Workshop on

MANUAL ROBOTICS
Presented By

The Robotics Club Of

IIT (ISM), Dhanbad
 Definition
• Manual Type Robots, as the name suggests, require human
intervention for controlling and guiding the robot

• Manual robots are used for performing complex jobs

Fundamentals Blocks Of A Robot

Basic Parts
Controllers
(Switches, PC, PLC,
µP, µC)

Mechanical
Sensors system

Actuators (Motors, ICPower supply

engines, Pneumatics,
Hydraulics) system
MECHANICAL System
 Mechanical System

The most basic and important part of the robot.

It comprises of chassis, wheels and their placement.

This system decides the locomotion of the robot.

 Chassis

• Readymade chassis like this that are available in the market are
really good, cheap and for all you know they might have been
subjected to a R&D before fabrication

• But these have some disadvantages. They may not be of the

size required by you and they are not flexible.
 Chassis Materials
• WOOD
Cheap, Strong, Easily Available

• PLASTICS
Cheap, Easy to cut and drill

• METAL
Very Strong, Durable, Hard to Cut And Shape

• FIBRE GLASS
Very Strong, Rigid, Waterproof, Used to Create Specific
Shapes
Wheeled Locomotion Systems

Differential drive

Car type drive

Synchronous drive
Wheeled Locomotion Systems:
Differential Drive
Wheeled Locomotion Systems:
Car Type Drive
Wheeled Locomotion Systems:
Synchronous Drive
Different Types Of Wheels
 Different Types of Wheels
Standard Wheels ●
Used in general purpose robotics.

Omni Wheels ●
For Bidirectional movements any time

Mecanum Wheels ●
Used to move in 2D plane independently.

●
Specialized tracks for movement in all terrain
Tank Tracks environment.

Castor Wheels ●
To enable the object to roll in any direction
 Different Types of Wheels

Omni Wheel

Standard Wheel
Castor Wheels
Tank Track
Mecanum Wheel
Gears, Spurs and Pinions
Plastic Gears
Gear Train
POWER SYSTEM
 Power Supply System

Suitable power source is needed to run the robots.

Robots are most suitably powered by batteries.

The weight and energy capacity of the batteries may become the
determinative factor of its performance.
 Power Supply System

Main Sources Of Power : Battery & Adapters

 Types of Rechargeable Batteries
Lead Acid Battery : Vehicle Battery

Nickel Cadmium Battery (NiCd) : Low Charge Battery

Lithium Ion Battery : Consumer Electronics

Lithium Polymer Battery : RC Planes and Cars

Nickel Metal Hydride(NiMH) : High charge capacity

Types of Rechargeable Batteries
Lead Acid
Battery

Nickel Cadmium
Battery

Lithium Polymer
Battery

NiMH
Battery
Types of Non - Rechargeable Batteries

Alkaline Batteries: Common Dry Cell

9 Volt Battery: Lithium Iron Disulfide or Zinc Carbon Alkaline, Mainly

used in Radios and Transistors.
 Power Adapters

Widely used to power robots and high current demanding machines.

Efficient and cheap source of power.

Special Type of Power Adapter called SMPS(Switched Mode Power

Supply) is preferred over normal Bridge Rectifier – Transformer Adapter
because of better efficiency and reduced heat dissipation.
 Power Adapters

A High Output SMPS Adapter

ACTUATORS
 Actuators

They convert the electrical energy into meaningful mechanical work.

Mechanical output can be rotational or linear.

Motors provide rotational motion.

Electromagnets provide linear motion.

 Actuators
The Different Type Of Actuators Are :

1) Hydraulic

2) Pneumatic

3) Electrical

4) Magnetic

5) Mechanical
 Hydraulic Actuator
A hydraulic actuator consists of a cylinder or fluid motor that uses
hydraulic power to facilitate mechanical operation

The mechanical motion gives an output in terms of linear, rotary or

oscillatory motion.

Suitable for applications where huge amount of force is required.

Generally require heavy machinery for proper functioning.

 Pneumatic Actuator

A pneumatic actuator converts energy formed by vacuum or

compressed air at high pressure into either linear or rotary motion

Pneumatic actuators enable large forces to be produced from

relatively small pressure changes

Suitable for applications where huge amount of force or impulse is

required for short amount of time.
 Electric Actuators

An electric actuator is powered by a motor that converts electrical

energy into mechanical torque

An electric actuator is powered by a motor that converts electrical

energy into mechanical torque. The electrical energy is used to
actuate equipment such as multi-turn valves. It is one of the cleanest
and most readily available forms of actuator 

Better known as Motor. Discussed in detail later.

 Magnetic Actuators

Actuators which can be actuated by applying magnetic energy have

been used in commercial applications

They tend to be compact, lightweight, economical and with high

power density. 

Highly preferred in Robotics application due to high power to size

ratio and small size.
 Mechanical Actuators

A mechanical actuator functions by converting rotary motion into

linear motion to execute movement.

It involves gears, rails, pulleys, chains and other devices to operate.

An example is a rack and pinion. 

Most Basic type of Actuator, they are used in everyday life

 Different Types of Motors
A.C. Motors ●
Not used much in robotics

Stepper Motors ●
For controlled rotation

D.C. Motors ●
Finds extensive general use

Brushless DC Motor ●
Widely used in aerial crafts like quadcopter.

Servo Motors ●
DC motor with in built feedback & error compensation
D.C. Motors
D.C. Motors

It requires D.C. power for its operation.

Can run in both directions.

