UNIVERSITI TEKNOLOGI MALAYSIA
Contents
1. The title of this project is wireless forklift with omni directional movement 12 PROBLEM STATEMENT Most of forklift that use in manufacturing industry can only move forward and reverse so it will have a problem to move a load when the forklift enter a narrow space It also will take a time when the driver wants to adjust the forklift to go to the desired place Therefore this wireless forklift with omni directional movement is designed to resolve this problem 13 OBJECTIVE OF PROJECT This project is carried out three objectives the first objective of this project is to design and build a forklift that can lift up and lift down a load and carry the light object This project is fabricated by applying the concepts and characteristics of the real forklift The second objective is to make this forklift can move to all direction without rotate the wheels The last objective is to design an operating system for forklift so this forklift can be control using wireless joystick 14 SCOPE OF PROJECT The scopes that states below is the guidelines that listed to ensure the project is conducted within its boundary of mechanical hardware circuit design and software design This is to ensure that the objective of this project will achieve e Design mechanical and electronic hardware that will suit with software that will do developed e Using one servo motor to lift up and lift down a light object e The forklift will be equipped with tra2. Checksum 0x19a2 Eltymow amp 2 GApsm testing try c f include lt pic h gt include the PIC microchip header file E try mcp 8 1 Source Files configuration try c __ CONFIG 0x3FA2 configuration word register 1 for the microcontroller 5 Header Files __ CONFIG 0x3FBC configuration word register 2 for the microcontroller Object Files u 2 define CA Library Files fdefine lmspeed CCPRIL left motor driver speed control pin L298N enable pin CA Other Files define Ilmotorl RDE left motor driver inputl define 1motor2 RD7 left motor driver input2 define rmspeed CCPR3L right motor driver speed control pin L298N enable pin define rmotorl RB3 right motor driver inputl efine 2 RDS right motor driver input2 E Files 1 Symbols ES ad ME Files 5 define bmspeed CCPR2L back motor driver speed control pin L238N enable pin fdefine bmotorl RD3 back motor driver inputl define bmotor2 RD2 back motor driver input2 skps protocol fdefine p select fdefine p joyl fdefine p joyr define p start define p up fdefine p right define p down define p left define p 12 define p_r2 fdefine 11 efine p triangle fdefine p joy 1x define p joy ly define p joy rx define p joy ry fdefine p joy lu e p joy Id efine p joy ll define p joy Ir define iov ru PIC16F777 W 0 zdcc bank0 Ln1 Coli INS WR Figure 3 25 MPLAB IDE compiler interface
3. lt RAS AN4ILVDIN SSIC20UT REO RD ANS REINNRIANG RE2Z CSIANT lt gt VDD qm Vss_ p OSCA CLKURAT OSC2 CLKO RAG gt RCOTIOSOTICKI lt 51 153 656 2 RC2 CCP1 ROVSCKISCL RDO PSPO lt RDM PSP1 lt gt PIC16F747 777 RBY PGD RB amp PFGC RES AN13 CCP3 REPANTI RBYICCPA ANG RB2 AN8 RB1 AN10 RBO INT AN12 RD6 PSP6 RDS PSP5 RDAIPSP4 REFRADT RESTAR RCS SDO RC4 SDUSDA RDAIPSP3 RD2 IPSP2 Figure 3 19 Pin Diagram of PIC16F777 26 Operating Freguency DC 20 MHz Resets and Delays POR BOR PWRIT OST Flash Program Memory 14 bit words Data Memory bytes Interrupts VO Ports Ports A B C D E mers Capture Compare PW M Modules Master Serial Communications MSSP AUSART Parallel Communications PSP 10 bit Analoa to Digital Module 14 Input Channels Instruction Set 35 Instructions Packaging 40 pin PDIP 44 pin QFN 44 pin TQFP Table 3 1 PIC16F777 Device Features 3 3 4 L298 MOTOR DRIVER If a DC motor is connected directly to the battery DC motor will be provided with a constant power all the time Due to this constant power the speed of motor will slow down or speed up regarding the load it takes If the load is heavier the speed of motor will be slow down and speed up when the load is lighter Hence DC motor driver is ne
4. C language is chosen as the programming language for this project due to the memory size of C language is small and easy to understand MPLAB IDE software that use in this project was employed to write the C language programming USB ICSP PIC programmer is use together with PICkit2 software to load the hex file into 33 the PIC microcontroller Figure 3 26 illustrate the PICkit2 software and Figure 3 27 shows the circuit of USB ICSP PIC programmer Use ibe FFEFFEFF 2 found and connecied PIC Device Found El Enabled HecOriy Source None Empty Erased 0033 2040 0043 0050 0059 EEPROM Data Gel Enabled Hex Oriy 00 FF FF FF FF FF FF TF FF FF FF IT 10 FF FF FF FF FF FF FE TF OFF FF FF PF FF FF FF FF 20 FF FF FF FF FF FF FF FT FF re FF er rr TT 30 FF FF FF FF FF TE TF TF FF FF FF FF FF FF FF TT e Figure 3 26 PICkit2 Programmer Interface Menu Bar Device Configuration Stans Window Status Bar Device Von Memori Source EEPROM Data Memory 34 Figure 3 27 USB ICSP PIC Programmer Flow chart that show the basic process of software programming design 15 illustrate in the Figure 3 28 Note that in the flow chart there are joy lu joy Id joy rr and joy rl This variable 15 being name according to the standard format Joy XX means right joystick d means down axis r means right axis means left axis 35 Sta
5. 6 volt voltage regulator that has been built 2 f LED BLUE TEXTS Figure 3 15 Voltage regulator circuit with 6 volt output 23 Figure 3 16 Main Circuit Power supply that used to supply the voltage regulator circuit is Lipo battery 11 1 volt DC Sometimes the input supply may be noisy To overcome this problem and to get a better 5 volt and 6 volt output capacitor 15 added to the circuit 3 3 2 LIPO BATTERY Lithium Polymer or Lipo battery is a type of rechargeable battery In this project I use two 11 1V Lipo batteries One of battery is used for two DC geared motor and another one is used to one DC geared motor and to both voltage regular to supply power to circuit Figure 3 17 shows the picture of Lipo battery 24 Figure 3 17 11 1 Lipo Battery 3 3 3 YO PIN ASSIGNATION OF PIC16F777 Microcontroller 15 used in this project because of its small size low cost but high performance Microcontrollers is combination microprocessor memory I O ports and other special function registers such as timer ADC PWM and interrupt PIC16F777 was selected as microcontroller that will be used in this project Figure 3 18 shows the picture of PIC16F777 Figure 3 19 pin diagram of PIC16F777 and Table 3 1 shows the features of this microcontroller 25 Figure 3 18 Dual In line type PIC16F777 MCLRVFRREI e RADANO RAVAN1 lt gt RAZIANZIVREF ICVREF a RAVANINREF lt RAATOCKUCIOUT
