Final_Semester_Project _Report

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PROJECT REPORT
ON
MICROCONTROLLER BASED HUMANOID ARM
Submitted in partial fulfilment of the requirements
for the award of the degree
Of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
MUTHAMIZH SELVAN. A (1020940099)
NITHIN KUMAR. D (1020940106)
SRIRAM. R (1020940168)
Under the guidance of
Mr E. THAMBIRAN, M.E
(Asst. Professor (Sr.G), School of Mechanical Engineering)
FACULTY OF ENGINEERING AND TECHNOLOGY
SRM UNIVERSITY
(Under section 3 of UGC Act, 1956)
Ramapuram Campus - Part, Vadapalani
Chennai - 600 026
APRIL-2013

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BONAFIDE CERTIFICATE
Certified that the project report entitled “MICROCONTROLLER BASED
HUMANOID ARM” Submitted by “MUTHAMIZH SELVAN. A (1020940099),
NITHIN KUMAR. D(1020940106), SRIRAM. R (1020940168)” is a record of
project work done by them under my supervision towards the partial fulfilment of the
requirements for the award of the degree of Bachelor of Technology in Mechanical
engineering in SRM University, Chennai during the year 2012-2013. This project has
not formed the basis for the award of any degree, diploma, associate ship or
fellowship.
Mr E. THAMBIRAN Prof.C.K.LAKSHMYNARAYANAN
PROJECT GUIDE HOD
MECHANICAL ENGINEERING MECHANICAL ENGINEERING
Internal Examiner External Examiner

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DECLARATION
I do hereby declare that the project report entitled “MICROCONTROLLER BASED
HUMANOID ARM” is a record of original work carried out by MUTHAMIZH
SELVAN. A (1020940099), NITHIN KUMAR. D (1020940106), SRIRAM. R
(1020940168) under the supervision of Mr E. THAMBIRAN, Asst. Professor,
department of Mechanical Engineering, SRM
UNIVERSITY, RAMAPURAM PART – VADAPALANI. This project has not been
submitted earlier in part or full for the award of any degree, diploma, associate ship or
fellowship.
MUTHAMIZH SELVAN. A
NITHIN KUMAR. D
DATE: SRIRAM. R

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ACKNOWLEGDEMENT
This final year project was the result of the thought process combined with hard work of
not just us, but a group of other people. This thesis would be incomplete without
expressing our heartfelt gratitude to them.
First and foremost we want to thank god or enabling us to complete our project in the
required time. We are extremely grateful to our beloved Dr.R.PACHAMUTHU
(Chancellor, SRM University) for providing us with the quality infrastructure and lab
facilities.
We choose this moment to thank our Dean Dr.N.VASUDEVAN, B.E., M.TECH., PhD
for the support he has rendered throughout OUR educational experience in SRM
University City campus.
We are grateful to our Head of the department Prof.C.K. LAKSHMI NARAYANAN,
B.Sc.Engg., M.E,(Head Of The Department) for his invaluable guidance, motivation,
timely and insightful technical discussions. We are immensely grateful for his constant
encouragement, smooth approach throughout our project and make this work possible.
We wish to express our heartfelt thanks to our guide Asst.Prof .E. THAMBIRAN M.E,
for guiding us in this endeavour throughout the project. We are deeply indebted to him for
his unconditional support and thorough guidance.
Our Sincere thanks to Asst.Prof.E. SANKAR, M.E, (Project Coordinator) who shared
his valuable information that helped in the successful completion of this project.
We also express our sincere thanks to Mr SANTHOSH Diploma in A.M.I.E, technical
assistant, Automation laboratories helping and rendering his valuable help to us in our
research.
We are very grateful to Mr PRAKASH (Simple Labs) and Mr BASKAR (Mercy
Electronics) for dealership of all the required components for this project at a reasonable
price and also for his whole hearted support during the entire project.
We also take this opportunity to thank all our colleagues and other teaching faculty, whose
valuable suggestion and motivation, without which we could never have completed this
work.

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ABSTRACT
This Paper gives a clear-cut idea about design, manufacturing, theory and application of
Humanoid Robotic Hand. The task was to develop a prototype of a Wireless operated -
Humanoid hand, This Five-Fingered Humanoid hand has the capability of replicating
complex actions of an actual human hand operated from distance of up to 300-400 ft in
the line of sight outdoor and 100ft indoors.
The focus of this thesis within the project lied on to improve the function and wireless
application of the robotic hand. From Mechanical point of view and interest in addition
to the control system, a Conceptual design & 3D-Model should be developed and NX-
CAM code for milling the prototype has to be generated.
Simultaneously a developing the control interface of the hand glove using Flexible
sensor and Arduino Uno was also made. To reduce the cost of the hand, working model
was made as simple as possible. To keep the manufacturing costs down is also an
important issue developing the new Prototype. Several different concepts where analysed
before the final Prototype was built. To designing and rendering the hand Solid Works
was used. CAM codes were generated using NX-CAM. This project revolves around
applications from subjects such as Mechatronics, Fluid Power Control and Engineering
Design etc…. from our undergraduate study.

