SHANMUGHA

ARTS,SCIENCE,TECHNOLOGY & RESEARCH ACADEMY

SASTRA - University
THANJAVUR 613 402

SCHOOL OF MECHANICAL ENGINEERING

MAMGL207
MECHATRONICS and AUTOMATION
LAB
Manual

Index

Exerc
ise

Title
Pneumatics

Design a pneumatic circuit using a double acting cylinder to draw a liquid

metal from a smelting crucible by a casting ladle and cast in moulds. The
raising and lowering of the ladle should be controlled by push buttons.

Design a pneumatic circuit using a double acting cylinder and 5/2 Hand
operated valve to open a main gate of a factory.

Design a simple pneumatic circuit to open and close the bus door.

Design a pneumatic circuit using AND and OR gate

Design a circuit using Time delay valve

Design a pneumatic circuit using a double acting cylinder, roller operated

valve, 3\2 push button and 5\2 single pilot valve to control the cylinder
position.

Design a circuit to control the double acting cylinder using double pilot valve.
The double pilot valve has to be controlled by only one push button.
Electro pneumatics

Washers for injection pump are to be cleaned in a cleaning bath. The double
acting cylinder is used to dip washers in and out of the cleaning bath.
Write a program to count the 10 strokes of the cylinder and stop the cycle.

Design a circuit using LSM controller to control the A.C. Non servo motor
clockwise and anti-clockwise with time delay.

10

Exercises on sequencing conveyors, single and double acting cylinders.

Page
no

6 Dof Serial Manipulator & WORKSPACE Software

11A

Study Exercise and Calibration of Home position

11B

D-H table Formation

11C

Straight Line Programming

12A

Design a Turntable (Rotary Joint) and Linear slide(Translational joint)

12B

Design and simulate a 3-dof RRR serial manipulator

12C

Path Planning for Welding Application using 6 dof serial manipulator

MAPS & Mobile Robot

13A

Study Exercise of Mini-Automation and Production and System

13B

Study of Mobile Robot Pioneer P3 AT

13C

To develop a Map of an unknown environment

Exercise 1: Design a Pneumatic circuit using double acting cylinder and two push
buttons.
Task
Design a pneumatic circuit using a double acting cylinder to draw a liquid metal from a smelting
crucible by a casting ladle and cast in moulds. The raising and lowering of ladle is controlled by
push buttons.
Apparatus required:
FRL unit
T-connector
3/2 Push buttons ( 2 nos)
5/2 Air-Air valve
Double acting cylinder
Connecting hose
Procedure:

A Double acting cylinder is used to draw the metal from the crucible and cast
the mould.

5/2 Air air valve is used to control the forward and return stroke of the
cylinder

The pilot ports X and Y of the 5/2 valve are controlled by two 3/2 push button
valves.

The air which is stored in the reservoir of the compressor enters the FRL
unit and passes through the pressure ports of two 3/2 push buttons and 5/2
Air-air valve.

When the push button 1 is pressed, the working port of the push button 1 will
lead the supply to the pilot port X of the 5/2 air-air valve. Thus the spool in
the 5/2 valve moves and connects the working port A to the rod end of the
cylinder. The cylinder extends and the pressure at the piston side is
exhausted through the port S to the atmosphere.

When the push button 2 is pressed, the working port of the push button 2 will
lead the supply to the pilot port Y of the 5/2 air-air valve. Thus the spool in
the 5/2 valve moves and connects the working port B to the Piston side of
the cylinder. The cylinder retracts and the pressure at the rod end is
exhausted through the port R to the atmosphere.

The circuit which is designed is simulated in the P- Simulation Software

The components are connected in the pneumatic board with the connecting
hoses as per the circuit.

A Pressure of 2 bar is applied through the FRL unit and by pressing the
push button the cylinder extends and retracts

Circuit Diagram:
Double Acting cylinder

5/2 Air-Air Control

Valve

FRL unit

3/2 Push Button

Valve

3/2 Push Button

Valve

Result:
Thus the circuit is simulated in the software; the connections are made on the board and tested
with pneumatic supply
Note: Exercise 1 may be taken as model exercise for exercises 2 to 7

Exercise 2: Design a simple pneumatic circuit using 5/2 hand operated valve
Task
Design a circuit to operate the main gate of a factory from the security room using a hand
operated valve.
Identify the apparatus required:
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 3: Design a simple pneumatic circuit to open and close the bus door.
Task
Design a circuit to operate the door of a bus assuming the control is present with the driver and
the bus instructor.
Identify the apparatus required:
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 4: Design a pneumatic circuit using AND and OR gate