6. Mobile Robot and Its Applications Seoul National University 2000 Tua Augustinus Tamba Bonghee Hong and Keum Shik Hong A Path Following Control of an Unmanned Autonomous Forklift Proc of the International Journal of Control Automation and Systems 2009 7 1 113 122 PIC16f777 Microcontroller User Manual 2006 L298 datasheet 2000 RC Servo C36R C40R C55R datasheet 2009 SKPS User s Manual Oct 2008 http malaysia rs online com 48 APPENDIX APPENDIX A Source Code include lt pic h gt include the PIC microchip header file configuration CONFIG 0x3FA2 configuration word register 1 for the microcontroller _ CONFIG 0x3FBO configuration word register 2 for the microcontroller define define Imspeed CCPRIL left motor driver speed control pin define Imotorl RD6 left motor driver inputl define Imotor2 RD7 left motor driver input2 definermspeed CCPR3L right motor driver speed control pin define rmotor RB3 right motor driver input define rmotor2 RD5 right motor driver input2 definebmspeed CCPR2L back motor driver speed control pin define bmotor RD3 back motor driver inputl define bmotor2 RD2 back motor driver input2 define servo RBO skps protocol definep select 0 define p_joyl l define p_joyr 2 define p start define p up define p right define p down define p left definep 12 definep 12 define p 11 define p 1 define p triangle define p circle
7. define p cross definep sguare define p joy Ix definep joy Iy define p joy rx define p joy ry define p joy lu define p joy Id define p joy Il define p joy Ir define p joy ru define p joy rd define p joy rl define p joy rr definep con status define p motorl define p motor2 void 1init void 28 29 30 void Im run unsigned char dir void rm_run unsigned char dir void bm_run unsigned char dir 49 void left void void right void void backward void void forward void void clockwise void void anticlockwise void void stop void void deg 30 void void deg 120 void void deg 240 void void deg 330 void void delay unsigned long data void uart send unsigned char data unsigned char uart rec void unsigned char skps unsigned char data void skps vibrate unsigned char motor unsigned char value void main void unsigned char up_v down v left v right_v initQ initialize microcontroller stopO while 1 read joy stick value process up v skps p joy lu down v skps p joy Id left v skps p joy ri right v skps p joy rr if skps p_up 0 50 51 Imspeed rmspeed 255 assign speed to respective motor pwm pin bmspeed 0 forward else if skps p down 0 1 Imspeed rmspeed 255 bmspeed 0 backward j else if skps p_left 0 bmspeed 255 Imspeed rmspeed 1 90 leftQ j e
8. guidance and support throughout this project Besides that I would like to record my gratitude to my beloved parents because without them I will not be able to do well in my final year project They did give me a lot of support both from money and moral support to help me continue for what I had started on Last but not least I would like to appreciate to my colleagues and others who provided assistance at various occasions involved either directly or indirectly in completing this project Their views and tips are useful indeed May Allah S W T bless for the cooperation and support 1V ABSTRACT Forklift is powered industrial truck used to lift and transport materials Forklift has become indispensable equipment in manufacturing and warehousing operations This project was implemented a mobile robot concept to the forklift The mainly is about designing and fabricating forklift which is can move in omnidirectional movements and operated by PS2 wireless controller This forklift can move freely in ten movements PIC16f777 was act as a brain for this forklift to produce the output signal to control the forklift movements Three transwheel was been used to make this forklift can move in omnidirectional movements and one servo motor to lift up and down the light object To make it can control using PS2 wireless controller is by using SKPS module that can receive data from PS2 wireless controller and transmit to PIC16f777 This research has a
9. 60 the coupling Figure 3 13 shows the picture of the transwheels 21 WWW CYTRON N COM MY Figure 3 13 Transwheels 33 ELECTRONIC AND CIRCUIT DESIGN In the electronic and circuit design the first step is must to understand the requirements of the project and the limitation of various constraints like the level of technology reliability of microcontroller and the complexity of programming codes and interfacing devise By using datasheet that search using internet analyze about the component that want to use in the project and by using reference from the previous researcher Circuit designs are drawn by using Proteus software 3 3 1 POWER SUPPLY CIRCUIT Two type of power supply circuit voltage regulator circuit are used in this project The output voltage that supplies 3 volt and 6 volt will be used Power supply with 5 volt output will be used to supply on main circuit motor driver circuit and to PS2 controller starter kit To make a 5 volt power supply LM7805 voltage regulator has been used and in the Figure 3 14 shows the circuit of 5V voltage regulator 22 1000nF TEXTS Figure 3 14 Voltage regulator circuit with 5 volt output Another power supply is 0 volt output voltage regulator To make it can produce 6 volt LM7806 voltage regulator has been used and Figure 3 15 shows the circuit design of 0 volt voltage regulator Figure 3 16 shows the main circuit that consist PIC circuit and 5 volt and
