DIGITAL TECHNOLOGIES

COMPETITION IN INDUSTRY
PROJECT DETAIL REPORT
TEMPLATE
Team Name: Team Baitussalam
Team ID: #472753

Application ID: #1991743

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Table of contents

1. REPORT SUMMARY (10 POINTS)..........................................................3

2. TEAM CHART (5 POINTS).....................................................................3
3. PROJECT CURRENT STATUS ASSESSMENT (5 POINTS)........................5
4. VEHICLE DESIGN (40 POINTS).............................................................6
4.1. System Design (10 Points).........................................................................................6
4.2. Mechanical Design of the Vehicle..............................................................................6
4.2.1. Mechanical Design Process (3 Points)...................................................................6
4.2.2. Ingredients (3 Points)..............................................................................................9
4.2.3. Production Methods (2 Points)..............................................................................10
4.2.4. Physical Characteristics (2 Points).......................................................................10
4.3. Electronic Design, Algorithm and Software Design..................................................10
4.3.1. Electronic Design Process (3 Points)...................................................................10
4.3.2. Algorithm Design Process (3 Points)....................................................................13
4.3.3. Software Design Process (4 Points).....................................................................15
4.4. External Interfaces (10 Points).................................................................................16
5. SECURITY (10 POINTS)......................................................................17
6. TEST (5 POINTS)...............................................................................19
7. EXPERIENCE (5 POINTS)....................................................................20
8. TIME, BUDGET AND RISK PLANNING (5 POINTS)...............................21
9. ORIGINALITY AND LOCALITY (5 POINTS)...........................................25
10. COMMERCIALIZATION POTENTIAL (5 POINTS)...................................26
11. BIBLIOGRAPHY (5 Points)..................................................................29

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 1. REPORT SUMMARY (10 POINTS)

Team Baitussalam has been tirelessly working on completing the project.

After finalizing the 3D design, we immediately started the work on the circuits
and electronics for our robot. One of our biggest challenges was organizing
the wiring and circuits in a way that facilitated easy access without creating a
mess inside the robot. Our Mechanical team carefully crafted the robot,
anticipating and addressing potential issues. This phase proved to be the
most demanding part of our endeavor. Utilizing powerfully built yet lightweight
aluminum sheets for the base and other components, we ensured durability
without compromising agility. Nuts and bolts were chosen to guarantee quality
assembly, with all parts crafted in-house using CNC machines or skilled labor.
Our robot is equipped with sensors for line following, junction detection, QR
code reading, and overload warnings, with an LCD display for real-time
monitoring. Our programmers developed algorithms predominantly in C or
Python to drive the robot's functionality. In addition to functionality, we
prioritized security by installing a dedicated panel for emergency shutdowns in
case of short circuits or other issues.
Amidst global economic challenges, we've tried our best to maintain the
affordability of our robot without compromising quality

2. TEAM CHART (5 POINTS)

2.1. Team Members

M.Ehtesham Haider is an A-level Sciences
Student. He actively pursues Maths and Physics
Applications in Technology and is the head of our
Institute’s Robotics Department. He will serve as
Team Leader.

Hassan Abdullah is an A-level Sciences

Student. He engages in Printed Circuit Design
and Software Configuration in Robotics. He
will be creating the Circuit Structure for the
mechanical parts, Control Panel, and
Algorithm design.

Saad Abdullah is an A-level Sciences Student. He is

interested in Base-level Electronic Projects and
Component Compatibility. He will set up the Serial

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Transmission Protocols using ZigBee for our Robot and decide on the most
Task-Efficicent Components.

Sajid-Rehman is a First-Year A-level Student.

He is interested in CAD Applications and
mechanical production processes. He has
knowledge of SolidWorks and improving
Assembly. He will design the local indigenous
parts our robot will use and re-design other parts
for better efficiency.

Jareer Ahmad is a Final-Year O-level science

student. He is undertaking several courses in
wirelessly operated interfaces and the use of
relevant hardware electronics. He will be
designing the GUI of our Robot and
programming the mounted Touch-Screen
Display on our robot.