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TABLE OF CONTENT
CHAPTER TITLE PAGE No.
NUMBER
1 INTRODUCTION 8
1.1 ABOUT OUR PROJECT 8
1.2 ROBOTICS 9
1.3 BIO INSPIRED TECHNOLOGY 9
1.4 STUDY ON HUMAN HAND 10
1.5 HUMANOID HAND 10
1.6 APPLICATION OF HUMANOID HAND 13
2 MECHANICAL DESIGN 15
2.1 SOLIDWORKS 16
2.2 PART MODELING 16
2.3 ASSEMBLY MODELING 17
2.4 RENDERING 19
2.5 DRAWING AND DETAILING 19
3 ANALYSIS 21
4 COMPUTER AIDED MANUFACTURING 26
5 MICROCONTROLLER BOARD AND
WIRELESS COMPONENTS 34
5.1 ARDUINO UNO 34
5.2 WIRELESS CAPABILITIES 36
6 ACTUATOR AND SENSOR USED 38
6.1 SERVO MOTOR 38
6.2 FLEX SENSOR 39
7 COMPONENTS PURCHASE QANTITY 41

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8 EXPERIMENTS CONDUCTED 42
9 PROGRAMMING THE ARDUINO 43
9.1 SENDING ARDUINO CODE 43
9.2 RECEVING ARDUINO CODE 44
10 FINAL ASSEMBLY 46
10.1 CONTROL GLOVE 46
10.2 HUMANOID HAND ASSEMBLY 47
11 WORKING 48
12 RESULTS AND DISCUSSIONS 50
13 CONCLUSION 51
14 BIBLIOGRAPHY 52

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1. INTRODUCTION
In this chapter, the sole purpose of this project and theory behind this project will be
described. It will also be mentioned why it is important to develop Humanoid hand and
what was important to achieve within this project.
1.1 ABOUT OUR PROJECT
The task was to develop a prototype of a Wireless operated -Humanoid hand, This Five-
Fingered Humanoid hand has the capability of replicating complex actions of an actual
human hand. The focus of this thesis within the project lied on to improve the function and
wireless application of the robotic hand. In addition to that a Conceptual design & 3D-
Model should be developed and NX-CAM code for milling the prototype has to be
generated. Simultaneously a developing the control interface of the hand glove using
Flexible sensor and Arduino Uno was also made. To reduce the cost of the hand, working
model was made as simple as possible. To keep the manufacturing costs down is also an
important issue developing the new Prototype. Several different concepts where analyzed
before the final Prototype was built. To designing and rendering the hand Solid Works was
used. CAM codes were generated using NX-CAM. This project revolves around
applications from subjects such as Mechatronics, Fluid Power Control and Engineering
Design etc…. from our undergraduate study.
WIRELESS
TECHNOLOGY
MECHATRONICS
ENGINEERING
DESIGN

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1.2 ROBOTICS
Robotics is the branch of technology that deals with the design, construction,
operation, and application of robots. The study of robots involves various aspects of
Mechanical Engineering, Electrical Engineering and control Theory. Robotics deals
with automated machines that can take the place of humans in dangerous
environments or manufacturing processes, or resemble humans in appearance,
behaviour, and cognition. These definitions are also not enough or not very close to
defining Robotics, as it’s a vast, rapidly growing and multidisciplinary field.
Many robots do jobs that are hazardous to people such as defusing bombs, exploring
shipwrecks, and mines. They are also employed in jobs which are too dirty or dull to be
suitable for humans. Robots are widely
used in manufacturing, assembly,
packing and packaging, transport, earth
and space exploration, surgery,
weaponry, laboratory research, safety,
and the mass production of consumer
and industrial goods. Japan and
Germany are the leading nations in the
field of robotics, which has substantially
helped those countries to become
Industrial super powers of this field.
Robots are mainly used in
manufacturing firm especially
Automobile manufacturing plants. Japan
and Germany are leaders in Advanced
Robotic research and development; this
has substantially paid of them by making
contributing to manufacturing sector.
Now Japan and Germany are two
Industrial super powers of the world. Figure 1.1
1.3 BIO INSPIRED TECHNOLOGY
Biologically inspired technology is a power full tool for advanced research in Mechanical
Engineering especially in the field of robotic locomotion and object handling. Bio-inspired
robotics is about studying biological systems, and look for the mechanisms that may solve
a problem in the engineering field. The designer should then try to simplify and enhance
that mechanism for the specific task of interest. It is about observing the nature and
learning from it, later the principles or the mechanism devised is applied to the real world
engineering systems. More specifically, this field is about making robots that are inspired

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by the biological systems. As a product designer and developer we can refine our product
for better looks and performance maximum 15-20 iterations, but nature has course of
thousands of years evolution and infinite number of iterations.
Figure 1.2
1.4 STUDY ON HUMAN HAND
Developed under many years of evolution the human hand has made us to what we are today.
The human hand is composed by 27 different bones and the opposing thumb is characteristic
For the human. The opposing thumb enables the precision grasp between the long finger and
The thumb which enables us to write or to perform precision work. Further the hand has 20
DOF and the most muscles are placed in the forearm and transmit their developed force via
tendons to the fingers. The bigger muscles in the hand are the thenar muscle on the thumb
side and the Hypothenar muscle on the side of the little finger.
1.5 HUMANOID HAND
In our project we have the inspiration from the Human hand, a microcontroller based
humanoid arm with wireless capabilities. Our design and mechanism are very much
similar to an actual human arm. The very word Humanoid means human like , A humanoid
is something that has an appearance resembling a human being.