10. 98 SKPS PS2 Controller Starter Kit Function Description 33 34 35 36 40 41 4 43 PAGE 26 27 30 DC RC PIC PS2 RM TEG ICSP USB UART Li Po APPENDIX A LIST OF ABBREVIATIONS Direct Current Radio Controlled Programmable Interface Controller Play Station 2 Ringgit Malaysia Transistor transistor Logic In Circuit Serial Programming Universal Serial Bus Universal Asynchronous Receiver Transmitter Lithium Polymer Watts Voltage Ampere kilograms centimeter Second millisecond Gram LIST OF APPENDIX TITLE PAGE Source Code 48 CHAPTER 1 INTRODUCTION 11 PROJECT BACKGROUND Nowadays forklifts have become an alternative in term to move loads from one place to another place For instance forklift is widely being used in manufacturing industry Forklift will make our work more efficiency and easier Omni directional wheels have become popular for mobile robots because these wheels allow the mobile robot to drive on a straight path from a given location on the floor to another without any rotation needed by the mobile robot Moreover the mobile robot can arrive to its destination at the correct angle with combination of the rotation of these wheels In this project the mobile robots that will be built are implementing using these two concepts Forklift will be implementing with transwheels so it can move load in omni directional movement and will be controlled using wireless joystick
11. G 30 20k The locomotion of the wireless forklift was achieved by utilizing DC geared motor to each transwheels The model of the motor was used is MO SPG 30 20K bought from Cytron Technologies The rated voltage of this motor is DC 12V and it maximum current rating is 300mA An addition the flexible rated speed at 185 RPM and rated torque at 78 4mN m were offered by this model of DC geared motor The unit price of this DC geared motor is RM70 In this project three DC geared motor have been use thus 1t costs me RM210 Figure 3 7 shows the picture of a MO SPG 30 20K geared motor CYTRON COM MY Figure 3 7 DC Geared Motor MO SPG 30 20K 17 3 2 2 RC SERVO MOTOR C55R Servos are controlled by sending them a pulse of variable width The signal wire is used to send this pulse Inside a typical RC servo contains a small motor and gearbox to do the work a potentiometer to measure the position of the output gear and an electronic circuit that controls the motor to make the output gear move to the desired position Because all of these components are packaged into a compact low cost unit RC servos are great actuator 101 robots C55R RC Servo Motor 15 designed for closed feedback control The pulse width range of this servo is from 0 5ms 2 5ms The dimension and picture of CS5R servo motor are shows in Figure 3 8 and 3 9 The weight of this servo motor is 55g and the gear material that provide in this motor 15 metal gear Furt
12. PSZ 19 16 Pind 1 07 UNIVERSITI TEKNOLOGI MALAYSIA DECLARATION OF THESIS UNDERG RADUA TE PROJ ECT PAPER AND COPYRIGHT Authors full name MUHAMMAD AKMAL BIN MOHAMAD ROSLAN Date of birth 27 DECEMBER 1988 Title WIRELESS FORKLIFT WITH OMNIDIRECTIONAL MOVEMENT Academic Session 2010 2011 declare that this thesis is classified as CONADENTIAL Contains confidential information under the Official Secret Act 1972 RESTRICTED Contains restricted information as specified by the organisation where research wasdone OPEN ACCESS agree that my thesisto be published asonline open access full text I acknowledged that Universiti Teknologi Malaysia reservesthe right as follows 1 The thesis isthe property of Universiti Teknologi Malaysia 2 The Library of Universiti Teknologi Malaysia hasthe right to make copiesforthe purpose of research only 3 The Library hasthe nghtto make copies of the thesisforacademic exchange Certified by SIG NATURE SIG NATURE OF SUPERVISOR 881227 56 6125 MOHD ARIFFANAN BIN MOHD BASRI NEWIC NO PASSPORTNO NAME OF SUPERVISOR Date 16 MAY 2011 Date 16 MAY 2011 NOTES 2 If the thesis is CO NFIDENTIA L or RESTRICTED please attach with the letter from the organisation with period and reasonsforconfidentiality or restriction I hereby declare that I have read thesis and in my opinion this thesis 15 sufficient in terms of scope and guality for the award of the degree of Bac
13. c and 3m sec appropriate Robot with three wheel mechanism is quite faster and more flexible in order to reach the ball and the desire orientation To kick the ball spring that capable of compressing and releasing has implemented Second type of robot 15 consists four omniwheels and rotational kicker part Each omniwheels are supported with one DC servo motor that can make the robot move The movement of this robot 15 according from the result of the comparative generating motors thus each pair of wheels will force robot to move And for the system kicks on top of this robot can turn 360 degrees that can enables the robot to optimize the way to reach the ball with necessary orientation for the right kick This will saves time and also simplify the rotation of the robot control algorithm which is a significant advantage of this robot 2 5 FLEXIBOT USING TRANSWHEEL The Flexibot 15 a three transwheels mobile robot which 15 allows Flexibot to move in any direction without having turn relative to the robot base For example to move sideways normal mobile robots need to turn 90 degrees move forward and then turn back to its original direction But using this Flexibot it can execute a single sideways motion and further can easily track a moving oject while maintaining a required orientation with respect to it This Flexibot 15 an autonomous robot it have a push button to select the mode of movement of the Flexibot Furthermore this Flexibo
14. eded which is it can control the magnitude of supply voltage in order to control the speed of DC motor Motor Driver L298 is used in the main circuit as driving chip of three DC geared motors This motor driver gives a high voltage high current dual full bridge driver designed to accepted TTL logic levels and drive inductive loads such as 21 relays solenoids DC and stepping motors This motor driver allows a total of 4A high current to pass through it during operation Table 3 2 below shows function of each pin of chip L298 Pin Function Between this pin and ground is connected the sense resistor to Sense A Sense B control the current of the load bana Outputs of the Bridge A the current that flows through the load connected between these two pins is monitored at pin 1 Supply Voltage for the Power Output Stages A non inductive 100nF capacitor must be connected between this pin and ground TTL Compatible Inputs of the Bridge A TTL Compatible Enable Input the L state disables the bridge A enable A and or the bridge B enable B Ground Supply Voltage for the Logic Blocks A100nF capacitor must be connected between this pin and ground TTL Compatible Inputs of the Bridge B Outputs of the Bridge B The current that flows through the load Out 3 Out 4 P connected between these two pins is monitored at pin 15 Table 3 2 Pin Function of Chip L298 I have bought two of L298 motor driver at RS Comp
