UNIVERSITI TEKNIKAL MALAYSIA MELAKA ANALYSIS ON CORNERING PERFORMANCE OF PLC BASED MOBILE ROBOT NAVIGATION SYSTEM

UNIVERSITI TEKNIKAL MALAYSIA MELAKA ANALYSIS ON CORNERING PERFORMANCE OF PLC BASED MOBILE ROBOT NAVIGATION SYSTEM This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for Bachelor Degree of Manufacturing Engineering (Robotic and Automation) with Honours. by NUR SABIHA BINTI HASBULLAH B051110149 920105-03-5448 FACULTY OF MANUFACTURING ENGINEERING 2015

DECLARATION I hereby, declared this report entitled Analysis Cornering Performance of Plc Based Mobile Robot Navigation System is the results of my own research except as cited in references Signature : Author s Name : Nur Sabiha Binti Hasbullah Date : 2 June 2015

APPROVAL This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfilment of the requirements for the Degree of Bachelor of Manufacturing Engineering (Robotics And automation) with Honours. The member of the supervisory committee is as follow: (Dr. Fairul Azni Bin Jafar)

ABSTRACT Mobile robot is defined as a programmed machine that is skilled of movement in any controlled environment. They have capabilities to move around in their environments and are not fixed to one physical location as categorized as fixed robot. The example of mobile robot such as mobile robot navigation, mobile robot at the space and so on. Although the robot has been created with a good design and control, it still have a problem. The problem that always faced by the robot like, speed, program, sensor and also avoidance obstacles of the objects. Thus, it motivates to analysis the one of the problem of the mobile robot navigation system which is the problem during make a cornering. To analyze the project, a navigation experiment will be test on u shape path and experiment will repeat with two different program. The experiment results are presented in graph in order to know the cornering performance of the mobile robot. The first experiment in this research which are the experiment with transistor and without transistor. Second experiment to analyze the effect of the program on the navigation of mobile robot. The programs have developed into two which are the program with reverse action and the program without reverse action. Each of this experiment will be repeated three times to get better results. For the first experiment, the navigation with transistor is better than without transistor. And for the second experiment, the program without reverse action give a good results during make a cornering. i

ABSTRAK Robot mudah alih ialah didefinisikan sebagai sebuah mesin diprogramkan yang mahir pergerakan di mana-mana persekitaran terkawal. Mereka mempunyai kebolehan bergerak-gerak dalam persekitaran mereka dan tidak ditetapkan bagi satu lokasi fizikal seperti yang dikategorikan sebagai robot tetap. Contoh robot mudah alih seperti pelayaran robot mudah alih, robot mudah alih di ruang dan sebagainya. Walaupun robot telah mewujudkan dengan satu perancangan baik dan mengawal, ia masih lagi satu masalah. Masalah yang sering menghadapi oleh robot seperti kelajuan, sistem, penderia dan juga halangan-halangan pengelakan objek. Maka, ia mendorong kepada analisis salah satu masalah sistem pandu arah robot mudah alih yang merupakan masalah semasa membuat satu membelok Untuk analisis projek, eksperimen pelayaran akan diuji di laluan bentuk u dan eksperimen akan berulang dengan tiga perkakasan berbeza. Keputusan eksperimen akan mewakili di graf supaya tahu prestasi takik keliling robot mudah alih. Dua experiment akan dijalankan dalam kajian ini iaitu untuk experiment pertama, pergerakan robot dengan menggunakan transistor dan tanpa transistor. Experiment kedua yang dijalankan adalah untuk menganalisis keberkesanan program. Dalam kajian ini program telah terbahagi kepada dua iaitu program tanpa proses pengunduran dan dengan pengunduran. Experimen akan dijalankan sebanyak tiga kali bagi mendapatkan keputusan yang terbaik. Bagi experimen yang pertama, keputusan yang menunjukkan lebih baik adalah pengemudian dengan menngunakan transistor. Dan bagi experiment kedua, pengemudian dengan menggunakan proses tanpa penguduran adalah lebih baik. ii

DEDICATION Especially dedicated to my beloved parents, Hasbullah bin Mat Yaman and Azmah binti Sapii and to my supervisor, Dr.Fairul Azni bin Jafar, and all my friends who have encouraged, guided, and inspired me throughout the study process. iii