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1.5.1. TWO TYPES OF HUMANOID HANDS
 MODULAR HAND
They are autonomous units with all the components required to function that includes
actuator, sensor etc ...They are more of an end effector that connects to the robot's arm
kinematics to execute their functions An overall complex design is required , still in
research and development level. Slightly lower gripping is achieved that the integrated
hand , and slightly bigger in size compared to human hand.
Modular Hand Examples- Stanford Hand, Barret Hand, DLR Hand, SRM Hand…
 2. INTEGRATED HAND
End effector is integrated to the robotic Arm kinematics. Larger actuators can be used to
generate greater gripping force as they are placed away from the hand housing. One
disadvantage is force transfer from actuator to finger is difficult due to distance involved.
Example: Airics Arm from Feisto and Robonaut from NASA.

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1.6 APPLICATIONS OF HUMANOID HAND
1.6.1. NUCLEAR FACILITIES:
Safe operation, avoidance of direct radiation on workers with the use of wireless operated
humanoid arms. Radiation exposure is a long standing problem in nuclear research and
reactor facilities. Exposure to harmful nuclear radiation causes several health related
hazards that includes lethal cancer. Hence an Operator or a scientist will definitely has to
seek the help of wireless-operated humanoid hand for the safe distance handling of
radioactive materials. During times of emergency robots will be of great use in Nuclear
facilities were people will be forbidden to enter, robots without robotic hand will be
useless.
1.6.2. BOMB DETECTION AND DEFUSING:
The major application of this project id Bomb detection and defusing, an highly trained
person can only defuse a bomb, though special Anti-Bomb suits are developed many a
time loss of life is encountered because the bomb can only be defused at closer distance by
physical contact. During war time in the war zones powerful Explosives are placed in
many places leading to loss of several lives. When our Humanoid Hand is connected to a
Robotic Arm mounted on a RC vehicle, it can be wirelessly operated by our specialist with
video camera installed on RC vehicle. The risk will be greatly reduced and our Bomb-
defusing specialist can operate at safer zone and defuse the bomb. Hence this project will
be highly regarded in Defence research circle like DRDO, DARPA..

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1.6.3. SURGICAL ROBOT:
Telemedicine is highly regarded technology of 21st century; Humanoid hand will find its
application in surgical robotics research for its ability of replicating Complex tasks of
human hand. Here doctors can operate the robotic arm and humanoid hand via internet to
perform emergency procedure that can save precious life.
1.6.4. PROSTETIC HAND:
Better designed artificial hands for those who lost their hands in accidents and war will be
a gift to mankind from Engineers. Our Humanoid hand is designed close to human hand
hence it can be extended for use in prosthetics.

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2. MECHANICAL DESIGN
AIM
The aim is to design a Five-Fingered Humanoid hand using Solidworks software.
Specification is taken from actual human hand because this is a Biologically inspired
technology- project and innovative in nature. The design specification must be
practical considering the shape and the assembly properties of the hand
TASK SPECIFICATION
• The hand shall be able to grasp objects of smaller diameter, irrespective of height.
That means the hand has to perform grasp.
• The hand shall be able to replicate the Gestures of Human hand operating the sensor
Glove
• The hand shall also be able to operate with Servo motor placed at distance of
100mm-300mm from the figure tip.
• The hand shall be able to press a button.
DESIGN SPECIFICATIONS
• The Hand shall house all actuators, control board and cables.
• The dimensions and the shape of the palm (hand) shall be close to a human hand..
• The hand shall also be able to operate with Servo motor placed at distance of
100mm-300mm from the figure tip.
• The hand shall be easier to assemble.
• The Hand must be attractive in looks to the customers with good aesthetic features.
PERFORMANCE SPECIFICATIONS
• The mass of the hand shall be less than 500 g.
• The hand and full wireless control setup shall cost less than Rs.18,000 to prototype.

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2.1 SOLIDWORKS
SolidWorks is a 3D mechanical CAD (computer-aided design) program that runs on
Microsoft Windows and is being developed by Dassault Systems SolidWorks
Corporation
MODELING METHODOLOGY
SolidWorks is a Para solid-based solid modeller, and utilizes a parametric feature-
based approach to create models and assemblies.
Parameters refer to constraints whose values determine the shape or geometry of the
model or assembly. Parameters can be either numeric parameters, such as line lengths
or circle diameters, or geometric parameters, such as tangent, parallel, concentric,
horizontal or vertical, etc. Numeric parameters can be associated with each other
through the use of relations, which allow them to capture design intent.
In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch
geometry, assembly mates define equivalent relations with respect to the individual
parts or components, allowing the easy construction of assemblies. SolidWorks also
includes additional advanced mating features such as gear and cam follower mates,
which allow modelled gear assemblies to accurately reproduce the rotational
movement of an actual gear train.
The drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model, and notes, dimensions and tolerances can then be
easily added to the drawing as needed. The drawing module includes most paper sizes
and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).
2.2 PART MODELING:
This module produces parts easily and rapidly by creating features such as
extrudes, revolves, thin features, lofts, sweeps, advanced shelling, feature patterns and
holes.
The 3D part is basic building block of the SOLIDWORKS mechanical
designing software. In solidworks the part can be designed by sketching its component
shapes and defining their size, shape and inter relationships. By successfully creating
their shapes, called features, the part can be constructed.

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STEPS INVOLVED IN MODELLING PROCESS
• Plan the part
• Create the base feature
• Create the remaining feature
• Analyse the part
• Modify the features as necessary
FINGER AND END CAP
Fingers are designed to act like spring once released from bend position they must
return to their original extended shape. The lines from the Servo motor horn is directly
tied through the centre hole in the End cap.
2.3 ASSEMBLY MODELING:
Assembly design gives a user the ability to design with user controlled
associability. SolidWorks builds these individual parts and the sub-assemblies into
assembly in a hierarchical manner. This is based on the relationships defined by the
constraints.
SolidWorks assembly design reference parts directly and maintains
relationships when creating new parts. In the assembly module, physical simulation
and mechanical interaction between the parts can be performed and potential design
flaws can be avoided.
In Assembly Servo motors mounting position can also be determined by placing
them on the hand chassis, before actually mounting them.