Zakariyya Khan is a Final-Year O-level Science-

cum-Economics Student. He is very interested in
Specialized Coding and Financial oversight. He
will oversee the budget plan, evaluate Market
Potential, and compare cost-efficiency while coding
and setting up the QR code Sensors for the Load-
Operations.

Consultant Information:

The name of the consultant is Zeeshan Abbasi, who is also acting as an

advisor to the team. Mr. Zeeshan has done his Electrical Engineering and
Masters in Education from National University of Science Technology,
Islamabad. He is currently serving as Principal and Robotics Instructor at
Baitussalam School.

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2.2. Organizational Chart and Distribution of Tasks

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 Organizational Chart

3. PROJECT CURRENT STATUS ASSESSMENT (5

POINTS)

Following the completion of the Technical Qualification report, our team found
that no fundamental alterations were necessary for the integral components of
the robot. However, we did implement a series of enhancements to both the
electronics and the external design of the robot.

In terms of electronics, we opted to integrate DWIN display technology for our

graphical user interface (GUI), recognizing its superior quality compared to
local alternatives. Additionally, we introduced a breaker within the robot's
circuitry to safeguard against potential overcurrent or short circuit
occurrences. This proactive measure significantly increased the reliability and
resilience of our robot's electrical systems.

Addressing the mechanical structure, we identified a need to expand the

dimensions of the robot. The initial size constraints posed challenges for
accommodating essential components such as circuits, batteries, motors, and
the lifting mechanism. By enlarging the dimensions, we decreased the risk of
internal congestion, thereby reducing the likelihood of hazards or accidents
within the robot.

Furthermore, we improved the appearance of the robot by giving its front a

curved design. This not only made the robot look better but also helped it
function more effectively.

After implementing these modifications, we reviewed our projected budget.

While the changes themselves didn't significantly impact our budget, we
anticipated a substantial variance between the final and planned budgets due
to additional expenses related to transportation, import fees, and customs
duties. As our operations are based in Pakistan, we often need to import
various components from countries like China, America, or Turkey.
Consequently, we intend to pursue financial assistance to help alleviate these
additional costs and remain optimistic about securing the necessary support.

4. VEHICLE DESIGN (40 POINTS)

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4.1. System Design (10 Points)

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4.2. Mechanical Design of the Vehicle

4.2.1. Mechanical Design Process (3 Points)

After a long discussion with the supervisor and the research on the
industrial robots, we finally came up with the idea of outer design of the
robot.Before submitting the Technical Qualification Report the outer
design of the robot was designed on the solidworks (a 3D designing
software) after having read all the specification in details.

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 Fig. 4.1 Robot External Design
Research went on on the internal design of the robot,Lifting
Mechanism,Actuators,Tyres,Chain etc. Before every thing the base, the primary
thing,was designed and the places of each component was decided and
designed.The material decided for the base is aluminium because of its excellent
combination of propeties, Light weight, High strength to weight ratio,Formability
and malleability.

(Picture of
base)

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 The base has the L-shaped angles connected on it for fixing the
lifting mechanism and rest of the components.The lifing mechanism is a gear
lifter mechanism that will convert the circular motion in the lifting mechanism into
linear motion.The circular motion is generated using the DC motor with high
torque.The reason to select this motor is the property of high torque which could
easily lift the weight of 100kg.

(Picture of
mechanism and motor
connected to base)

The drive
motors and tyres:
The two drive motors are the high quality gear motors with operating voltage
24V which are connected to sprockets and chain and each of them
are connected to two tyres,the tyres are with 10cm diameter each.
This whole movement system is good enough for driving the robot smoothly.
After adding the mechanism, motors and sprockets,tyres and chain to the base the
final internal system with everything was designed.
Also added the other components like ,power supply,GUI,sensors and circuitary.
The model of this design is given in Fig.4.x
To easily acsess the circuitry, without opening the external sheet we designed an
opening cover on the back side of robot , the cover is wide and long enough for easily
working inside the robot.T

We chose a robot design that balances functionality and performance well,

meeting our needs efficiently and cost-effectively. Its straightforward
manufacturing and assembly processes make it easy to scale up production
while keeping things simple. Safety features and user-friendly design ensure
easy operation and maintenance. Feedback and analysis confirmed it's the
right choice for our project.