Controllable speed.
 D.C. Motors

Let's start by looking at the overall plan of a simple two-pole DC electric motor.
A simple motor has six parts, as shown in the diagram below: Armature or rotor,
Commutator , Brushes, Axle, Field magnet, DC power supply of some sort.
 D.C. Motors

Just as the rotor reaches alignment, the brushes move across the commutator
contacts and energize the next winding. In the animation the commutator
contacts are brown and the brushes are dark grey. A yellow spark shows when the
brushes switch to the next winding.
 D.C. Motor: Characteristics

D.C. Motors are high–speed devices.

Using gears, the high speed of the motor is traded off

into torque
D.C. Motor Direction Control
Power
VCC
Transistor
Switches

S1 S2
M
__ 1 2 __
S1 S2

• H – Bridge Circuit Diagram

 Dual Channel H-Bridge IC L298D
VCC VCC

S1 S2 S3 S4
M M
__ 1 2 __ __ 1 2 __
S1 S2 S3 S4
D.C. Motor with Gear Box
Stepper Motors
Stepper Motor

A stepper motor is a brushless, synchronous

electric motor which converts electrical pulses
into stepped rotational motion

The shaft or spindle of a stepper motor rotates

in step increments when electrical command
pulses are applied to it in the proper sequence.
Stepper Motor

The motors rotation has direct relationship to the

applied input pulses.

The sequence of the applied pulses is directly related to

the direction of motor shafts rotation.

The speed of the motor shafts rotation is directly related

to the frequency of the input pulses

The angle of rotation is directly related to the number of

input pulses applied.
 Stepper Motor Advantages

The rotation angle of the motor is proportional to the input pulse.

The motor has full torque at standstill (if the windings are energized)

A wide range of rotational speeds can be realized as the speed is

proportional to the frequency of the input pulses. Excellent response to
starting/stopping/reversing

Very reliable since there are no contact brushes in the motor. The motors
response to digital input pulses provides open-loop control, making the
motor simpler and less costly to control.
 Stepper Motor Disadvantages

Not easy to operate at extremely high speeds.

Very low torque to weight ratio.

Torque decreases with increase in the stepping frequency

Servo Motors
 Servo Motors
Servos are DC motors with built-in gearing and feedback control
loop circuitry with no motor drivers required.

Servos are extremely popular with robot, Radio Controlled plane,

and Radio Controlled boat .

Most servo motors can rotate about 90 to 180 degrees. Some rotate
through a full 360 degrees.

However, most servos are unable to continually rotate, meaning they

can't be used for driving wheels (unless modified), but their precision
positioning makes them ideal for robot arms and legs, rack and pinion
steering, and sensor scanners to name a few.
 Close Loop Operation

A closed-loop motion control system, as shown in block diagram has one

or more feedback loops that continuously compare the system’s response
with input commands or settings to correct errors in motor and/or load
speed, load position, or motor torque. Feedback sensors provide the
electronic signals for correcting deviations from the desired input
commands.
Brushless D.C. Motors
 Brushless D.C. Motor

A brushless dc motor has a rotor with permanent magnets and a stator with
windings. It is essentially a dc motor turned inside out. The control electronics
replace the function of the commutator and energize the proper winding.
 Brushless DC Motor
Extensively used in radio controlled vehicles due to its high power and small
size.

Brushless DC motor have significant advantage like longer life and efficiency
compared to Stepper or normal DC motor.

Drones and RC Planes using BLDC motor can have thrust to weight ratio even
above 1.5:1.

Brushless DC Motor need a ESC(Electronic Speed Controller) which sends the

motor 3 phase AC to run.

Electronic Speed Controller is a circuit which convert DC supply into AC

signals.
CONTROLLERS
Switches
 Switches: Classification

S.P.S.T. (Single Pole Single Throw)

S.P.D.T. (Single Pole Double Throw)

D.P.D.T. (Double Pole Double Throw)

S.P.S.T. (Single Pole Single Throw)
S.P.D.T. (Single Pole Double Throw)
S.P.D.T. (Single Pole Double Throw)
D.P.D.T. (Double Pole Double Throw)
D.P.D.T. (Double Pole Double Throw)
D.P.D.T. (Double Pole Double Throw)
D.P.D.T. (Double Pole Double Throw)
+ -
M

1 6

2 5

4
3

+ -
D.P.D.T. (Double Pole Double Throw)
+ -
M

1 6

2 5

4
3

+ -
D.P.D.T. (Double Pole Double Throw)
+ -
M

1 6

2 5

4
3

+ -
D.P.D.T. (Double Pole Double Throw)
+ -
M

1 6

2 5

4
3

+ -
 Hands On Steps
Mounting MOTORS on the vehicle

Coupling of motor shaft and wheels

Mounting of switches on the remote box

Connecting remote with vehicle

Run the LEVEL 1 vehicle

Mounting MOTORS on the vehicle
Pairing of wires
Pairing of wires
Connecting 4-pin connector to Motors
Apply Insulation Tape on all the junctions
Pairing of wires
Coupling of motor shaft and wheels
Mounting of switches on the remote box
6 core Cable and connections
Switch Connections
Switch Connections
Switch Connections
Switch Connections
Mount 6V battery on the remote box
6 core cable from switches
Connection of battery to 6 Core Cable
Connections made to 4 core cable
Connection of Switch and 4 Core cable
4 Core Cable connection
Final Connections
Some websites where you can buy
gear for Robotics
• www.robomart.com
• www.ebay.com
• www.amazon.com
• www.nex-robotics.com
• www.robokits.co.in
• www.vegarobokit.com
Some of our
previous
projects
The journey has just begun…..
There’s a long way to go…….
All the best !!!