ACKNOWLEDGEMENT In the name of ALLAH s.w.t, the most Gracious and most Merciful. thanks for giving me the strength and confidence to complete this Final Year Project (FYP). First of all, In this great opportunity, i wish to express my sincerest, appreciation and thousand thanks to my project supervisor, Dr.Fairul Azni bin Jafar who had guided me to complete this project successfully. I would like to express an appreciation for his ideas, guidance, encouragement and professionally giving constant support in ensuring this project possible and run smoothly as per planning schedule. I also truly grateful to those lecturers and staff of the Faculty Manufacturing Engineering, UTeM that willing to help me in many ways. Sincerely thanks to them for their excellent corporation, supports and inspiration during this project. Last but not least, thanks to my beloved parents and other family members who give a lot of encouragements. Thanks to all. iv

TABLE OF CONTENT Abstract Abstrak Dedication Acknowledgement Table of Content List of Tables List of Figures List of Abbreviations i ii iii iv v viii xi xii 1. INTRODUCTION 1 1.1 Background 1 1.2 Motivation 3 1.3 Problem statement 4 1.4 Objectives 4 1.5 Scope 5 1.6 Report structure 6 2. LITERATURE REVIEW 7 2.1 Overview of mobile robot 7 2.2 Robot navigation 8 2.2.1 Landmark based navigation 8 2.2.1.1 Natural landmarks 9 2.2.1.2 Artificial landmarks 10 2.2.2 Line following 10 2.2.3 Global Positioning System ( GPS ) 12 2.3 Problems faced by mobile robot 13 2.3.1Speed 14 2.3.2 Cornering performance 15 2.3.3 Sensors 15 v

2.3.4 Natural landmark sensoring 16 2.3.5 Artificial landmark sensoring 17 2.3.6 Exploiting wheel slips 18 2.3.7 Obstacle avoidance 20 2.4 Summary 21 3. METHODOLOGY 21 3.1 Overall methodology 23 3.2 Literature review 23 3.3 Planning 25 3.3.1 Generate basic idea 25 3.3.2 Check each components 25 3.3.3 Identify experiment concept 26 3.4 Design of experiment 27 3.4.1 Designing the programming 27 3.4.2 Check input and output 27 3.4.3 Preliminary test 28 3.5 Testing of the hardware 29 3.5.1 Experimental setup 30 3.5.2 Experiment procedure 31 3.5.3 Data collection 32 3.5.4 Expected results 32 3.6 Summary 33 4. RESULTS AND DISCUSSION 34 4.1 Specification of input and output 34 4.2 Programming flowchart 37 4.2.1 Flowchart 37 4.3 Programming and simulation 38 4.4 Simulation result 41 4.4.1 Programming with reverse action 41 4.4.2 Programming without reverse action 45 4.5 Wiring debugging 50 4.6 Uploading programming 51 vi

4.7 Navigation experiments 52 4.8 Experiment requirement 53 4.9 Navigation experiments results 54 4.9.1 Transistor effect 54 4.9.2 For the distance between the sensor 4 cm with reverse action 58 4.9.3 For the distance between the sensor 3 cm with reverse action 62 4.9.4 The distance between the sensor 4 cm without reverse action 66 4.9.5 The distance between the sensor 3 cm without reverse action 70 4.10 Discussion 74 5. CONCLUSION AND RECOMMENDATION 75 5.1 Conclusion 75 5.2 Recommendation 76 REFERENCES 77 APPENDICES A Gant Chart for FYP 1 B Gant Chart for FYP 2 vii

LIST OF TABLES 4.1 Input task 35 4.2 Output task 35 4.3 Output task for program without reverse action. 36 4.4 Error data tabulation with transistor and without transistor 55 4.5 Error data recorded for first run, second run and third run 59 4.6 Error data recorded for first run, second run and third run 62 4.7 Distance between the sensor 4 cm 67 4.8 The distance between the sensor 3 cm 71 viii