15. es have been collected such as journals past year thesis from library utm and internet 13 A Idea and Concept In Literature Review and Research e Mechanical Design and Construction e Circuit Design and Making e Software Programming e Testing and Implementation e FinishingProject Figure 3 1 Step taking in developing wireless forklift with omni directional A 5 ae Hardware and Software Integration 7 8 movement 3 2 MECHANICAL STRUCTURE DESIGN The mechanical design of the base and the fork arm of wireless forklift with omni directional movement was design using SolidWorks Figure 3 2 and Figure 3 3 below shows the design of the base and fork of the forklift Figure 3 4 shows the combination of base and the fork arm 14 Figure 3 2 Base design Figure 3 3 Fork arm design Figure 3 4 Complete mechanical design of forklift The design of forklift 15 to have a capability to move in all direction smoothly and can do a simple task to lift up an object by using its fork arm In order to achieve that target design of the mobile robot and forklift has been studied The dimension of the base that will be used in this project is shown in Figure 3 5 And in Figure 3 6 shows the picture of base that has been done and the material was used to build the base is prospect 86 30 a A PR TW IS 51 28 Figure 3 6 The base o a i F E 15 16 3 2 1 DC GEARED MOTORS MO SP
16. forklift with omni directional movement Base design Fork arm design Complete mechanical design of forklift Dimension of base design The base DC Geared Motor MO SPG 30 20K Dimension of RC Servo Motor C55R RC Servo Motor C55R Specification of Servo Motor Signal of Pulse Servo Motor Rotation of Servo Regarding The Pulse Given Transwheels Voltage regulator circuit with 5 volt output Voltage regulator circuit with 6 volt output Main Circuit 11 1 Lipo Battery Dual In line type PIC16F777 Pin Diagram of PIC16F777 Left side is the pin diagram and right side is picture of L298 motor driver Circuit Design of L298 Motor Driver Motor Circuit Driver SKPS PS2 Controller Starter Kit PS2 Wireless Controller with receiver MPLAB IDE compiler interface Vill PAGE 13 14 14 14 15 15 16 17 18 18 19 20 21 22 22 23 24 23 25 29 28 28 30 31 32 3 26 327 3 28 3 29 41 4 2 4 3 4 4 PICkit2 Programmer Interface USB ICSP PIC Programmer Software Programming Design Flow Chart Flow Chart of Wireless Forklift w th Omni directional Movement Programming Different view of Wireless Forklift w th Omni directional Movement Wireless Forklift at Early Stage Direction of the forklift by using transwheel Flow of Wireless Forklift to Lift Up a Light Object LIST OF TABLES TABLE TITLE 1 1 1 2 3 1 22 22 Gantt chart FYP 1 Gantt chart FYP 2 PIC16F777 Device Features Pin Function of Chip L2
17. great functions and benefits and can be proceed in the future ABSTRAK Forklift merupakan salah satu trak industri berkuasa yang digunakan untuk mengangkat dan menyusun barang Kini forklift telah dianggap sebagai peralatan yang amat penting untuk operasi di gudang dan kilang Dalam projek ini konsep robot mudahalih telah dilaksanakan pada forklift Tujuan rekabentuk model robot ini adalah untuk membolehkan forklift bergerak omnidirectional dan kawal dengan menggunakan PS2 wireless controller Forklift ini boleh bergerak dengan sepuluh arah PIC 16f777 bertindak sebagai otak yang memproses maklumat dan member isyarat keluaran untuk mengawal operasi motor Tiga transwheel tayar digunakan untuk membolehkan forklift bergerak omnidirectional dan satu servo motor untuk mengangkat dan menurunkan objek yang ringan Modul SKPS digunakan untuk menerima maklumat dari PS2 wireless controller dan menghantar maklumat tersebut kepada PIC16f777 untuk diproses Penyelidikan dalam bidang ini mempunyai fungsi yang hebat dan kebaikan serta dapat dilanjutkan di masa hadapan VI TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION 11 ACKNOWLEGEMENTS 111 ABSTRACT iv ABSTRAK V TABLE OF CONTENT vi LIST OF FIGURES Vill LIST OF TABLES 1X LIST OF ABBREVIATIONS X LIST OF APPENDIX X 1 INTRODUCTION 1 1 1 Project Background 1 2 Problem Statement 2 1 3 Objective of Project 2 1 4 Scope of Project 2 1 5 Outline of Thesis 3 1 6 Summa
18. he programming of the movements of forklift is coded The first stage of programming is to make the movements forklift which is forward north backward south left west and right east direction Eventually the programming for the north and south direction was success but there is an error west and east direction The actual problem has solved after change the tyre of forklift Last challenging during doing this project 1s the tools that used to make the mechanical structure for the fork mechanism to lift up and down There is a machine that provided by faculty but faculty does not provided the learning to use that machine Help from Robocon team member has been asked to teach how to use that machine and the mechanical structure has successfully done CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 51 CONCLUSION Project has been successfully carried out to design create and build the Wireless Forklift with Omni Directional Movements It was able to pick and place a light object to the destination and capability of omni directional movement which is forward north backward south left west right east north east north west south east south west clockwise and anticlockwise direction This also can be controlled using wireless controller which is using PS2 wireless controller It can be concluded that all objectives that has been discussed in chapter was successfully been implemented and achieved by the end of this projec