Task
The door of a room containing safe deposit boxes is operated by a spring return cylinder. The
door remains closed by a spring force. There are 3 toggle switches namely S1, S2, S3 available
at the safe deposit room (for user), guard room and reception respectively for operating the
door. The user is acknowledged by the guard constantly monitoring the safe deposit boxes. In
the absence of the guard, the entrance lobby receptionist monitors it.
Identify the apparatus required:
Design the circuit:
Write the procedure:
Furnish Result:
6

Exercise 5: Design a circuit using Time Delay, AND gate& OR gate

Task
Embossed name plates are to be produced from a thin metal sheet. The double acting cylinder
should extend when both push button S1 and S2 are pressed simultaneously. The return stroke
is to occur only after the forward end position and achieving a desirable pressure limit. The
cylinder should immediately retract if Emergency push button S3 is pressed
Identify the apparatus required:
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 6: To perform sequencing operation with Single acting cylinder and Double
acting cylinder combined together.
Task
Assume the paint tins are moving on a conveyor. At a certain position, the operator uses a push
button valve to place the caps on the tin. A double acting cylinder lifts up the tin and cap is
pressed by a single acting cylinder. Make the circuit to perform this operation by a push button
valve.
Identify the apparatus required:
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 7: Design a circuit to control the double acting cylinder using double pilot valve.
The double pilot valve has to be controlled by only one push button.
Task
Design the circuit:
Write the procedure:
Furnish Result:

ELECTRO PNEUMATICS
Exercise 9: Design a circuit using LSM controller to actuate a Double acting cylinder
Task
Washers for an injection pump have to be cleaned in a cleaning bath. The double acting cylinder is used
to dip a container with washers in and out of the cleaning bath. For good cleaning, the washers have to
be immersed in the bath for count of 10 strokes. Write a program to perform this sequence.
Program:
// i, - input(sensor)
//x,y - output(actuator)

dim a as integer
dim b as integer
for a = 1 to 5
if inp(i) = 1 then
b= outp(x,1)
b=outp(x,0)
delay(1000)
b=outp(y,1)
b=outp(y,0)
delay(1000)
endif
next
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 9: Design a circuit using LSM controller to servo motor control

Task
Controlling the A.C non servo motor in clockwise and anticlockwise direction with time delay in repeated
cycles
Program:
Design the circuit:
Write the procedure:
Furnish Result:

Exercise 10: Sequencing using electro-pneumatics with single and double acting cylinders.

Task
Two cylinders are used to transfer parts from a stack on to a chute. When a push button is pressed the
nd
cylinder 1.0 extends pushing the parts from the stack, to the conveyor and positions it to transfer by 2
cylinder on to the out feed chute. A servo motor runs the conveyor system. Once the part is transferred
the first cylinder retracts followed by the second. The speed of both the cylinders is adjustable.

Program:
// i, j,k - input(sensor)
//x,y,z - output(actuator)
dim a as integer
dim b as integer
for a = 1 to 5
if inp(i) = 1 then
b= outp(x,1)
delay(1000)
b=outp(x,0)
delay(1000)
if inp(j) =1 then
b= outp(z,1)
delay(1000)
b= outp(y,1)
delay(1000)
b=outp(y,0)
if inp(k) =1 then
b= outp(z,0)
delay(1000)
endif
endif
endif
next

Design the circuit:

Write the procedure:
Furnish Result:

6 DOF SERIAL MANIPULATOR

11A. Study Exercise and Calibration of Home position

Configuration
No. of Axes
Link 1
Link 2
Vertical Height
Joint Actuators
Transmission

Gripper
Robot
Control

: Vertically Articulated Five-bar Linkage

: 6 (3 axes waist-shoulder-elbow with 3 axes Roll-Pitch-Roll wrist)
: 300 mm
: 300 mm
: 400 mm
: DC Servo geared motors
: Joint 1
: Gear Train
Joint 2 & 3
: Ball screw
Joint 4, 5 & 6 : Timing belt
: Pneumatic / Electrical
: 35 kg
: 20 kg

Joint Motion
Manipulator
Joint 1
Joint 2
Joint 3
Joint 4
Joint 5
Joint 6

:
:
:
:
:
:

300 degrees
60 degrees
60 degrees
300 degrees
180 degrees
300 degrees
10

11B. Denavit - Hartenberg Table Methodology

OBJECTIVE
1. To establish the axes and construct the DH-Table for solving the forward kinematics
or inverse kinematics
PROCEDURE

Assign frames to each links

Nominate the X-axes and Z-Axes for each frame

Formulate the transformation of frames in order to create the D-H table

Z3
Z4

Z2

Z5
Z6

Z0

Z1

D-H Table:

1.

d
d1

a
0

90

2.