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PALM ASSEMBLED WITH FIVE FINGERS
Palm is designed in such a way that base of the
Fingers are accommodated rigidly in their
respective slots by fitting method. In
Solidworks assembly is done using mating
options, there are various mating like
circumferential mate, planar mate, parallel and
several other.
HUMANOID HAND WITH SERVOS
MOUNTED TO CHASSIS

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2.4 RENDERING
Rendering is the final product with finishing touch generated by Solidworks rendering
tool. The Hand design is complete with realistic render produced.
2.5 DRAWING AND DETAILING:
2D drawings module develops complete production ready engineering
drawings without drawing the sketches, makes the revision quickly and accurately,
and generates bill of materials and balloons automatically, easily controlling and
alignment of balloons.
• Modelling Dimensions: Model dimensions are created as the part feature is
created and then it is inserted into various drawing views. Change in dimension in the
model updates the drawings and changing an inserted dimension a drawing changes of
the model.
• Reference Dimensions: Dimensions cans be added in the drawing document,
but these are reference dimensions and are driven; the values of the reference
dimensions cannot be edited to change the model. However, the values of reference
dimension change when the model dimensions change.

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3. ANALYSIS
Once the 3D Modelling and Drafting is over the product has to be tested using
analysis software like ANSYS , NASTRAN etc.. We used ANSYS Workbench to
analyse our design.
ANSYS WORKBENCH
ANSYS Workbench, developed by ANSYS Inc., USA, is a Computer Aided Finite
Element Modeling and Finite Element Analysis tool. In the Graphical User Interface
(GUI) of ANSYS Workbench, the user can generate 3-dimensional (3D) and FEA
models, perform analysis, and generate results of analysis. We can perform a variety
of tasks ranging from Design Assessment to Finite Element Analysis to complete
Product Optimization Analysis by using ANSYS Workbench. ANSYS also enables
you to combine the stand-alone analysis system into a project and to manage the
project workflow.
The following is the list of analyses that can be performed by using ANSYS
Workbench:
1. Design Assessment
This analysis system is used to perform a combined solution for static and
transient structural analyses. It also performs post-processing through a script using
additional data associated with the geometry.
2. Explicit Dynamics
This analysis system is used to identify the dynamic response of a component
under stress wave propagation, or time-dependent loads or impacts. It is also used for
modal mechanical phenomena that are highly non-linear.
3. Fluid Flow (CFX)
This system allows users to carry out flow analysis of compressible and
incompressible fluids. It is also used to analyze heat transfer in fluids.
4. Fluid Flow (FLUENT )
Like Fluid Flow (CFX), Fluid Flow (Fluent) system is also used to carry out
fluid flow analysis of compressible and incompressible fluids and their heat transfer
analysis.
5. Harmonic Response

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Harmonic response is the response of a system under a sustained cyclic load.
Harmonic Response analysis system is used to analyze a system working under
periodic or sinusoidal loads. This analysis helps in determining whether a particular
structure will be able to withstand resonance, fatigue, and other effects of forced
vibration.
6. IC Engine
This analysis system helps determine the performance of the whole system of
an IC engine. It takes into consideration the various fluid properties, moving
components, and electric and electronic components inside an engine.
7. Linear Buckling
This analysis system is used to evaluate the buckling strength of a system under
external loads.
8. Magnetostatic
This analysis system is used to analyze the magnetic field developed due to the
presence of a temporary or permanent magnet.
9. Modal
Modal analysis is the study of dynamic properties of a model, subjected to
vibrations. Modal analysis system in ANSYS Workbench helps in determining the
frequencies and mode shapes of a model.
10.Random Vibration
This analysis is carried out to determine the reaction of a structure or a
component to changing frequencies of vibrations. Many components experience
vibrations which are random in nature. This analysis system is used to determine the
responses of structures that are exposed to such varying or random vibrations.
11.Response Spectrum
Response Spectrum analysis system is similar to Random Vibration analysis
system and is used after a transient analysis is done.
12.Rigid Dynamics
Rigid Dynamics analysis system is used to determine the response of a rigid
body or a mechanism consisting of rigid bodies. Response of a robot mechanism is an
example of rigid body analysis.
13.Static Structural

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The Static Structural analysis system is used to determine the response of a
structure subjected to static loading conditions. The loads in this case are assumed to
produce no or negligible time based loading characteristics. Using this type of
analysis, displacement, stresses, and deformations of structures under static loading
conditions can be determined.
14.Steady-State Thermal
Steady-state thermal analysis system is used to determine the temperature,
thermal gradient, heat flow rates and heat fluxes under the influence of thermal
loading which remains constant with time and are static in nature.
15.Transient Structural
Transient Structural analysis system is used to determine responses of
structures under the action of time dependent variables. Using this analysis, time-
varying displacement, stresses and strains can be determined.
16.Transient Thermal
Transient Thermal analysis system is used to determine the temperature and
other thermal variables of a structure that vary over time.
STATIC STRUCTURAL ANALYSIS: Static structure analysis is used to analyse
our design. Following steps are performed to obtain results.
STEP1: The Palm solid model is imported and fixed

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STEP 2: Force magnitude and direction is specified
STEP 3: Mesh is generated.

