was between 3100 and 3800, it was light. Any result below 3100 assumed the gripper had no object in it, making it go back to its ready position. If the object was heavy, the gripper was opened to drop the block. A light block was released on the other side of the conveyer belt. Once that process was over, the gripper would get back in its ready position and the program would wait once again for an object to appear in front of the IR Sensor. The program used in this lab made use of many of the functions programmed in previous RBE3001 labs. This included the following functions. The functions controlling the link positions using PID

6 control were found in motor.c. Similarly, the program borrowed functions from our timer.c that initialized Timer0 to throw interrupts at a given frequency. Functions initializing the DAC and SPI and allowing commands to be sent through the DAC from ADC.c were also used. These functions included DACSP IInit(), which initialized the SPI bus for the DAC, and sendcommand(), which allows commands to be sent to the DAC. Those functions complemented the code found in RBElib, which was written by Kevin Harrington, to give the robot the capabilities it needs to finish the task. IV. RESULTS After the system was fully integrated and the necessary software was developed the system as a whole was evaluated in terms of reliability and usefulness. Overall the automated sorting system preformed fairly well in many metrics. The success rate of picking up a block was about 65% with the major limitation being the IR sensors ability or rather inability to report the distance to the block accurately. In terms of measuring the weight, the system correctly sorted the block about 90% of the time and never missed a distinction between a heavy and light block. The only trouble is the ability of the arm to sense the weight difference between the light block and no block, mostly due to the very small difference in weights. Overall, the system functioned largely as expected and did show some potential as an automated sorting system. V. CONCLUSION Overall, the system was relatively successful in demonstrating the basic principles behind this method of automated sorting by weight. The major limitation was reliability of the IR sensor. Without good measurements from this sensor, the arm does not know where to pick up the block, which is the main reason behind most misses. Some possible causes could be the effect of ambient IR from sunlight or other sources, sensitivity to the angle of the object, or sensitivity to the reflectiveness of the object. In either case, the IR sensor could not produce reliable data and was the main limitation of the system. If future work were considered for this type of system, an alternative method for sensing the block s location would be required. Possible replacements could be better quality laser range finders or various uses of digital sensors such as photo-interrupters. Another limitation of the system that was notable was the small workspace. There was just enough range to pick up the block at either side of the conveyer belt, however more range would be desired especially in offering more flexibility in where the arm can place the block. The method of DAC counting performed very well and rarely got the weight wrong. This was definitely an advantage of the system as it provided a way to accurately measure weights without any additional sensors. PID and inverse kinematic control of the arm also performed well. Future work should focus on a new method of sensing where the block is on the conveyer belt if higher repeatability is to be achieved. ACKNOWLEDGMENTS We would like to thank Professor Taskin Padir and Professor Gregory Fischer for teaching us the material necessary to complete this project and assisting us with any help we might have needed along the way. We would also like to thank Joe for creating the arm used in the project and helping out when it was needed. Finally we would like to thank Kevin Harrington for creating the RBElib library, the RBE Development Boards, and assisting us when we needed help with either of those or any other part of the project. REFERENCES (1) ATmega644P Datasheet. Atmel Products. card.asp? part id=3896 (2) Quad 12-/10-/8-Bit Rail-to-Rail DAC. LTC2634 Datasheet. Linear Technology. C9A254234CA9FD/courses/1/RBE3001-A10- W1/content/ /2634fc.pdf (3) High-Voltage, High-Current Operational Amplifier. OPA548 Datasheet. Texas Instruments. A254234CA9FD/courses/1/RBE3001-A10- W1/content/ /opa548.pdf (4) RBE Development Board. courses/1/rbe3001-a10-w1/content/

7 /RBE%20Devel%20Board Schematics Rev1.pdf (5) IM-13 Motors W/ Optical Encoder. E-2120 Datasheet. Globe Motors. 160B8DC5A AD/courses/1/ RBE3001-A10-W1/content/ /Globe Encoder 13en in.pdf (6) IM-13 Gearmotors. E-2135 Datasheet. Globe Motors. DC5A AD/courses/1/RBE3001- A10-W1/content/ /Globe GearMotor 13 sp in.pdf (7) General Purpose Type Distance Measuring Sensors. GP2D12 Datasheet. Sharp. acroname.com/robotics/parts/sharpgp2d12-15.pdf

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