LIST OF FIGURES 1.1 Mobile Robot of Vision System for Landmarks Detection 2 1.2 Example of Automated Guided Vehicle 3 2.1 Mobile robot line following prototype 11 2.2 Block diagram of how the line follower robot works 11 2.3 Robot path following (a) simulation (from top view) showing (b) small slip and (c) large slip 19 3.1 (a) Flowchart symbol, and (b) Example of simple flowchart 21 3.2 Overall Methodology 24 3.3 Planning 26 3.4 Design of experiment 27 3.5 Testing 29 3.6 The proposed pathway 30 3.7 Expected results on U Shape 32 4.1 The process flow of the mobile robot for 4 relay used 37 4.2 The process flow of the mobile robot with two relay 38 4.3 Plc programming before simulation with 3 sensor 39 4.4 Plc programming before simulation for 2 sensor with reverse action 40 4.5 Start button activated. 41 4.6 Left sensor activated. 42 4.7 Right sensor activated 43 4.8 Left sensor and right sensor activated 44 4.9 Plc programming before stimulation without reverse action 45 4.10 Push button activated 46 4.11 Left sensor activated 47 4.12 Right sensor activated 48 ix

4.13 Left and right sensor activated. 49 4.14 Pin out connection between RJ11 and RS232 DB9 50 4.15 RS232 DB9 51 4.16 RJ11 51 4.17 Connectivity cable for PLC Keyence KV16T to desktop computer 51 4.18 Actual condition for u shape 53 4.19 Actual path for straight line 53 4.20 Line graph for data analysis 54 4.21 Line graph of error path VS experimental path 56 4.22 Actual path for navigation with transistor and without transistor 56 4.23 Error at 5 cm 57 4.24 Error at 30 cm and 35 cm 57 4.25 Error at point 5 cm 58 4.26 Error at point 55cm until 85 cm 58 4.27 Actual path for first run, second run and third run. 58 4.28 Graph analysis for first run, second run and third run 60 4.29 Error point for first run at point 65cm 60 4.30 Error at point 60cm 61 4.31 Error at point 15cm 61 4.32 Error at point 40 cm, 45 cm, 50 cm 61 4.33 Error at point 70 cm 61 4.34 Graph analysis for first run, second run and third run 63 4.35 Actual path for first run, second run and third run 63 4.36 Error at point 30cm 64 4.37 Error at point 65cm until 80cm 64 4.38 Error point at 20cm 4.39 Error point at 60cm 65 4.40 Error point at 50cm until 65cm 65 4.41 Actual path for first run, second run and third run 66 4.42 Graph analysis for first run, second run and third run 68 4.43 Error at point 35 cm 69 4.44 Error at point 75 cm 69 4.45 Error at point 55 cm 69 4.46 Error at point 70 cm 69 x

4.47 The graph analysis for first run, second run and third run 72 4.48 Navigation for first run with no error 72 4.49 Error at point 80cm and 85cm for second run 73 4.50 Error at point 60cm 73 xi

LIST OF ABBREVIATIONS AGV - Automated Guided Vehicle FKP - Fakulti Kejuruteraan Pembuatan FYP - Final Year Project WMR - Wheeled Mobile Robot GPS - Global Positioning System MDARS - Mobile Detection Assessment and Response System PLC Programmable Logic Controller xii

CHAPTER 1 INTRODUCTION This chapter will explain the background of the project, the details of the problem statement and motivation, the objectives, the scopes, report structure and the report configuration of the project entitled Analysis on Cornering Performance of PLC Based Mobile Robot Navigation System. 1.1 Background Mobile robot is a type of robot that has ability to move around and is not fixed at only one position. It can move from one position to other position depends on the physical geometry and environment. Mobile robot will acts like a human and can performed the human tasks. In order for mobile robot to work successfully in human living environment, they need to have skills which allow them to perform tasks similar to the human being. One of the skills which could be considered as most important for mobile robot is navigation. Navigation is ability of the robot to move in an environment. There are various types of mobile robot navigation one of the examples like manual remote. This type of mobile robot is control by driver by using joystick or other control instruments. Mobile robot navigation is where a robot capable to navigate to a position in its environment. It will guide its own position and determine their respective positions in the frame of reference and then plan the way towards few target location. In order for robot to navigate to a position or move through real world it needs the mechanism includes locomotion sensing, localization, and motion planning. A good 1