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4. COMPUTER AIDED MANUFACTURING
Computer Aided Manufacturing is the use of computer software and hardware in
transforming the computer aided design models into manufacturing instructions for
numerical controlled machine tools. Computer Aided Manufacturing refers to
automation process, which accurately converts product design and drawings into code
format which is read by the machine to manufacture the designed product.
CAM software converts 3D models generated in CAD into set of basic
operating instructions written in G-code. The G-code is a programming language that
can be understood by numerical controlled machine tools – essentially industrial
robots. The G-code provides instructions to the machine tool to manufacture a large
number of items with perfect precision and faith to CAD design.
NX CAM
NX CAM provides a wide range of machine tool programming capabilities in a single
integrated solution enabling one to take advantage of the latest machine tool
technologies and manufacturing processes.
BENEFITS OF USING NX CAM:
1. Maximizing productivity and efficiency
2. Total design to manufacture connectivity
3. First time quality through simulation
4. Efficiency through leading technology
5. An all-inclusive solution for machining
BROAD SUPPORT OF MACHINE TOOLS AND OPERATIONS
1. MILLING
 2 and 3 axis machining
 5 axis machining
 Drilling
 Feature based machining
 High speed machining
 Engraving

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2. TURNING
 Turning
 Merging lathes
 Milling and turning combination
3. OTHER
 Electrical discharge machining
 A full set of applications
4. DESIGN/ASSEMBLY
 Fixture design
 Part and assembly modelling and editing
 Geometry translators
5. AUTOMATION TOOLS
 Process templates
 Tool libraries
 Feeds and speeds data
6. VERIFICATION AND SIMULATIONS
 Tool Path Verification
 Machine tool modelling and kinematics
 Machine tool simulation
7. OUTPUT
 Postprocessor building and editing
 Shop documentation output
 Data management

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GRAPICAL OVERVIEW OF NX-CAM
Steps involved :
1. Import the solid model
2. Create the milling tool
3. Define work piece and block.
4. Insert operation and define operation parameters
5. Generate the cut pattern
6. Visualize milling in 3D
7. Post process and code generation
NX-CAM
NC
programming
and machining
database
3D modelling
of machine
tools
Machine tool
kinematics
definition
Machine tool
simulation
Post
processing
Post processor
creation and
editing
3D modeling
of tools and
fixtures
Tool path
verification

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NX-CAM CODES GENERATED FOR CNC-MACHINE
=========================================================
N0010 G40 G17 G90 G70
N0020 G91 G28 Z0.0
N0030 T00 M06
N0040 G0 G90 X.4211 Y-1.8504 S0 M03
N0050 G43 Z1.1024 H00
N0060 Z.315
N0070 G1 X1.3027 Z.0787 F9.8 M08
N0080 X-1.2785
N0090 Z.1969
N0100 G0 Z1.1024
N0110 X1.3027
N0120 Z.1969
N0130 G1 Z.0787
N0140 X1.3301 Y-1.7917
N0150 X-1.2886
N0160 Z.1969
N0170 G0 Z1.1024
N0180 X1.3301
N0190 Z.1969
N0200 G1 Z.0787
N0210 X1.3575 Y-1.7329
N0220 X-1.2987
N0230 Z.1969
N0240 G0 Z1.1024

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N0250 X1.3575
N0260 Z.1969
N0270 G1 Z.0787
N0280 X1.3849 Y-1.6742
N0290 X-1.3088
N0300 Z.1969
N0310 G0 Z1.1024
N0320 X1.3849
N0330 Z.1969
N0340 G1 Z.0787
N0350 X1.4123 Y-1.6154
N0360 X-1.319
N0370 Z.1969
N0380 G0 Z1.1024
N0390 X1.4123
N0400 Z.1969
N0410 G1 Z.0787
N0420 X1.4397 Y-1.5567
N0430 X-1.3291
N0440 Z.1969
N0450 G0 Z1.1024
N0460 X1.4397
N0470 Z.1969
N0480 G1 Z.0787
N0490 X1.4671 Y-1.4979
N0500 X-1.3392

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N0510 Z.1969
N0520 G0 Z1.1024
N0530 X1.4671
N0540 Z.1969
N0550 G1 Z.0787
N0560 X1.4945 Y-1.4392
N0570 X-1.3494
N0580 Z.1969
N0590 G0 Z1.1024
N0600 X1.4945
N0610 Z.1969
N0620 G1 Z.0787
N0630 X1.5218 Y-1.3805
N0640 X-1.3595
N0650 Z.1969
N0650 Z.1969
N0660 G0 Z1.1024
N0670 X1.5218
N0680 Z.1969
N0690 G1 Z.0787
N0700 X1.5492 Y-1.3217
N0710 X-1.3696
N0720 Z.1969
N0730 G0 Z1.1024
N0740 X1.5492
N0750 Z.1969

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N0760 G1 Z.0787
N0770 X1.5766 Y-1.263
N0780 X-1.3797
N0790 Z.1969
N0800 G0 Z1.1024
N0810 X1.5766
N0820 Z.1969
N0830 G1 Z.0787
N0840 X1.604 Y-1.2042
N0850 X-1.3899
N0860 Z.1969
N0870 G0 Z1.1024
N0880 X1.604
N0890 Z.1969
N0900 G1 Z.0787
N0910 X1.6314 Y-1.1455
N0920 X-1.4
N0930 Z.1969
N0940 G0 Z1.1024
N0950 X1.6314
N0960 Z.1969
N0970 G1 Z.0787
N0980 X1.6588 Y-1.0867
N0990 X-1.4101
N1000 Z.1969
N1010 G0 Z1.1024

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N1020 X1.6588
N1030 Z.1969
N1040 G1 Z.0787
N1050 X1.6862 Y-1.028
N1060 X-1.4203
.
.
.
.
N1350 G0 Z1.1024
N1360 X1.6535 Y1.9488
N1370 Z.7087
N1380 G1 Z.5906
N1390 X1.6142
N1400 X-1.6142
N1410 X-1.6535
N1420 Z.7087
N1430 G0 Z1.1024
N1440 M02 (Code end line)
%
**The code was very lengthy, hence it was cut shorted.

