In this project, students will embark on an exciting journey to develop a line following robot designed to optimise warehouse operations. The primary objective is to create a robot that efficiently navigates the warehouse floor, following pre-defined paths to pick up and deliver parcels to designated stations. This hands-on project will provide students with a deep understanding of robotics, sensors, and automation systems, fostering essential skills in programming, electronics, and problem-solving.
The project will start with a given design for the robot, providing a solid foundation for students to build upon. However, students are encouraged to exercise their creativity and technical skills to modify or improve the robot’s design to enhance its performance.
Through this project, students will:
Assemble a robot capable of following lines on the warehouse floor using the provided design.
Integrate sensors and actuators to enable precise navigation and obstacle avoidance.
Develop algorithms for efficient route planning and parcel handling.
Test and refine their robots to ensure reliable and accurate performance in a dynamic warehouse environment.
Explore innovative modifications to the robot’s design to improve efficiency, reliability, and functionality.
By the end of the project, students will have gained valuable insights into the practical applications of robotics in industrial settings, preparing them for future careers in engineering and automation.
This project not only teaches technical skills but also encourages creativity and innovation in solving real-world problems.
Before embarking on the line following robot project, students should possess a foundational understanding of key concepts and skills that will be essential for their success. This section outlines the initial knowledge and skills that students are expected to have, ensuring they are well-prepared to tackle the challenges of developing, building, and programming an autonomous robot for factory automation.
Students should have prior experience or familiarity with the following areas:
Basic Electronics: Understanding of fundamental electronic components such as resistors, capacitors, LEDs, and transistors, and other subsystems, along with the ability to read simple circuit diagrams, data sheets and assemble basic circuits.
Soldering: Proficiency in soldering techniques, including how to safely and effectively solder components onto a printed circuit board (PCB) or Vero board. Students should be comfortable using a soldering iron, tinning wires, and creating strong, reliable solder joints.
Programming: Proficiency in a programming language commonly used in robotics, such as Arduino C. Students should be comfortable writing, debugging, and testing code, as well as understanding basic programming concepts like loops, conditionals, and functions.
Microcontroller Basics: Knowledge of microcontrollers, such as Arduino, including how to interface with sensors and actuators, write and upload code, and troubleshoot common issues.
Sensors and Actuators: Familiarity with various types of sensors (e.g., IR sensors, ultrasonic sensors) and actuators (e.g., motors, servos) used in robotics, including how to connect and use them in a circuit.
Mechanical Assembly: Basic skills in assembling mechanical components, using tools, and understanding simple mechanical drawings. Experience with gears, motors, and chassis construction will be beneficial.
Testing and Measurement: Ability to use a multimeter to measure voltage, current, and resistance. Students should be capable of using a multimeter for diagnosing and troubleshooting basic circuit issues.
Problem-Solving and Critical Thinking: Ability to approach problems methodically, think critically about potential solutions, and iterate on designs based on testing and feedback.
Note to Teachers: By ensuring that students have these foundational skills and knowledge, they will be better equipped to engage with the project, apply their learning effectively, and innovate as they develop their line following robot. This groundwork will enable them to focus on the more advanced aspects of the project and achieve successful outcomes.
Te Whare Pūmanawa Electronics is a robotics company in the heart of Aotearoa. Today, a group of new graduates is joining the robotics team. They're excited about the challenge of creating a robot for an online electronics business that has been experiencing a surge in activity.
Guided by mentors, they will implement a design where they have the opportunity to add their own unique touch. In the end, only four of them will be chosen to leave a lasting impact where innovative ideas and values, including sustainability, come together. Welcome to a short but significant journey where they'll craft sustainable and reliable robots at Te Whare Pūmanawa Electronics!
"Te Whare Pūmanawa Electronics" translates to "The House of Innovation Electronics" in English. The name is a combination of Māori and English words. In Māori, "Te Whare" means "The House," "Pūmanawa" can be interpreted as "Innovation" or "Creative," and "Electronics" remains the same in both languages. The combination reflects a fusion of Māori cultural elements with a focus on innovation and technology within the field of electronics.
You are to build an automated robot system with the ability to follow a designated line on the warehouse floor using the following guidelines. The layout is as shown below. There are three stations: A. B and C. The idea is to pick up parcels from Station B and C and drop them off at Station A.
Although the most important function is the ability to follow the line, extra features such as the ability to stop at pickup stations, wait for package addition, continue to delivery stations, and return to the pickup station should be included. You must Include an indicator on the empty robot, like a green LED, to signal readiness for loading. You can add an extra display for instructions or status of the robot. All the initial designs are given to you.
Note to Teachers: This project can be modified to fit the resources available in your classroom. All components required for the line following robot are readily available online, allowing flexibility in procurement and adaptation to different educational environments.
In this section you are given the initial design and starter code for your project. All components will be available. You must add line following plus another function of your choice. The specifications are:
The Robot must
Follow a black line 32mm wide
Be less than 200 x 150 x 120mm
Have a mobile power source
Use recyclable materials
The Robot should
Be able to carry objects up to 100 grams (this is the maximum weight of a package), with a size (diameter) of up to 2 centimetres
Stop when an object is less than 30mm away
Show a green LED when it is ready for a package
The Robot could
Stop at Station A
Stop at Station B and C
Flash a light when it loses the line or crashes
The robot will be developed in stages:
Movement -> One sensor line following - > Two sensor line following -> Then add other features.
