THE ROBOTIC STACKER

Robotic Stacker as the name implies, it is use to stack object preferably on any slot of a shelves which is applicable in warehouses. This project is composed of 3 main parts: the main system, the shelf and the 2 object platform.

The main system is connected to a decoder which is also connected to a computer machine that runs the program for the main system. It is composed of:

· 5 stepper motor, which is use in the movement of the gripper, subarm, movement for vertical, horizontal and 90 rotation.

· A total of 20 relays connected together with other components (transistor, resistor and diode) which are primarily use to control the stepper motor.

· Thread, use as a guide for vertical movement of the gripper.

· Belt, use as a guide for horizontal movement the main arm.

· Input Switches, use for selecting a particular slot on the shelf where the operator intends to put or get the object. One switch serves as the exit path for terminating the program of the main system.

The shelf is use as a storing medium of the main system where objects are being put or get. It is composed of 12 available slots which each have its own Light Emitting Diode (LED). This LED corresponds to the switch selected by the operator, it will also serve as a guide for the operator to see on what slot the object will be put or get.

The 2 object platform, serves as the starting point for the main system. In the 1^st platform the object will be place there for the main system to get a hold and put in the shelf. The 2^nd platform will hold the object that has been obtained by the main system from the shelf.

This robotic stacker was design to perform specific tasks that was program to it. It can store 12 objects to any available slot of the shelf that was selected by the operator. It is able to show to the operator through a LED indicator where it intends to put or get the object on the particular slot of the shelf. The main arm is able to move horizontally and is able to rotate a total of 180® clockwise and counterclockwise. The subarm is able to move vertically and can move the gripper forward and backward.

The gripper is only able to grip 1” square box as much as the shelf can accept it. Because of the limitation of having the fine thread, the vertical movement of the system is very slow. In addition to that is the weight of the gripper and the subarm, limits the motor to be configured to use higher gears for faster movement. The shelf also was limited only to accepting and storing the object as it contain no sensors to detect object that was put in its slot.

OBJECTIVE OF THE DESIGN PROJECT
===To apply the knowledge, skills and the application of all our learning's from beginning of our stay in the college.

===To create a Robotic Arm system that is capable of following task:

=== Able to put the object in any empty slot of the shelf according to what number the user inputted using the switch.

===Able to get the object in any filled slot of the shelf according to what number the user inputted using the switch.

SCOPE AND LIMITATION

OPERATING PROCEDURE

1. ISA connector of the decoder must be connected to the ISA slot of the motherboard.

2. Output port of the decoder must be connected to the 12 LEDs and 20 relays enable to control 5 stepper motors.

Input port of the decoder must be connected to the 15 available switches of the system.

3. By turning the supply of the system, press F8 and the boot selection menu will be displayed.

Select Command prompt only

Type the file name (stacker) of the program.

PUT OBJECT

There are 3 switches that serve as, GET switch, PUT switch and the EXIT switch. The user will select a button what will the robot will do (if the robot will put the object in the empty shelf or get the object inside a specific shelf).

4. The user will press a PUT button and next press a number in a button pad (12 available buttons). Press P for PUT.

The robotic stacker will get the object in the platform and put it in a blank slot of the shelf (12 available slots) according to the number the user selected in the button pad.

The LED in a particular envelope will turn ON the same with the number of the pressed button of the user shelf.

If a number button is being pressed before GET or PUT button, the system will not respond.

If a number button is being pressed twice, the system will respond to first action.

GET OBJECT 

5. The user will press a GET button and next press a number in a button pad (12 available buttons). Press G for GET.

The LED in a particular slot on shelf will turn ON the same with the number of the pressed button of the user.

The robotic stacker will get the object in the slot of the shelf selected by the user in the button pad and put it in the platform.

If a number button is being pressed before GET or PUT button, the system will not respond.

If a number button is being pressed twice, the system will respond to first action.

EXIT

6. Press the EXIT Switch at the switch pad. The program will automatically terminate. Press E for exit.

LIST OF COMPONENTS

INTEGRATED CIRCUITS

DM74LS244 - Octal 3-STATE Buffer/Line Driver/Line Receiver

DM74LS373 - 3-STATE Octal D-Type Transparent Latches and Edge Triggered Flip-Flops

DM74LS02 - Quad 2-input NOR

DM74LS1 - Triple 3-Input NAND Gate

DM74LS138 - Decoder/Demultiplexer

STEPPER MOTOR

SWITCH

RELAY

RESISTOR

TRANSISTOR

DIODE

LED

CIRCUIT DIAGRAM

16 BIT DECODER, OUTPUT PORT, INPUT PORT CIRCUIT DIAGRAM

RELAY AND MOTOR CIRCUIT DIAGRAM

LED CIRCUIT DIAGRAM

SWITCH CIRCUIT DIAGRAM

SYSTEM BLOCK DIAGRAM

SOFTWARE USED

CIRCUIT SIMULATION SOFTWARE

Circuit Maker is a circuit simulation software that allows to design, analyze and test a circuit virtually on a computer. They simulate the behavior of an electronic device/circuit, and are often used because it is cheaper, quicker and often more practical to simulate a circuit than to physically build one. It provides either analogue ("analog") or digital simulation capabilities or has a schematic editor, a waveform viewer, support resistors, capacitors, diodes, etc.

PCB DESIGN SOFTWARE

PCB Designer provides design layout of printed circuit board (PCB) designs. All PCB design packages allow designing boards from the component side of the board.

PCB Designer allows you to create single, or double sided PCBs, up to 14" square, using the PhotoEtch principle. Its main features are Double and single sided PCB's, Four fixed sizes of round PCB pads, Four fixed widths of PCB track, Four fixed IC sizes, 8pin 14pin and 16pin and Custom sized IC's, any number of pins, at 0.1", 0.3" and 0.6" widths.It is ideally suited for use in educational establishments, for the home hobbyist and for small businesses. PCB Designer is a Microsoft Windows application that enables you to design masks for printed circuit boards. It is to make this process as easy as possible. The program acts like a sheet of paper, onto which you can place pads, tracks, IC's, etc.

PROGRAMMING LANGUAGE
Assembly language is commonly called assembly or asm, is a human-readable notation for the machine language that a specific computer architecture uses. Machine language, a pattern of bits encoding machine operations, is made readable by replacing the raw values with symbols called mnemonics.