34
5. MICROCONTROLLER BOARD AND WIRELESS COMPONENTS
5.1 ARDUINO UNO (MICROCONTROLLER BOARD)
The Arduino Uno is a microcontroller board based on the ATmega328 .It has 14
digital input/output pins ,6 Analog inputs, a 16 MHz ceramic resonator, a USB
connection, a power jack, an ICSP header, and a reset button. It contains everything
needed to support the microcontroller; simply connect it to a computer with a USB
cable or power it with a AC-to-DC adapter or battery to get started.
Reasonably price and reliable quality were the deciding factors for choosing this
microcontroller board for our project. Added advantage of using an Arduino is that it
is Open-source hardware and supporting software provided. Working with Arduino
can be fun and easy, at the same time one can learn a lot about electronics and
robotics. Especially when Mechanical Engineering students and other disciplinary
students getting started with electronics can explore the amazing world of robotics
control with Arduino Uno.
DETAILS- ARDUINO UNO
Microcontroller ATmega328
Operating Voltage 5V
Input Voltage (recommended) 7-12V
Input Voltage (limits) 6-20V
Digital I/O Pins 14 (of which 6 provide PWM output)
Analog Input Pins 6
DC Current per I/O Pin 40 Ma
DC Current for 3.3V Pin 50 Ma
Flash Memory 32 KB (ATmega328) of which 0.5 KB used by boot loader
SRAM 2 KB (ATmega328)
EEPROM 1 KB (ATmega328)
Clock Speed 16 MHz

35
AT MEGA-328
(MICROCONTROLLER)
The ATmega328 is a single chip
micro-controller created by Atmel
and belonging to the megaAVR
series. In our case it comes along
with Arduino Uno board which
makes our work easy.
SERVO MOTOR SHIELD
The Simple Labs' Servo Shield is
a custom designed Shield to drive Servo Motors. The Shield Can drive up to 10 servo
motors at a time. It was originally designed for our Quadbot Robot Kit (8 Servos) +
Mini Pan and Tilt Kit (2 Servos). In addition to this, the servo shield has suitable pin
outs to be able to connect the Compound Eye IR Sensor.It has a screw terminal for
external supply to be connected to power the servos. We can use 6V battery to Power
these up.
The servo shield has Servo control pins on Arduino Digital Pins D2, D3, D4, D5, D6,
D9, D10, D11, D12 & D13. Refer to the TOP Legend on the board "D + - " for the
Orientation of the Servo Connector Connection. We used five outputs from this motor
shield, maximum ten servo motors can be operated using this servo shield. We were
very fortunate to find this board as it made our control system very compact and neat.
The pins are designed in such a way it mounts directly into the Arduino Uno-Wireless
setup shield.

36
5.2 WIRELESS CAPABILITIES
Our project the Humanoid Hand or the Robotic Hand has the capability of replicating
figure flex and gestures of Human Hand with the help of Control Glove. We later
included the wireless control in this setup , It would greatly enhance the project in its
application area. Wireless control of our Robotic Hand helped us break into the world
of communication and expand our horizon to Military ,Defence Bomb defusing and
Nuclear Facility applications. Working with wireless can be hard and frustrating,
especially when you are a Mechanical student. We have found an easier and cost
effective solution for these problems. Just buy the following components in pair , we
will need one as a sender(master) and other as receiver(Slave).
5.2.1 XBEE SERIES-2 MODULE
The XBee XB24-Z7WIT-004 Series 2 improves on the power output and data
protocol. XBee Series 2 modules allow a very reliable and simple communication
between microcontrollers, computers, systems, really anything with a serial port!
Point to point and multi-point networks are supported. We just need to create
communication between two Arduino Uno Boards. The Series 2 requires considerable
setup and configuration but there are tons of tutorials out there in Internet. To create a
network pair we must configure using X-CTU Software. One must be configured as
Co-ordinator and other must be Router device. Indoor/Urban range up to 133 ft.
(40m) , Outdoor RF line-of-sight rang up to 400 ft. (120m)
5.2.2 ITEAD XBEE SHIELD
XBee Shield is an enhanced Zigbee XBee Series modules breakout board for Arduino,
it can directly plug in with Arduino Uno Board. It Protects the XBee modules from
damage due to higher voltage and has a 3.3 V regulator for this purpose. The XBee
Shield simplifies the task of interfacing an XBee with your Arduino. This board mates
directly with an Arduino Pro or USB board, and equips it with wireless
communication capabilities using the popular XBee module. This unit works with all
XBee modules including the Series 2 (and 2.5), standard and Pro version. There was
no need of soldering in wireless system, they are easy to assemble, just place the
wireless shield on Arduino make sure the pins are correctly matched and gently press,
same applies for Servo motor shield and XBee module.

