HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

CHAPTER 3
SELECTION OF MOTOR
In the Market many different motors like servo motors, stepper motorcar synchronous
motors, dc motors with and without gears are available.
According to their applications and requirements these different motors are used for e.g.
We need to use servo motors if we want high torque and precise position. Stepper motors are
used if we want only position and high torques are not required .If we need high torque then
Dc geared motors are used . DC motors are used for only smooth motion . As though servo are
best suited for robotics it wasnt economically viable , So we have used here stepper motor
.Stepper motors are of many types for e.g. Variable reluctance motors, permanent magnet motors
and hybrid motors.

2.1) Introduction of D.C motor:DC motors plays a vital role in most of the industrial areas now a days , it can be seen in
most of the electronic devices. For the mechanical movements of physical applications such as
rolling the bundle of sheets or CD drives, lifts etc we use mainly D.C Motors.
In order to control the revolution of a motor many methods are evolved. We can control
DC motors either by software or directly by hardware. Software controlling needs computers
which are bulky and common man cannot afford for it, so hardware controls are in use. Even in
hardware if it is programmable device then it is preferred because it can be modeled according to
the requirements of the user.

Advantages of using DC motor are given below

1. SPEED: In PIC IC the execution of an instruction is very fast (in micro seconds) and can be
changed by changing the oscillator frequency. One instruction generally takes 0.2 microseconds.
2. COMPACT: The PIC IC will make the hardware circuitry compact.
3. RISC PROCESSOR: The instruction set consists only 35 instructions.

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HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

4. EPROM PROGRAM MEMORY: Program can be modified and rewritten very easily.
5. INBUILT HARDWARE SUPPORT: Here no extra hardware is needed since PIC IC has
inbuilt programmable timers, ports and interrupts,.
6. POWERFUL OUTPUT PIN CONTROL: Using a single instruction, output pins can be
driven to high state. The output pin can drive a load up to 25mA.
7. INBUILT I/O PORTS EXPANSIONS: This reduces the extra ICs which are needed for port
expansion and port can be expanded very easily.
8. INTEGRATION OF OPERATIONAL FEATURES: Power on reset and brown/out
protection ensures that the chip operates only when the supply voltage is within specification. If
the chip ever malfunctions and deviates from its normal operation, a watchdog timer resets PIC.

Construction of a DC Motor
The very basic construction of a dc motor contains a current carrying armature which is
connected to the supply end through commutator segments and brushes and placed within the
north south poles of a permanent or an electro-magnet as shown in the diagram below.

Figure 5.6.1 Construction of DC Motor

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It is important that to have a clear understanding of Flemings left hand rule to determine the
direction of force acting on the armature conductors of dc motor to go into the details of the
operating principle of DC motor.

WORKING PRINCIPLE
Flemings left hand rule says that if we extend the index finger, middle finger and thumb
of our left hand in such a way that the electric current carrying conductor is placed in a magnetic
field (represented by the index finger) is perpendicular to the direction of current (represented by
the middle finger), then the conductor experiences a force in the direction (represented by the
thumb) mutually perpendicular to both the direction of field and the current in the conductor.

Figure 5.6.2 Flemings Left Hand Rule

Force, F = B I L newton
Where B is the magnetic field in weber/m2 .
I is the current in amperes and
L is the length of the coil in meter.
The force, current and the magnetic field are all in different directions. If an Electric
current flows through two copper wires that are between the poles of a magnet, an upward force
will move one wire up and a downward force will move the other wire down.
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For clear understanding the principle of DC motor we have to determine the magnitude
of the force, by considering the diagram below.
We know that when an infinitely small charge dq is made to flow at a velocity v under
the influence of an electric field E, and a magnetic field B, then the Lorentz Force dF
experienced by the charge is given by:-

Figure 5.6.3 Magnetic Flux due to Current Flow

Figure 1: Force in DC Motor

Figure 2 : Magnetic Field in DC Motor

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Fi
gure 3 : Torque in DC Motor

Figure 4 : Current Flow in DC Motor

The loop can be made to spin by fixing a half circle of copper which is known as
commutator, to each end of the loop. Current is passed into and out of the loop by brushes that
press onto the strips. The brushes do not go round so the wire do not get twisted. This
arrangement also makes sure that the current always passes down on the right and back on the
left so that the rotation continues. This is how a simple Electric motor is made.
3) Calculations For Torque
Motor ratings - VOLTAGE =12V ,CURRENT =0.6A , GEAR RATIO =1:20
1) POWER P =V*I =7.2 W
2) Angular speed =2N =2*3.14*38 =3.97 rps
3) Torque T=0.8*P/ (because 0.8=motor efficiency) =1.45 Nm
By using the formula T=F*R the load lifting capacity of our motor is 0.328kg.