19. helor of Engineering Electrical Mechatronics Signature Tabanan e anne at Name of Supervisor MOHD ARIFFANAN BIN MOHD BASRI Date l 16 MAY 2011 WIRELESS FORKLIFT WITH OMNI DIRECTIONAL MOVEMENT MUHAMMAD AKMAL BIN MOHAMAD ROSLAN A thesis submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Engineering Electrical Mechatronics Faculty of Electrical Engineering Universiti Teknologi Malaysia MAY 2011 11 I hereby declare that this thesis entitled Wireless Forklift with Omni Directional Movement is the result of my own research except as cited in the references The thesis has not been accepted for any degree and is not concurrently submitted in candidature of any other degree Signature A a ee ee NE Name of Candidate MUHAMMAD AKMAL BIN MOHAMAD ROSLAN Date 16 MAY 2011 111 ACKNOWLEDGEMENTS Alhamdulilah I finally complete and finish my final year project successfully It helps me so much in understanding my previous lectures Experience that I obtain from doing my final year project shall prove to be an asset in the pursuit of my studies as well as for my future career prospects First and foremost I would like to praise to Allah S W T for giving me a little strength and ability to done my final year project successfully Alhamdulillah I would like to take this opportunity to thank to my supervisor Mr Mohd Ariffanan Bin Mohd Basri for his supervision
20. hermore the speed and torgue of this servo motor can reach are 0 22 s 60 speed and 9 00 Kg cm for 4 8V operation 0 20 s 60 speed and 11 00 Kg cm torque for 6 0V operation and last but not least 0 17 s 60 speed and 13 00 Kg cm torque for 7 0V operation Figure 3 10 shows the specification on servo motor One C55R servo motor has bought from Cytron Technologies that costs me RM 80 Figure 3 8 Dimension of RC Servo Motor C55R 18 Figure 3 9 RC Servo Motor C55R cor CSR om or jon Toge Kem 5 ew s0 LT speed on 01 016 Y Torque gem am 70 no cc METAS or Torque age 0 Signal To Control Angle TILPWM TILPWM TILPWM PWM At Min Angle ms 0 582 BE SI lt lt 4 8 7 0 50 0 0 180 PWM At Max Angle ms Operating Voltage VDC Operating Frequency Hz Moving Range degree 0 180 Wiring Black Brown Wire Ground Wiring Red Wire 4860 48 60 48 70 Wiring Orange Other Wire PWM sianal PWM signal PWM signal Dimension mm 4025198136 402x19 806 amaess7 Weight 360 380 sso Gear material Plastic Gear Plastic Gear Nota Gear Servo type Standard Standard Ngtandang NS Figure 3 10 Specification of Servo Motor N N 2 m 19 Servos are controlled by sending them a pulse of variable width Pulse Width Modulation 15 the pulse that applied to servo motor to determine the angle of servo motor The co
21. ler uart send value void Im_run unsigned char dir Function to run the left motor Imotor1 dir assign variable dir to left motor pin 1 Imotor2 dir assign the oppesite value of dir variable to left motor pin 2 void rm_run unsigned char dir Function to run the r ght motor rmotor1 dir assign variable dir to right motor pin 1 rmotor2 dir assign the oppesite value of dir variable to right motor pin 2 void bm_run unsigned char dir Function to run the back motor bmotor1 dir assign variable dir to back motor pin 1 bmotor2 dir assign the oppesite value of dir variable to back motor pin 2 57 void forward void Function to run Flexibot O degree Im run J assign the direction to respective motor rm run 0 void backward void Function to run Flexibot 180 degree lm run 0 rm run J void right void Function to run Flexibot 270 degree bm_run 0 lm run 0 rm run 0 void left void Function to run Flexibot 90 degree bm_run 1 Im_run 1 rm_run 1 void stop void Function to stop the motor 58 Imotor1 0 Imotor2 0 rmotor1 0 rmotor2 0 bmotor1 0 bmotor2 0 void clockwise void Function to run Flexibot clockwise Imspeed rmspeed bmspeed 200 Im run J rm run 1 bm run 0 void anticlockwise void Function to run Flexibot anticlockwise Imspeed rmspeed bms
22. lse if skps p_right 0 1 bmspeed 255 Imspeed rmspeed 1 90 right j else 1f skps p_11 0 anticlockwise else 1f skps p_r1 0 clockwise else if skps p_square 0 32 servo 1 set servo pin high delay 70 servo 0 set servo pin low delay 2635 else if skps p_circle 0 servo 1 set servo pin high delay 317 servo 0 set servo pin low delay 2385 else if up_v gt 0 1f right_v gt 0 assign speed to respective motor pwm pin bmspeed rmspeed up_v 140 Imspeed 0 assign the direction respective motor to bm_run 0 rm_run 0 else if left_v gt 0 bmspeed Imspeed up_v 140 rmspeed 0 bm run J Im_run 1 else Imspeed rmspeed up_v 140 bmspeed 0 53 forward else 1f down_v gt 0 if right_v gt 0 bmspeed rmspeed down_v 140 Imspeed 0 bm_run 1 rm_run 1 else if left_v gt 0 else bmspeed Imspeed down_v 140 rmspeed 0 bm_run 0 lm run 0 Imspeed rmspeed down_v 140 bmspeed 0 backward else if right_v gt 0 bmspeed right_v 140 Imspeed rmspeed right_v 90 right else if left_v gt 0 54 bmspeed left_v 140 Imspeed rmspeed left_v 90 left j else 1 stop j void init ADCON I ObOOO1 1111 set ADx pin digital I O TRISB 0600000000 configure PORTB VO direction TRISD 0600000000 configu
23. mplete cycle for servo 15 20ms Figure 3 11 shows the square wave signal of servo motor How far the motor turns was determined by the length of the pulse An example if a 1 5ms pulse sends to servo it will make the motor turn to the 90 degree position neutral position Pulse Width 0 5ms 2 5ms Figure 3 11 Signal of Pulse Servo Motor The position pulse must be repeated to make the servo stay in that position The servo will rotate anticlockwise if the pulse sent to servo is less than 1 5ms Hence to make servo rotate clockwise the pulse that sent to servo must be higher than 1 5ms However there is a minimum and maximum pulse that can send to servo otherwise servo motor will be damaged The minimum pulse can be sent is Ims and the maximum pulse is 2 5ms Figure 3 12 shows the rotation of servo for the pulse given 20 Figure 3 12 Rotation of Servo Regarding The Pulse Given 3 2 3 TRANSWHEEL Three transwheels were used and attached to the base of the forklift and the DC geared motor Transwheel is unique wheel it can make mobile robot moving in all direction by controlling the speed of the DC motor Transwheel are place in sequence 120 around the base Each transwheel are attached to the coupling before attached to the DC geared motor Transwheel and coupling also have been bought from Cytron Technologies with RM70 per unit and RM20 per unit In my project I use three transwheels so it costs me RM210 for this wheel and RM