38
6. ACTUATOR AND SENSOR USED
6.1 SERVOMOTOR:
Servomotor is a mechanical actuator that gives highly precise angular motion using
closed loop position feedback. Servomotors are used in applications such as robotics,
CNC machinery or automated manufacturing.
MODELS PURCHASED
V 3006 Servomotor
It is a heavy duty plastic geared economy hobby servo motors for general purposes.
Specification:
Operating Voltage: 4.8-6.0V
Stall Torque: 6 kg-cm at 4.8V, 7.1 Kg-cm at 6V
Operating Speed: 0.18 sec/ 60Â° at 4.8V, 0.16 sec/ 60Â° at 6V at no load
Weight: 40g
Size: 41.3*20.3*38.7
Connector wire length: 30cm
TowerPro SG5010
TowerPro SG5010 is a high quality but really low-cost servo for all your mechatronic
needs. It comes with a 3-pin power and control cable, even a dozen of hardware as
shown.
Features:
3 pole ferrite, all nylon gear, Top ball bearing.
Operating
Voltage:
4.8V~6.0V
Operating
speed:,
0.16sec/60deg
(6.0V)
Stall torque:
6.5kg*cm
(6.0V)
Dimension:
41 x 20 x
38mm
Weight: 41g
Connector wire
length: 30cm

39
6.2 FLEX SENSOR
Description: A simple flex sensor 4.5" in length. As the sensor is flexed, the
resistance across the sensor increases. Patented technology by Spectra Symbol - they
claim these sensors were used in the original Nintendo Power Glove which was used
as control glove for gaming.. The resistance of the flex sensor changes when the metal
pads are on the outside of the bend (text on inside of bend).Connector is 0.1" spaced
and bread board friendly. It can bend and flex physically with motion device.
Possible Uses
• Robotics
• Gaming (Virtual Motion)
• Medical Devices
• Computer Peripherals
• Musical Instruments
Mechanical Specifications:
• Life Cycle: >1 million
• Height: 0.43mm (0.017")
• Temperature Range: -35°C to +80°C

40
6.2.1 CONNECTING FLEX SENSOR WITH ARDUINO UNO
Flex sensor has two terminals one is for 5v and other must be connected to Analog pin
resistor (10K or 22K) which acts as a voltage divider, then grounded. In order to
connect five Flex sensor to Arduino a separate PCB board has to be made. This board
is mounted on the Control Glove, ready for acton.

41
7. COMPONENTS PURCHASE-QANTITY
Major components like Servo motors, Arduino Uno( microcontroller ),Custom
designed plastic cut parts, Robotic- Frame, Flexible sensors, Wireless shield, Xbee
series-2 Hand Gloves purchased are listed along with the quantity of purchase in the
following Table.1.1
Purchase of components ( Table 1.1 )
S.No Components Quantity
1 Servo motor 5
2 Flexi sensor 4.5 5
3 Arduino Uno 2
4 Wireless shield 2
5 Servo Motor shield 1
6 Xbee series-2 2
7 Hand Glove 1
8 Robotic chassis 2
9 Rechargeable 6V battery 1

42
8. EXPERIMENTS CONDUCTED
For the successful operation of the wirelessly controlled Humanoid Hand the
following series experiments must be performed. This experiment leads to better
understanding of the mechatronic systems, microcontrollers, sensors etc. Doing a
project like this could be hectic, we need to assure the quality and working condition
of all the electronics components all the time, hence doing this following experiments
in regular interval gives good results and confident boost. These experiments require
some additional components but very cheap like LEDS, push buttons, and some
patience.
The following experiments are listed out in the Table 1.2
ExNo Title of the Experiment parameters Date Status
1. Servo control sweep Speed &
Position
07.03.2013 Completed
2. Servo control knob Angle 09.03.2013 Completed
3. Wireless Blink Signal
strength
4. Observing Flexi Sensor Reading Deflection,
Angle &
voltage output
5. Assembly & Final working All 06.04.2013 Completed

43
9. PROGRAMMING THE ARDUINO
It is a major and final step in this project, the codes written is compiled and uploaded
to the ATmega in the Arduino Uno by the use of Arduino IDE software. Arduino IDE
can be downloaded for free of cost from Arduino.cc website. The microcontroller is
reprogrammable, at a time it can only accommodate a single programme.
Screen shot of Aduino 1.0.1 software with basic LED blink code
SENDING ARDUINO (CONTROL GLOVE) – CODE
int Finger1 = 0;
int Finger2 = 2;
int Finger3 = 3;
int Finger4 = 4;
int Finger5 = 5;
void setup()
{
Serial.begin(9600);

44
}
void loop()
{
int FingerV1 = analogRead(Finger1);
if (FingerV1 < 470) FingerV1 = 470;
else if (FingerV1 > 545) FingerV1 = 545;
int servoVal1 = map(FingerV1,545, 470, 9, 1);
Serial.print(servoVal1);
delay(100);
}
RECEVING ARDUINO (HUMANOID HAND) -CODE
#include <Servo.h>
Servo myservo1;
Servo myservo2;
Servo myservo3;
Servo myservo4;

45
Servo myservo5;
void setup()
{
Serial.begin(9600);
myservo1.attach(2);
myservo2.attach(3);
myservo3.attach(4);
myservo4.attach(5);
myservo5.attach(6);
}
void loop()
{
if (Serial.available() >= 5)
{
int servoAng1 = Serial.read() - '0';
int Angle1 = map(servoAng1, 9, 1, 179, 0);
Angle1 = constrain(Angle1, 179, 0);
myservo1.write(Angle1);
Serial.flush();
}
}
We had written like number of codes for this project, First few didn’t work well,
thank god this pair worked for us. We were not specialist in programming, just
learned it from tutorials in Arduino support sites.