2 + 90

a2

3.

90

4.

d3+ d4

-90

5.

5 - 90

90

6.

d5+ d6

0
11

11C. Solving Forward Kinematics

OBJECTIVE
1. To determine 0T6 from the D-H table and verify the Cartesian coordinates of the endeffector, for a particular set of joint values
PROCEDURE

For each row the total transformation matrix is computed

D-H Table:
0T

1.

d
d1

a
0

90

2.

2+90

a2

3.

90

4.

d3+ d4

-90

5.

5-90

90

6.

d5+ d6

T1 = [ cos(teta1)
sin(teta1)
0
0

0
sin(teta1) 0;
0 -(cos(teta1)) 0;
1
0
d1;
0
0
1];

Calculate 0T6 which is given as

The calculated position vector in the matrix 0T6 is compared with the Cartesian

0T

=0T1 x 1T2 x 5T6

coordinates of the end-effector, for a particular set of joint values

12

12A. Design a Turntable using a Rotary Joint

AIM:
To create a turn table in workspace software and simulate its rotation by having an
object fixed at its edge.
PROCEDURE:
Creating the shell:
1. The basic shape of a turn table is two cylinders mounted one above the other
2. Bottom cylinder is the table base with larger diameter compared to the other. The
dimension of the base is radius-10units, height-100units.
3. Click on the object to select it and go to the position. The values are given such
that the base is aligned to the inertial frame.
4. Now, the top cylinder is given dimensions radii -50units, height-10units.
5. The top cylinder is aligned with the upper face of the table base.
6. A small object (box) of dimensions 5x5x5units is fixed over the top as shown in
the diagram and the object is positioned at the edge of the table top.
7. The general layout of the turntable mechanism has been created but the part
needs to be attached to the turntable top, as shown in figure 1.
8. Select the object Part as the attachment child. From the Modify main menu,
select Attach. Click on the object Top as the attachment parent.

Creating the Mechanism and Defining the Rotational Joint:

The next stage of the construction is to create the mechanism, create the joint
and specify the type of joint.
The cylinder Base is selected and the Mechanism is created from the Create
main menu.
13

 The Turntable has been defined as a mechanism, with 1 auxiliary joint variable.
A rotational joint is created by at the origin of the parent object (Base). This can
be seen represented by a co-ordinate frame and a graphical representation of
the rotational joint, as shown in figure 2.
Learning a GP:
1. Go to view
pendant
learn GPs of the joint between object and the table
top.
2. Create a new path file say, TURN and keep adding various GPs.
3. On clicking simulation, the turn table rotates with the given GP like +90, +180, 30, -60, etc
4. If the speed of the simulation is fast, the speed can be controlled by using
simulator options say, 100ms.

RESULT:
A model of turn table is drawn in workspace and its rotations are simulated successfully
with an object attached to its corner.

14

Design a Turntable using a Rotary Joint

AIM:
To create a translational joint (slider mechanism) using Workspace 5 software and
simulate the translations of the slide.
PROCEDURE:
The mechanism to be created is a translational mechanism, i.e. slide in a guideway.
1. Three cuboids of suitable dimensions named as, guideway, tool and the slide,
are created
2. CUBOID 1 (guideway):
Construct a cuboid of dimensions 100x20x20 and align it to the inertial
frame as follows,
X=50; Y=10; Z=10
R=0 (roll); P=90 (pitch); Y=0 (yaw)
CUBOID 2 (tool-creating slot):
A cuboid of dimensions 65x10x10 is made and placed over CUBOID 1
(guideway).
Using the BOOLEAN operation (subtract), the necessary slot is created
by subtracting tool (child object) from the parent object.
Hence the slot for the slide in the guideway is created.
CUBOID 3 (slide):

Now, another cuboid named SLIDE, is created to fit at the centre of the
slot and give appropriate inside and outside movement while defining its
mechanism parameters.
Once defining the construction of the model, attach the slide onto the
guideway by MODIFY option.
Create the joint, specify the mechanism as translational. Give the suitable
GPs from the VIEW options. Create a new path file as SLIDE and give
the motion.
Simulate the mechanism.

RESULT:
Thus the slider mechanism is created using Workspace 5.