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 4.2.2. Ingredients (3 Points)
We constructed our vehicle frame using
lightweight, corrosion-resistant aluminum,
reinforced with structural beams and supports
to ensure strength and stability tailored to our requirements.
Opting for aluminum not only provided the necessary
durability but also facilitated easy maneuverability due to its lightweight nature.
Secure and adjustable
connections were achieved
using high-quality nuts and
bolts, offering reliability and
flexibility in assembly.

For propulsion, we equipped our vehicle with high-torque motors capable of

delivering optimal RPM for efficient movement. We
integrated worm gears known for their lifting capabilities.
Additionally, we utilized chains for the drive mechanism,
ensuring smooth and consistent power transmission.

While the frame and fasteners were designed in-house, we bought the gearbox,
chains, and motors from trusted market suppliers to meet our specific requirements
and standards.In consideration of safety, we developed a dedicated emergency stop
button panel to swiftly address any unforeseen emergencies or short circuits.
Furthermore, each sensor was encased in custom-designed casings to safeguard

4.2.3. Production Methods (2 Points)

After succesfully designing the robot, we used CNC machining for the
production method due to the precision,
efficiency nad easy access to quality work.
The CNC machine could give us the parts
with exact dimensions we required
for our robot. However, at times we
used latheman services for small parts

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 such as manufacturing nuts and bolts or making some corrction in thr
already designed parts.

4.2.4. Physical Characteristics (2 Points)

The dimensions of the vehicle are 85 cm length with 75 cm of width
and 45cm of height. The weight of the robot will be around 60kg.

4.3. Electronic Design, Algorithm and Software Design

4.3.1. Electronic Design Process (3 Points)

Fig.4.3.1 Electronics Block Diagram

Quantity
No Product Name Description & Reason for Used
selecting
High-performance motor driver with 2
advanced features for precise control and
RoboClaw Motor
1 robust operation, ideal for this system
Driver
because of operating at high voltages and
current.
Powerful microcontroller board with an 1
expanded set of I/O pins and memory,
2 Arduino Mega
suitable for complex projects requiring
multiple sensors and actuators.
Essential components for connecting
electronic components, available in
__
3 Wires various lengths and gauges for different
applications.

Low-power, low-cost wireless 4

communication protocol for short-range
4 ZigBee networking in industrial automation and
suitable for this system.

Compact development board equipped 4

with ZigBee module and peripherals,
5 ZigBee Board facilitating rapid prototyping and
deployment of wireless communication.

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 The LCD display/control panel provides a 1
user-friendly interface for system
operation and monitoring.
It allows users to view important
LCD Display /
6 information such as battery levels, weight
Control Panel
measurements, and system status at a
glance.

Li-ion battery energy losses are low. It 4

7 Batteries was preferred because it can provide high
energy compared to its weight.
Buzzers serve as auditory alerts to notify 4
users of critical events or alarms,
8 Buzzers
enhancing situational awareness and
user safety.
Indicator LEDs provide visual feedback to 10
users, indicating various system states,
9 Indicator LEDs modes, or statuses such as power on/off,
charging, or error conditions, using
different colors.
Emergency buttons offer a quick and 1
easily accessible means for users to
activate emergency procedures or halt
system operation in critical
10 Emergency Buttons
situations.They are typically designed to
be highly visible and require deliberate
action to prevent accidental activation,
ensuring reliability during emergencies.
The HX711 module is a specialized chip 1
used for precise weight or force
measurement, especially in load cells or
11 HX711 Module scales. It offers high-resolution analog-to-
digital conversion and amplification,
ensuring accurate readings with minimal
interference.
Infrared sensors designed for precise line 4
Qtr Line following detection in robotics and automation,
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sensors ideal for line-following of this system.