representation is a massive important factor to the robot in a navigation system. The representations stated are the map of the environment and the capable to read the task. Those important tasks will encourage the precise result in navigation system. Mobile robot navigation systems have been creating as a function to navigate the position. This task will make human job become easier. Figure 1.1: Mobile robot of vision system for landmarks detection. (Source: http://www.neurotechnology.com/robotics.html). Navigation can be classified as a combination of three core competencies which are self-localisation, path planning, map-building and map interpretation. Definition of the navigation is comprised of three categories which are Global Navigation, Local Navigation, and Personal Navigation. These three categories have different ability to determine the position. Global navigation has the ability to determine the position of an absolute or map-referenced, and to move to the desired destination. While in Local Navigation, the ability to determine a position compared with objects either the objects is stationary or moving in the environment, and to interact with properly and Personal Navigation involving realizing the various parts that make up the self, in relation to each other and the object handle. Line-following robots, Automated Guided Vehicles (AGVs) are the best example of mobile robot that used line following navigation system. In order to navigate the system, an automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows the colour line or wires in the floor, or uses vision, magnets, or 2

lasers. AGVs have expressed hallway or area where it is or where they can navigate. For the guidance to mobile robot move successfully in the line, the AGVs use magnetic tape, buried guide wires, or painted stripes that have been draw on the ground. These vehicles have some disadvantages which are not freely programmable and cannot change their path in response to external sensory input (e.g., obstacle avoidance). However, the interested reader may find a survey of guidance techniques for AGVs in (Everett, 1995). Figure 1.2: Example of Automated Guided Vehicle. (Source:http://news.thomasnet.com/fullstory/Intelligent-AGV-enhances-lean-manufacturingenvironments-582126). Navigation is achieved by any one of several ways, including by an action defined by buried inductive wires, there is horse riding paths magnetic or optical, or alternatively as inertial or laser guidance. 3

1.2 Motivation For the revolution in technology undoubtedly is the robot. Every day a growth of robot can be seen with increasing human like capabilities, such as recognizing objects and moving around independent of human control (Girme et al. 2007). There are many types of mobile robot that have been developed today to perform human tasks. Although the robot has been created with a good design and control, it still has a problem. The problem that always faced by the robot like speed, system, sensor and also the obstacles avoidance. Thus, it motivates to analyze the problem of the mobile robot navigation system in order to produce a good navigation system for mobile robot. Mobile robot navigation have been installed correctly with a proper fundamental system like speed, shape, and the most important one its can navigate the position with a right performance according to the manufacturer s specifications and its environment. 1.3 Problem statement Previously, PLC based navigation system for mobile robot have been develop and successfully move on the line following. During the navigation, there is problem occurred at u shape path. The robot can move successfully during the straight path but facing some problem during making a cornering. During the cornering, the robot cannot follow the u shape line following and accidently move out of the line. In the case of this challenge, a study and analysis will be conducted to figure out the problem occur during the cornering performance. Three different experiments will be conducted in u shape. Each experiment will take a reading data and error will be record. 4

1.4 Objective i. To analyze the cornering problem of a PLC based mobile robot navigation system. 1.5 Scope The purpose of this project is to analyze the cornering performance of a PLC based mobile robot navigation system. i. The analysis covers about the motion and the problems of the robot. This research work is not covers the safety of the robots. The experiment that will be conducted to be in indoor environment. The environment setup will be in a flat silver area at the manufacturing laboratory hall. ii. The experiment will be conducted on the mobile robot navigation systems that have been developed by previous PSM project. iii. This project will involve the development of program of PLC and sensor. 5

1.6 Report structure Chapter 1 is the introduction of the project. Under this chapter, there have 6 subtitles which are the background of the project, motivation, problem statement, objectives, scope and report structure. Chapter 2 is all about literature review. This chapter comprises information about the robot, landmark based navigation, line following robot and problems needs to face by the robot. Chapter 3 describes a design process to achieve the project s objectives. It includes the overall project plan, overall methodology flow chart, and details explanation about methods to analysis the cornering performance of the robot. The result will be presented in chapter 4 and chapter 5 is regarding the conclusion of the project in form of whether it is successful or not based on the objectives achievement and in addition of future suggestion in order to improve this project. 6