46
10. FINAL ASSEMBLY
In order to obtain fully functioning model final assembly must be made, power supply
from USB or battery must be connected. Both Arduinos must be programmed and
shields must be mounted.
10.1 CONTROL GLOVE
The control glove is ready to be worn only when all five Flex sensors are sewed to the
glove and connected with the PCB and Arduino Uno. Flex sensor is very sensitive at
the base hence nice padding must be given so that when flexi is bent the base is not
damaged or disturbed. In our Glove the Arduino is also stitched neat and tidy way.
The Arduino can be powered by battery or USB based on the need.

47
10.2 HUMANOID
HAND ASSEMBLY
Servo motors are
rigidly mounted using
nuts and bolts on to the
robotic chassis, All the
fingers with end caps
with fishing tackles
tied to it internally are
mounted or attached to
the palm. The palm in
turn is attached to the
Servo chassis. All the electronics components are mounted to the Hand using proper
spacers.

48
11. WORKING
Operator wears the Control Glove (practically anyone can wear the glove, its elastic
and comfortable). The control glove and Humanoid Hand setup are placed within the
working range of wireless communication of XBee series-2. Final assembly is
complete.
Servomotors are connected to the Servomotor shield powered by 6V Rechargeable or
four ordinary 6v batteries. Arduinos are powered up either by USB or battery.
When the communication begins all the fingers come to the fully extended state, when
a finger is bent the flex sensor senses the bend and the angle is obtained and processed
by the Arduino.
According to the programme we written the obtained angle value is transmitted via
XBee module (Sending) to other XBee module (Receiving).
Subsequently the Receiving Arduino processes the signal and corresponding
Servomotor is actuates and the same figure is flexed exactly to the angle of finger
bend.
All five fingers can be flexed at the same time, and the corresponding Humanoid hand
finger will respond immediately.
By the above mentioned steps , Humanoid hand will be able to replicate any gestures
of the operator from distance of upto 300-400ft in line of sight.
Flex sensor senses
the angle of finger
bend
Value obtained is
processed by
Arduino Uno on
Control Glove
Value is sent
wirelessly by XBee
module
Value is received
by XBee module
on the Humanoid
Hand
The received value
is processed by
Arduino Uno
Servomotor is
actuated and
rotates the precise
angle of fingure

49
PICTURES OF THE WORKING MODEL
HUMANOID HAND SHOWING GERSTURES

50
12. RESULT AND DISCUSSION:
Thus a Wirelessly controlled Humanoid hand is designed and fabricated and testing is
done under supervision of our Project guide..
The Design can be improved to produce variety of movements that include wrist
movement and opposing thumb.
Two microcontrollers are successfully made to communicate with each other using
Wireless system.
Using computer we can monitor the sensor values of the glove to iterate and improve
the sensor value give in the code.
This Humanoid Hand being modular type can be integrated with any Robotic
Kinematic Arm. As it has all the actuators and power supply housed in it.
This programme (codes) can be modified and changed for higher resolution and
accurate bend of fingers.
Material property and manufacturability has to be improved.
In order to use the fullest potential of our motor the fishing tackle used to connect
Servomotor horn must be replaced by alternative line which can withstand higher load
and friction.
It will be great if this Mechatronic system is made closed loop feedback system,
presently our project is a open loop system.

51
13. CONCLUSION
The hand prototype is working fine but some improvements could be made. Also the
Design of the hand can be improved by including a stronger material and higher
mechanisms and additional motions.
The Ultimate goal to develop a functioning prototype and a wireless control glove
which was fulfilled, the Humanoid hand can replicate the complex gestures of an
actual Human hand. It can perform grasps using the palm and can grasp objects in a
better way. Also the assembly properties and cable routing is well planned.
As it’s a Bio- inspired technology the Humanoid hand has dimensions close to the
human ones and looks humanlike. The process is made wireless using XBee, Which is
used to send and receive signals.
A Five finger robot hand could be developed at a total project cost of Rs.18,000.
This project can be further developed in many aspects and futuristic ideas can be
implemented. The resolution, mechanism, degree of freedom (D.O.F), precision can
be improved considerably. Hence the system will be more flexible and can be used in
Advanced functions like Nuclear facility, Bomb defusing and defence research.

52
14. BIBLIOGRAPHY:
LITRATURE
“THEORY OF MACHINES”.. R.S.KHURMI..
“ENGINEERING DESIGN”.. R.S.KHURMI..
“MICROPROCESSOR, ARCHITECTURE, PROMMING AND APPLICATIONS”..
RAMESH S.GAONKAR, PENRAM INTERNATIONAL
“MECHATRONICS”.. W.BOLTON.. PEARSON EDUCATION.
“ARDUINO - A QUICK START GUIDE QUICK START GUIDE”..MAIK
SCHMIDT..THE PRAGMATIC BOOKSHELF
“ARDUINO COOKBOOK 2011”..JEREMY BLEM..OREILLY
“ARDUINO_ROBOTIC_EBOOKAMZ”..JOSH ADAMS..TECHNOLOGY IN
ACTION
WEBSITES :
www.Arduino.com
www.iteadstudio.com
www.simplelabs.com
www.sparkfun.com
www.makershed.com
www.element14.com
www.digi.com

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