24. nal movement To do this first we need to check connectivity of the circuit before try simple programming to this project which is to make this project clockwise and anti clockwise After simple programming has succeeded the programming of ten movements 1s implementing to this project However the first programming of movement is not including the controller it is automated After the programming has been confirmed then next step is to make this project can control using PS2 controller Figure 4 2 shows the picture of wireless forklift with omni directional movement at this stage step Figure4 2 Wireless Forklift at Early Stage 42 The forklift was able to move north forward south backward west turn left east turn right north east north west south east south west clockwise and anticlockwise Total all of the movement are ten movements The directions of the movement are shown on the Figure 4 3 below gan a Cay Worth cb South a a ol Eye gt North West cd South East i gt aj aa South West cm Worth East Eoo SS Sl e C2 Vest hiEast ol nn e y Cocco Figure 4 3 Direction of the forklift by using transwheel 43 44 MOVEMENT OF PICK AND PLACE LIGHT OBJECT The next step is to make the forklift can pick and place the light object This step only complicated when the hardware d
25. nswheels to move all direction e Forklift that can be controlled using wireless joystick 15 OUTLINE OF THESIS This thesis consists of five chapters In the first chapter it discusses about project background problem statement objective scope of this project While in the Chapter 2 will discuss about the literature review that have been done The next chapter is Chapter 3 that will reveal the detail of research methodology that use in this project In addition contains of chapter 3 will be included mechanical electronic and software design The result and discussion about of this project will be discussed in the Chapter 4 Last but not least Chapter 5 discusses the conclusion of this project and recommendation of the future work that can be done 1 6 SUMMARY OF WORKS Gantt charts as shown in Table 1 1 and Table 1 2 below show the planning schedule of the work in final year s first semester and second semester respectively e pala pa ele TopicResearch al Jala re BENER eater En Part s and FYP1Presentation sem pee Table 1 1 Gantt chart FYP 1 we iJo ase e o ee Hardware Completion Software Implementation Omniwheel Software Implementation Forklift messwetng FYP2 Presentation seportwrting pp ppp Table 1 2 Gantt chart FYP 2 CHAPTER 2 LITERATURE REVIEWS 21 INTRODUCTION This chapter are reviewing the similar p
26. oes Before implement software into the hardware first we need to test the programming at servo motor In this case servo motor has already been modifying to turn 360 degree After modifying Servo Motor is act like a DC motor The next step is implementing with the hardware Figure 4 4 shows the step to lift up a light object Figure4 4 Flow of Wireless Forklift to Lift Up a Light Object 44 45 DISCUSSIONS Even though this project was successfully completed but there are some challenging parts throughout this project The first and foremost is when to start the project the problem is what components to be used and the circuits design what the suitable base to be used and the programming that have to write The problem has been overcome by doing research on thesis journal and information from internet The next problem 15 during the circuit design After completing the soldering circuits motor driver circuit has some problem that cannot send the desired output and there 1s a short circuit on that motor driver circuit Some troubleshoot has been done vigorously to the motor driver circuit and the problem is identified However the circuit still can produce the desired output Next step 1s tried to change the connection of the motor driver circuit to the PIC and the problem has been solve After do some more investigation the circuit has no problem but the problem is the programming due to some setting does not include Next t
27. onent Company that cost me RM16 50 per unit and total 1s RM33 Figure 3 20 below show the pin diagram and picture of L298 motor driver and Figure 3 21 is show the circuit design L298 motor driver In the Figure 3 22 shows the motor driver circuit that has been built CURRENT SENSING 8 OUTPUT 4 OUTPUT 3 INPUT 4 ENASLE 8 INPUT 3 LOGIC SUPPLY VOLTAGE Ves GNO INPUT 2 ENASLE A INPUT 1 SUPPLY VOLTAGE Vs OUTPUT 2 OUTPUT 1 CURRENT SENSING A 28 Figure 3 20 Left side is the pin diagram and right side is picture of L298 motor driver inam ITO aoe STET CONN SIZTERT Figure 3 21 Circuit Design of L298 Motor Driver 29 y La a YA A i gt gt gt a 3 gt a gt Y ws Figure 3 22 Motor Circuit Driver 3 3 5 PS2 CONTROLLER STARTER KIT Play station 2 PS2 controllers is relatively easy to obtain from any game store and it offers good human manual input for control system More and more developers are looking into applying existing PS2 controller to control particular system On my project PS2 Controller Starter Kit will be used to connect wireless joystick and the main circuit to control this forklift movement The feature of this circuit is 5V powered low current consumption less than 150mA This controller is communicating with host microcontroller through UART The prices that sell at Cytron Technologies is RM99 90 Figure 3 23 shows the circuit of PS2 Controller S
28. peed 200 lm run 0 rm run 0 bm run J delay functions void delay unsigned long data delay function the delay time depend on the given value for data gt 0 data 1