3) Control Of Motor
There are mainly three types of controls which are used:1) Parallel ports of the PC
2) Micro controller IC
3) Plc

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PLC
Because of certain advantages that many other controllers cannot give, PLC is widely
used controller in the market. Many companies like AB,SIEMENS,OMRON etc manufacture
plcs, out of which AB and siemens are widely used . Allen Bradley SLC500 PLC is used here.
Plc works on our logic. It takes the inputs from input devices like switches etc then
according to the given logic gives the output to the actuators.
Inputs:- 230 v Ac supply 50hz frequency
Outputs:- 24 v Dc supply
Programming device :- PC having Rockwell software for programming
Modules :- Ac, Dc, Analog etc.
To control the manipulator we have used Allen Bradley Plc here. We have used fixed
type of Plc out of many types of plc available in the market like fixed, modular etc. Compared to
microcontroller we have used plc as it is better in many ways like it is easier to program, more
i/ps and o/ps and many more.
WORKING THEORY OF H-BRIDGE:
The name H-bridge is derived from the actual shape of the switching circuit which
controls the motion of the motor. It is also known as Full Bridge. Basically in the H-bridge
there are four switching elements as shown in the figure below.

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HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

There are four switching elements named as High side left, high side right, low side left,
low side right as shown in the above figure. Motor changes its direction accordingly when
these switches are turned on in pairs. The motor rotates in forward direction if we switch on high
side left and low side right, as the current flows from P\power supply through the motor coil goes
to the ground via switch low side right. This is the figure shown below.

Similarly the current flows in opposite direction and motor runs in forward direction, if we
switch on the low side left and high side right. This is the basic working of H-Bridge Motor.
L293D Dual H-Bridge Motor Driver:

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HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

With one IC we can interface two DC motors which can be controlled in both clock wise and
anti clock wise directions when we have motor with fixed direction of motion since L293D is a
dual H-Bridge motor Driver. We can connect up to four DC motors by using all the four I/os.
1. L293D IC:It is the quadruple high current half H driver. It is designed to drive inductive loads such
as relays solenoids d.c motors and to provide bidirectional currents from voltages 4.5 to 36 volts.
All inputs are TTL compatible. Each output is complete totem pole with darlington transistor
sink and a pseudo darlington source. It has two enables. When enables are high the driver
associated to it are high and vice versa.

FIG.6 L293D IC

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1. 7812 IC:2. In order to protect the circuit in
situations of over current over voltage

6. 7806 IC:7.

6V, it converts 12 V in to 6 V.

conditions it converts 12 to 40 v in to 12
v. This is used for protection.

8.
9.

3.
4. FIG. 7812 IC
5.

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As IC L293D works at input voltage of

10.
11. FIG. 7806 IC 11

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HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

12.
13. L293D has an output current of 600mA and peak output current of 1.2A per channel. Output
diodes are included within the IC to protect the circuit from back EMF. The output supply
(VCC2) has a wide range from 4.5 V to 36V, which has made L293D as the best choice for
DC motor Driver.

14.

15.

Three pins are needed for interfacing

DC motor (A, B, Enable) as shown in the circuit. If we want the output to be enabled
completely then we can connect the enable to VCC and only two pins needed from the micro
controller . It is fairly simple program to the micro controller as per the truth mentioned in
the above image. From the BJT circuit and L293D it is clear that the programming will be
same for both of them, just keep in mind of the allowed combinations of the A and B.

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HUMANROBOT COLLABORATION BASED ON MOTION INTENTION ESTIMATION

1. Motor Supply (+12V /
+24V)
2. Logic Supply (+5V)
3. Clockwise
(Active
Low)
4. Counter-Clockwise
(Active Low)
5. Ground
6. Points to be soldered
with DC motor
7. Power Transistor
8. Opto-Coupler Device
to provide isolation

16.
17. Fig.H.Bridge on PCB

18. Discussion
19. The above h-bridge thus can be used for moving motors, thus the Differential Mechanism

using two DC Motors is shown below.

20.
21.
DC MOTOR
1

DC MOTOR 2

22.
23.
24.

BASE

25.
26.
27.
28.
29.
30.

Figure 1 Forward Motion

31.
32.
33.
34.
35.
36.
37.
38.

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39.
40.
41.

DC MOTO

42.
43.
44.
45.
46.
47.

48.
49.
50.
51.

52.

Figure 2 Right Motion

A simplified differential motor mechanism has been shown in the above figures.

The mechanism involved in Forward motion is shown in Figure 1. In this both the shafts rotate in
the same direction (looking from the left, anti-clockwise). The direction of both the shafts is
reversed (looking from the left, clockwise) and the rest remains same for backward motion.
53.

The direction of rotation for the 2 motor shafts for taking a right turn is shown in

figure 2. In this, the motor on the right moves such that it makes a backward rotation (clockwise,
looking from left) while the motor on the left continues to rotate in the forward direction. This
makes the vehicle turn in the right. Although it is bit unreliable and backward rotation while the
right motor makes the forward rotation, similar effect can be achieved by stopping the right
motor.

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