CHAPTER 2 LITERATURE REVIEW Before starts analyze the project, some articles re-examine from the internet and book ensure the information from that source can be in order to do a research and analyze the cornering problem of mobile robot. These articles will be use as the guideline in this research project. This chapter will summarise and stress on paper content, report and article related to this project. A few theories that have related to this project also will be discussed in this topic. 2.1 Overview of mobile robot P.Lima et al. (2002) wrote that the term mobile robot is principally a platform with a hefty mobility within its environment such as air, land or even underwater. Mobile robot consists of functional characteristics such as a total mobility relative to environment, a certain level of autonomy which limited to human interaction and a perception ability in sensing and reacting in the environment. Locomotion mechanisms are important things for the mobile robot to enable it to move in unlimited all over the environment. But there are several of possible methods to move, so the selection approach of the robot to locomotion is one of important factor for mobile robot design. By the experiments that have been done in laboratory, the robots have prove that it can walk, jump, run, slide, skate, swim, fly, and, also can made a rolling. Most of these locomotion mechanisms have been motivate by their biological counterparts. The design of autonomous mobile robots competent of smart movement and action involve an integration of much knowledge of other bodies. In current industrial environment, robot especially mobile robot plays an important role since the capabilities in completing tasks that are impossible to be 7

completed by humans due to limited abilities. Robot are known have the higher ability in doing repetitive works with constant performance, working in dangerous area which could danger human life and make the job faster with less rest time. According to Dudek and Jenkin (2000), a mobile robot is autonomous systems which have intelligent function of traversing a facade with natural or artificial obstacles. The chassis is providing with wheel or legs and possibly a manipulator setup mounted on the chassis for work piece operation, tool or special system. There are variety trepanned operations are perform based on a reprogrammed navigation strategy taking into account the current status of the environment. The first mobile robot was created approximately 63 years ago beginning in 1950 when Grey Walter assumed to integrate these two cognitive operations, goal seeking and scanning, into en electronic toy that would simulate these most basic characteristics of animal and human behaviour (Walter, 2003). Thus, it resulted in creation of the first mobile which has three wheels and often described as turtle because of its shape. Walter named his robot as Elmer and Elsie also used to be called as Machine Speculatrix because it tendency to explore its environment. 2.2 Robot navigation 2.2.1 Landmark based navigation Navigation based on autonomy robot landmark was widely used in manufacturing industry. Navigation strategy depends on identification and recognition of a distinctive environment display or an object either known a priori or extracted dynamically. This process is inherently difficult in practice due to noise in detector and change in real world. This process is indeed hard in practice because of the noise problem in sensors and changes in the real world. Landmark navigation is the most important things for the mobile robot to navigate the system by using its sensory input and generally it s divided into three type of position which is fixed, known and relative position (BorensteinJ. etl.1997). Navigation orders that based on landmark more easy to follow, time saving, and 8

reduce confusion by preparing visual feedback on the approval of a navigation results. Landmarks are the geometrical features that a robot can detect from its sensory input. Landmarks can be variety of geometric shapes such as square, line and circle and they may contain an additional information (e.g., in the form of bar-codes). Landmarks are carefully selected in order to easy to recognize for example, there is must be contrast relative that is enough to all background. The characteristics of the landmarks must be known and stored in the robot s memory before a robot can use for navigate. The main function in localization is to identify the landmarks definitely and to measure the robot s position. In summarize, there are a few characteristic of landmark based navigation which are, the distance and angle between the robot and the landmark are important thing is positioning accuracy. When the robot move further afield from the landmark, the navigation will become inaccurate. When the robot is nearby a landmark, a greater degree of accuracy will be created. 2.2.1.1 Natural landmarks Natural landmarks work best in good structured environments such as corridors, manufacturing floors, or hospitals. On the other side, there has an argument that natural landmarks can navigate in best work when they are man-made as is the case in good structured environments. Natural landmarks are those objects or features that are already in the environment and have a function other than robot navigation. The recognizing and matching characteristic features from sensory inputs is the one of the main problem occur in natural landmark navigation. In natural landmarks, there is no modification involved and the flexibility of this landmark is good. 9