29. re PORTC I O direction TRISC 0b 10000000 PORTB 0x00 Setup up PWM operation PR2 259 Set PWM period CCPICON 0b00001100 Configure CCP1CON to on the PWM 1 operation CCP2CON 0b00001100 Configure CCP2CON to on the PWM2 operation CCP3CON 0b00001100 Configure CCP3CON to on the PWM3 operation T2CON 0600000100 Imspeed 0 Clear left motor speed rmspeed 0 Clear right motor speed bmspeed 0 Clear back motor speed setup USART SPBRG 0x81 set baud rate to 9600 for 20Mhz BRGH 1 TXEN 1 TX9 0 CREN 1 SPEN 1 RX9 0 RCIE 0 uart function 55 baud rate high speed option enable transmission enable reception enable serial port disable interrupt on eachdata received void uart_send unsigned char data function to send out a byte via uart while TXIF 0 wait for previous data to finish send out TXREG data send new data unsigned char uart rec void function to wait for a byte receive from uart unsigned char temp while RCIF 0 wait for data to received temp RCREG return temp return the received data skps function unsigned char skps unsigned char data information on ps controller uart_send data return uart_rec function to read button and joystick void skps_vibrate unsigned char motor unsigned char value 56 function to control the vibrator motor uart_send motor on ps control
30. roject according to my project This similar project will be my guideline to this project Literature review of this project are divided into two parts first part is about forklift and the other part about omni directional robot This chapter is important because this is my reference to start and during I doing this project 2 2 WIRELESS FORKLIFT BY ABDUL AZIZ A wireless forklift was built by Abdul Aziz Bin Abdul Rahman in his undergraduate project in year 2010 Figure 2 1 below shows the picture of wireless forklift 150 0mm 230 0mm 250 0mm Figure 2 1 Wireless forklift By Abdul Aziz This wireless forklift consist Tamiya Twin Motor Gearbox DC Motor one Hextronix HX5010 Servo Motor and Bluetooth Module This forklift use Tamiya Twin Motor DC Motor to move forward and backward and to lift up the load Hextronix HX5010 Servo Motor are been used Microcontroller that been use as the brain to this forklift is PF16f877A This wireless forklift are capable to move forward backward turn right and left by controlling using laptop the Bluetooth Module will connect with laptop and receive a command from the laptop and will give the information to the microcontroller The weight of load that this wireless forklift can lift up is around 100 grams and dimensions of 6 x 7 x 11 cm 2 3 UNMANNED AUTONOMOUS FORKLIFT This unmanned autonomous forklift 1s a standard industrial forklift that produced by the CLARK Company and name a
31. rt Desired Forklift Movement Writing Programming Compile Using MPLAB IDE Load to PIC Using PICkit2 Test Forklift Movement Fail Success gt Figure 3 28 Software Programming Design Flow Chart Figure 3 29 Flow Chart of Wireless Forklift with Omni directional Movement Programming 36 31 Figure 3 29 shows the complete flow chart of Wireless Forklift with Omni Directional Movement Forklift will not make any movement if any button of PS2 wireless controller does not press To make this forklift can lift up and down the light object sguare button was assigned to the lift up process while the lift down process circle button was assigned The movement of omni directional movement has been assigned by using two joysticks Left joystick was assigned to make forward north and backward south direction while to the left west and right east direction right joystick has been assigned However to make the north east north west south east and south west direction the both joystick has been assigned to used together Last but not least is the clockwise and anticlockwise movement LI button has been assigned to do the anticlockwise process and R1 button to do the clockwise process 34 SUMMARY OF CHAPTER 3 In this chapter was discussed about the mechanical structure design electronic and circuit design and last but not least programming design of the Wireless Forklift with Omni Directional Movemen
32. ry of Works 3 2 LITERATURE REVIEW 5 2 1 Introduction gt 2 2 Wireless Forklift by Abdul Aziz 6 2 3 Unmanned Autonomous Forklift 1 2 4 Cooperation Multi Agent Soccer Robot Team 8 25 Flexibot Using Transwheel 9 ATX Series Omni Directional 2 6 Forklift 10 3 METHODOLOGY 12 Jd Introduction 12 Mechanical 22 Design 13 A DC Geared 16 3 3 3 4 3 5 Motor 322 RC Servo Motor 323 Transwheels Electronic and Circuit Design 31 Power Supply Circuit RIZ Lipo Battery 3 3 3 I O Pin Assignation of PIC16f777 L298 Motor 3 3 4 Driver III PS2 Controller Starter Kit 3 3 6 PS2 Wireless Controller Programming Design Summary of Chapter 3 4 RESULT AND DISCUSSION 4 1 4 2 4 3 4 4 4 5 Introduction Final Hardware Design The Movement of Omni Directional Movement Movement of Pick and Place Light Object Discussions 5 CONCLUSION AND RECOMMENDATIONS 5 1 5 2 REFERENCES APPENDIX Conclusion Recommendation vil 17 20 21 21 23 24 26 29 31 32 31 39 39 39 41 43 44 45 45 46 47 48 LIST OF FIGURES FIGURE TITLE ZA 22 2 3 2 4 2 Sel 32 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 1 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 32 321 322 3 23 3 24 3 25 Wireless Forklift By Abdul Aziz Clark CRX 10 forklift equipped with sensors Right side is 3 wheel robot and left side is 4 wheel robot Flexibot Using Transwheel Airtrax ATX 3000 Forklift Step taking in developing wireless
33. s CRX 10 The CRX 10 forklift is shows in Figure 2 2 Figure 2 2 Clark CRX 10 forklift equipped with sensors This unmanned forklift are mounted with four wheels include one small caster wheel at the right rear side and two caster wheel at the front side and one main wheel at the left rear side for controlling the direction of the forklift These forklifts have ability for dual operations that is unmanned mode and manual mode For unmanned mode order motions are generated based on information provided by some Sensor pose 24 COOPERATIVE MULTI AGENT SOCCER ROBOT TEAM This robot has been designed to enter a RoboCup mobile robot competition and the objectives of this competition are a robot must be prepared to accelerate in an appropriate direction recognize ball and the others robot swiftly can kick ball with sufficient velocity and with proper accuracy To achieve the characteristics of this robot two type of multi agent soccer robot team have been design which 15 three wheel triangle robot and four wheel Cartesian robot that are shows in Figure 2 3 According to the different maneuvers of the two robots a team from both types of robot can have more flexibility and powerful mobility Chi Va Sem HE Hi Figure 2 3 Right side is 3 wheel robot and left side is 4 wheel robot Three 80 W DC servomotors are used on three wheel triangle robot Based on the physical characteristic robot the maximum speed acceleration is 2m se