15

12B.Design and simulate a 3-dof RRR serial manipulator

AIM:
To simulate a robotic arm as a model by using workspace software.
PROCEDURE:
First we have to create the shell of the robot.
Creating the shell of the robot:
1. Create a cylinder with the dimensions length=80 units and radius=120 units. The
coordinates are given as (0,0,40)
2. The coordinates are set. Then name the cylinder as obj0.
3. From the CAD window of the project view, under the layer branch, left click the
(+) icon on layer 0.
4. Browse in the list and click on the obj0 to select the object.
5. Change the name to ROBOT1. Make sure that the name entered is in capital letters
6. The second object is created with the following dimensions
7. Length=250 radius=70 centroid (0,0,230)
8. Change the name to LINK1. Select clear selection on the CAD view point.
9. Similarly LINK2 and LINK3 are created as per the dimensions in table
10. Before simulation edit the joints and necessary movement from the Robot main
menu, left-click Edit Joints. For the base frame( X=0, Y=0, Z=0), pitch and roll is
zero.

16

Setting the kinematics of the robot:

1. From the Robot main menu, left-click Kinematics. A Floating dialog is activated
2. Change the Templates field to 3R.
3. Left-click OK to the dialog shown below.
Give the necessary GPs to check the orientation of the arm and then simulate it.

RESULT:
Thus a robotic arm is simulated in workspace5 software.

17

12C. Automatic tool path generation for welding operation

AIM:
To create a welding path automatically for a Welding robot
PROCEDURE:
1. From the workspace directory, select the automatic path model folder and go to
the file automatic path.wsp.
2. Select CREATE
SUPER CHAIN
FACE FEATURE.
3. Select the top face of the flat part and click add button from the feature section of
the dialog box.
4. Select Exterior Wire and press OK.
5. Go to CREATE followed by PATH and then change the path name to PART 1,
and then select GENERIC AUTOMATED and press OK.
6. Select the feature FCO_00 and then edit the properties from APG dialog box.
7. Then select, USE MODIFIED CONFIG to change from FUT 0,0,0 to NUT 0,0,0
and give OK to all.
8. Right click on SK16 file to simulate the path on the object.

RESULT:
The automatic path (welding robot) is generated successfully in Workspace 5.
18

Mini Automation and Production System (MAPS)

3
4

10
8

12

Specifications:
S.NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

DESCRIPTION
Complete workstation mounted on an aluminum profile
plate with operating console
Belt conveyor module
Horizontal transfer unit
Linear pick and place
Rotary indexing table
Filling module
Capping module transfer
Transfer module
Weighing module
XY palletizer
vision inspection module
Siemens PLC Control Panel

19

13A. Study Exercise

SIEMENS PLC: SPECIFICATIONS:
Make: Siemens S7-200 Series.
Base model: CPU 226 base unit
24 Digital input / 16 Digital output (24V DC power ON)
Addressing I0.0 to I0.7, I1.0 to I1.7 and I2.0 to I2.7
Expansion model: 16 Digital input / 16 Relay output
(24V DC power ON)
Addressing I3.0 to i3.7 and I4.0 to I4.7
Expansion analog input model:
2 analog inputs 0-10 VDC (24V DC power ON)
Expansion analog Output model:
2 analogs output 0- 10 VDC (24V DC power ON & 0-10V DC)
Software: Step 7 Micro win ver 4.0 (Windows 98/windows XP)
With built in effective function blocks for modular programming.

20

CONTROL PANEL LAYOUT

CONTROL PANEL LAYOUT(Inside view)
Trunking

Trunking

Pneumatic
CPV valve
terminals
(Solenoid)

Expansion
Module
16I/ 16O

PLC(SIEMENS
-S7-226)

Analog
I/P

Analog
O/P

Opto
coupler

Relay
card

Pneumatic
CPV valve
terminals
(Solenoid)

Terminals

Trunking

Stepper
driver
card(X-Axis)

Transformer

Trunking

Trunking

Bridge
rectifier

Stepper
driver
card(Y-Axis)

24V,5V SMPS

Capacitor

21

PLC INPUT ASSIGNMENT DETAILS

Sl
No

Input element Connected

PLC Address

1.

Inductive sensor (at the Conveyor starting position)

I 1.0

2.

Photo electric sensor (at the Conveyor ending

position)

I 1.1

3.

Magnetic reed switch (at the cylinder

Retracted position in the HTU)

I 1.2

4.

Magnetic reed switch

position in the HTU)

I 1.3

5.

Magnetic reed switch (at the cylinder retracted

position in the LP&P Horizontal arm)

I 1.4

6.

Magnetic reed switch (at the cylinder extended

position in the LP&P Horizontal arm)

I 1.5

7.

Magnetic reed switch

position in the LP&P

I 1.6

8.

Magnetic reed switch (at the cylinder Extended

position in the LP&P Vertical arm )

I 1.7

9.