Testing movement and individual motors first is crucial in developing an Arduino robot.
It provides immediate feedback on hardware connections and programming, reinforcing the basics of motor control and troubleshooting.
By verifying each motor's functionality separately, students ensure correct wiring and coding before advancing to more complex tasks.
This approach builds confidence and establishes a reliable foundation for integrating sensors and advancing functionalities later on in the project.
Follow this step-by step guide.
Starting with one sensor for line following simplifies the learning process for students developing an Arduino robot. It helps them focus on understanding how sensor input affects motor control without the complexity of managing multiple inputs at once. This step-by-step approach allows for easier troubleshooting and code refinement. Once students master one sensor, they can then progress to integrating and synchronizing multiple sensors for more advanced line-following capabilities.
To be able to do line following you will use the TCRT5000 infrared sensor or equivalent. Your first task is to check the value of the sensor for various surfaces. Most line sensors have 3 outputs but others may have four outputs.
Your first step will be to find the optimum distance for the line sensor for the line you want to measure. Connect to the Arduino using the wiring diagram on the right.
Hold the sensor over the black line with the diodes facing down. Move over black line and find the optimum distance from the surface for maximum value difference between black and white as read on the serial monitor. You have to mount the sensor that height from the surface using spacers etc.
Complete single sensor line following for Achieved. This tutorial will give you ideas about how to mount and program the robot. Start with deciding if you want to follow the line from the left or the right, then create the pseudo code.
Pseudocode for left-sided line following with a black line:
If sensor sees black
turn left (Don’t rotate as you want to make a slow turn to ensure you move forward. Both motors should be moving, one will be must slower, Motor A 50, Motor B 100)
if sensor sees white
turn right
Experiment with increased speed and variations until the most reliable line- follow.
Note: There are sensors that return a digital value but it needs to be calibrated. You can use any you like.
When you have done one-sensor line following, add another sensor. You may have to review the position of your sensors. There are lots of tutorials online for these.
On the left have a look at the position of the line sensors. You must experiment with the distance between them and the height to get the optimum performance.
Use spacers to adjust the height. This height was determined earlier and should be check for all line sensor as they are not all the same.
The HC-SR04 ultrasonic sensor measures distance by sending out high-frequency sound waves and calculating the distance based on the time it takes for the waves to bounce back from an object. It's commonly used in robotics and automation for accurate proximity sensing and obstacle detection.
Program your robot to navigate the circuit without collisions, accounting for the possibility of multiple robots on the path.
You will need a mounting bracket for your distance sensor. This requires students to measure the sensor dimensions accurately using a vernier caliper to ensure a proper fit. This hands-on approach in designing and customising their own housings through 3D modeling and printing enhances students' learning experience in practical engineering and technology skills.
This tutorial clearly explains how it works: Ultrasonic Sensor HC-SR04 with Arduino Tutorial
The robot is designed to carry objects weighing up to 100 grams, with a maximum diameter of 2 centimeters. The system includes three stations: A, B, and C. Its primary task is to pick up parcels from Stations B and C and deliver them to Station A.
The most critical function is the robot's ability to follow a line. Additionally, it should have features such as stopping at pickup stations, waiting for package loading, continuing to delivery stations, and returning to the pickup stations.
To enhance functionality, a green LED indicator should be included to signal the robot's readiness for loading when it is empty. An additional display can be added to provide instructions or display the robot's status.
Precision Calibration Weights from Aliexpress
50g 2x20g 10g 5g Mini Weight set. These scales work well as potential packages and students design their package holder around this.
“Kaitiakitanga in Parcel Delivery" refers to the application of the Māori concept of "kaitiakitanga" within the context of parcel delivery. "Kaitiakitanga" is a Māori term that broadly translates to the guardianship, protection, and responsible management of natural and cultural resources.
In the specified context of parcel delivery, "Kaitiakitanga in Parcel Delivery" suggests an approach where those involved in the delivery process take on the role of guardians or stewards. This involves a commitment to responsible practices, efficiency, and environmental considerations throughout the parcel delivery cycle. It reflects an intention to manage the delivery process in a way that minimizes negative impacts on the environment and resources, aligning with the principles of sustainable and thoughtful management embodied in the concept of "kaitiakitanga."
As we use an Arduino it is important that we think about input and output. So the input is from the light via the voltage divider circuit to the analog input of the Arduino. We use an LED as an output on the Arduino.
Ensure that you calculate the value of R3 based on the specifications of your LED as the Forward Voltage of various colour LEDs are different. Go back to the Ohm's Law explanation if you are confused.
The housing for the package handler is 3D printed specifically to encase the light-dependent resistor (LDR) used in the Arduino robot.
Made from durable PLA material, the housing is designed to securely hold the LDR in place, ensuring accurate and reliable detection of whether the robot has a package.
The compact and lightweight structure allows for easy integration with the Arduino robot, ensuring it does not interfere with the robot's performance. The housing also features precise cutouts to facilitate wiring and connectivity, optimising the functionality of the LDR sensor in determining the presence of a package.
Additionally, the design is simple enough that students can easily create and customise their own housings, providing a hands-on learning experience in 3D modeling and printing.