34. t In mechanical design part the forklift with the specification discussed above was successfully done In electronic and circuit design section various electronic components module and circuits employed in this wireless forklift were discussed 38 Furthermore in the programming part the selection for software to do programming was determined and flow chart for the movement of Wireless Forklift with Omni Directional Movement was discussed CHAPTER 4 RESULT AND DISCUSSION 41 INTRODUCTION The result of Wireless Forklift with Omni directional Movement shall be explained in this chapter This chapter also discusses about the problems that are encountered throughout the completion of this project This project has been executed step by step The first step that been executed 1s to make this project can move in the omni directional movement After this objective have achieved the second step is to control this project using PS2 wireless controller and finally is to lift up and carry the light object 42 FINAL HARDWARE DESIGN The final hardware design of Wireless Forklift with Omni directional Movement 15 illustrated in Figure 4 1 40 Front view Back view Right view Left view Tea Plan view Isometric view Figure4 1 Different view of Wireless Forklift with Omni directional Movement 41 43 THE MOVEMENT OF OMNI DIRECTIONAL MOVEMENT The first step is to make this project can move in the omni directio
35. t The forklift is capable to pick and place a light object with moving in the omni directional movements and control by using PS2 wireless controller 46 52 RECOMMENDATION For the future works some modification can be implemented to enhance the capability of this project On the mechanism part larger base are needed to make this forklift more stable and more weight With the larger base the forklift can pick and place a more weight obyjects Besides that the system that uses to lift up and down the object can be changed instead of using rope It can be replace such as gear system and screw system to make it more like an actual forklift Furthermore there are more wireless controller can be used such as ZigBee controller RF controller and Bluetooth controller using computer or laptop 41 REFERENCE Airtrax Corp ATX Series Omni Directional Forklift New Jersey USA Product brochure 2006 Abdul Aziz Bin Abdul Rahman The Wireless Forklift Bachelor Degree Thesis Universiti Teknologi Malaysia 2010 Kuo Huang Lin Hsin Sheng Lee and Wei Ting Chen Implementation of Obstacle Avoidance and ZigBee Control Functions for Omni Directional Mobile Robot National Formosa University 2008 Illinois Department of Commerce and Economic Opportunity Forklift Safety Guide State of Illinois USA Safety Guide brochure 2008 Dong Sung Kim Hyun Chul Lee and Wook Hyun Kwon Geometric Kinematics Modeling of Omni directional Autonomous
36. t have LCD display to display the current mode and the situation The Figure 2 4 below shows the picture of Flexibot Using Transwheel 10 Figure 2 4 Flexibot Using Transwheel 2 6 ATX SERIES OMNI DIRECTIONAL FORKLIFT Airtrax ATX 3000 Industrial forklifts excel in applications requiring tight maneuvering or transporting long roads sideways The ATS s unique Omni Directional movement allows it to travel in all directions thus making it an ideal vehicle to work in tight spaces where turns are not possible and finite control is a must The truck feature 48 volt transistor controls with state of the art technology infinitely variable travel lift and lower speeds excellent visibility ergonomic controls and operator comfort The Figure 2 5 below shows the picture of the ATX Series Omni Directional Forklift Figure 2 5 Airtrax ATX 3000 Forklift CHAPTER 3 METHODOLOGY 3 1 INTRODUCTION This chapter will discuss about process in designing robot This project is divided into two parts hardware design and software design This project must be done step by step follow the flow such as shows in Figure 3 1 in order to achieve the objective of the project Idea and the concept to do this project is was inspired by the unique of transwheel that can move in all direction by controlling the speed of motor and to make it the forklift can do the work in a narrow space environment In the beginning of this project various sourc
37. tarter Kit and it functions describe in Table 3 3 30 wa MA N gui Ah Hc pe 2 a ea a P el 4 ways 2510 header pin for external power and interface to PC or microcontroller also depends to user On board indicator LED Blue indicators for check connection with controller status Table 3 3 SKPS PS2 Controller Starter Kit Function Description 31 3 3 6 PS2 WIRELESS CONTROLLER PS2 wireless controller is controller that uses to control the movement of Wireless Forklift with Omni directional Movement In this project I have assigned the button that need to push to move the forklift The Figure 3 24 shows the PS2 wireless controller with receiver The price of this PS2 wireless controller and the receiver is RM70 Receiver Figure 3 24 PS2 Wireless Controller with receiver 32 34 PROGRAMMING DESIGN After finishing mechanical and electronic circuit part the attention has been shift to the programming development There are two type of software were used in this project which is MPLAB IDE to write a program and convert to the hex file that the language that PIC microcontroller use and the other one is PICkit2 is to load the hex file into the PIC microcontroller Figure 3 25 illustrate the MPLAB IDE compiler interface Sry MOLARIDE ME D MES File Edit View Project Debugger Programmer Tools Configure Window Help E 3A8 Debug sd lt
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