Photoelectric sensor
(at the Rotary indexing
table to detect the presense of material )

I 2.0

10. Inductive sensor to count no of stations passed of

the rotary.(Below the rotary indexing table)

I 2.1

reed switch at the filling unit cylinder

11. Magnetic
retracted position
Magnetic reed switch at the filling unit cylinder
12. extended position

I 2.2

reed switch at the capping unit cylinder

13. Magnetic
retracted position

I 2.4

Magnetic reed switch at the capping unit cylinder

extended position

I 2.5

14.

(at the cylinder Extended

(at the cylinder Retracted

Vertical arm)

I 2.3

HTU- Horizontal Transfer Unit

LP&P- Linear Pick and Place Unit
All the inputs are of Normally open type

22

MOBILE ROBOT PIONEER P3 AT

Adept Mobile Robot platform uses revolutionary high-performance microcontroller with

advanced embedded robot control software based on the new-generation 32-bit
Renesas SH2-7144 RISC microprocessor, including the P3-SH microcontroller with
ARCOS, ARCS with PatrolBot
23

13B. Study of Mobile Robot Pioneer P3 AT

SOFTWARE AND PIONEER SDK
Adept Mobile Robot platform operates as the server in a client-server environment: Its
microcontroller handles the low-level details of mobile robotics, including maintaining
the platforms drive speed and heading, acquiring sensor readings. To complete the
client-server architecture, Adept Mobile Robot platform requires a PC connection:
software running on a computer connected with the robots microcontroller via the
HOST serial link and which provides the high-level, intelligent robot controls, including
obstacle avoidance, path planning, features recognition, localization, navigation, and so
on.

An important benefit of Adept MobileRobots client-server architecture is that different

robot servers can be run using the same high-level client. Several clients also may
share responsibility for controlling a single mobile server, which permits experimentation
in distributed communication, planning, and control.
The Pioneer SDK is a collection of libraries and applications that come with every
Pioneer mobile robot and with selected accessories. The standard Pioneer SDK
bundled with every robot at no extra charge includes the open-source ARIA and
ArNetworking, the MobileEyes and Mapper3-Basic network GUI applications,
SONARNL and MobileSim.
Features include
44.2368 MHz Renesas SH2 32-bit RISC microprocessor with 32K RAM and
128K FLASH
3 RS-232 auxilliary serial ports configurable from 9.6 to 115.2 kilobaud
1 HOST software control serial port
4 possible SONAR arrays (8 ultrasonic transducers in each arry)
16 digital inputs for bumper switches
24

 16 digital I/O lines for gripper or customer use

5 and 12 VDC power
Heading correction gyro port
2-axis, 2-button joystick port
User Control Panel
USER CONTROL PANEL
The User Control Panel gives access to the ARCOS-based onboard microcontroller. It
consists of control buttons and indicators and an RS-232 compatible serial port
(9-pin DSUB connector).
Power and Status Indicators
The red PWR LED is lit whenever main power is applied to the robot. The green STAT
LED state depends on the operating mode and other conditions. It flashes slowly when
the microcontroller is awaiting a connection with a client and flashes quickly when in joydrive mode or when connected with a client and the motors are engaged. It also flashes
moderately fast when the microcontroller is in maintenance mode.

Serial Port
The SERIAL connector, with incoming and outgoing data indicator LEDs (RX and TX,
respectively), is through where you may interact with the ARCOS microcontroller from
an offboard computer for tethered client-server control and for microcontroller software
maintenance. The port is shared internally by the HOST serial port, to which we connect
the onboard computer or an Ethernet-to-serial device. Either the SERIAL or HOST
connector may be used for client-server and maintenance mode communication with
the microcontroller.
25

13C. Mapping of an Unknown Indoor Environment Using a SICK LMS100 Laser

Rangefinder

SOFTWARE NEEDED:
SOPAS, ARIA, Mapper3.

PROCEDURE:
Connect the SICK LMS100 to a power source from the Pioneer 3AT and through
Ethernet to the onboard PC after placing the device at the front of the robot.
On the onboard PC, run SOPAS and connect the device to it. Please note that during
the change of IP address, all other network connections of the PC must be
switched OFF.After the connection has established, under the Basic Settings tab, click
on start measure.
Run a relevant mapping program through ARIA (example: sicklogger.exe). There is a
high chance that ARIA will not be able to connect to the laser directly. Under such a
circumstance, use the -laserport .. command.
Example in command promt:
Sicklogger.exe testscan.2d -robotport com3 -laserport 192.31.22.1
After jogging the robot through the indoor environment, search for the name of the 2d
file given in cmd in the onboard PCs C: drive. Run the file on mapper3 to view and edit
the obtained map.

RESULT:

26