Distance-measuring sensors utilizing 5

infrared light for accurate proximity
13 Sharp IR sensors
detection, suitable for detecting the
objects in front of the robot.

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 Installed in the robot for reading QR code 1
Embedded Qr Code
14 in the arena, it was preferred because of
scanner
its quick scanning
Precision load cell with high sensitivity 1
15 Pl50 Load cell and durability, designed for weight
measurement in the robot.

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4.3.2. Algorithm Design Process (3 Points)
Control/Navigation/Guidance Algorithm Processes:

We have used the PD controller for Line following, an obstacle-

detection method using IR sensors, a Load Cell to monitor the weight of the
load, a QR Code Scanner for QR code scanning and an internally installed
voltmeter to monitor the battery health of the robot throughout the run. These
methods are discussed in details below.

The QTR Analogue sensors send emissions and read their reflections
from the black line forming a numerical way to judge the current position of the
robot. This position is compared to the aimed position and, depending on how
for it is from the aimed position, an error is calculated. The bigger the error,
the larger the gap between the current and aimed position will be and the
robot will adjust the speeds of its motors and will change them to achieve the
desired position. How fast the robot moves to achieve its desired position is
determined by the P-Component of the code which is a constant. The
error calculated is multiplied with this number and then an update is made to
the motor speeds. So, the greater the error, the robot will move towards the
line with a faster speed.
Also, as the robot nears the line its speed begins to decrease to avoid
overshoot and of course unbalanced movements. This uses a derivative
method to check how fast the robot is moving towards the line and how far it is
to the line. This is done by continuously by calculating the change in the error
(Error – Last Error).

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 This is then multiplied to the D-component of the code and it contributes
to the changing adjustments in the motor speeds as the robot smoothly steers
back on the line perfectly.
We have used this method as it is the single-best way of precise and
accurate way of line following as it can manipulate to run the robot over almost
any line after a 5-seconds calibration. Moreover, it is also extremely smooth
and does not make those typical ‘oscillations’ like the robots do when using
digital data and a few ‘IF Statements’.
This algorithm is however bypassed at times when the robot detects an
obstacle ahead. We have used Sharp IR Sensors in front of the robot. These
are always sending and receiving signals to determine how close the robot is
to the object it’s approaching. When it reaches the fed distance, the
microcontroller commands the motors to apply brakes. The robot then checks
the QR Code and decides whether to lift or leave the load. Once the required
task is done, the robot then steers away from the obstacle, still keeping
distance using the Sharp IR Sensors, and moves back on to the black line
before re-enters the PD and begins to follow the line as before.
Then, for keeping a check on the weight of the load, we have a bending
load cell. The load cell bends on the side where the load is applied while the
other side remains fixed in one place, generating resistance which is then
converted to digital values and is stored in the computer as the weight. This
way, continuously monitors the weight of any load and gives an over-load
warning once the weight exceeds 125kg..
Also, to keep a check on the battery level, we have installed an internal
voltmeter that continuously measures the battery and keeps giving the
readings to the controller which then compares it with the given readings. As
soon as the reading is lower than 80(in our case), the robot’s other functions
are interrupted and robot is commanded to go to the charging area and get
charged. The battery level is still under monitoring and as soon as it is full, the
robot resumes its primary tasks.
Similarly, whether a load has to be lifted from a particular place or not is
decided by the QR Code on which the robot will scan using a QR Code
Scanner. The code will be checked for verification and the required task will
be performed.
So, we have chosen all these algorithms as they seemed to us the most
convenient and powerful. Also, these are the ways used worldwide in different
technological sectors for similar purposes. For example the load cell can
measure thousands of kilograms efficiently correct to decimal places. The PD
controller is the most sophisticated line following method used in industries
where robot are trained to carry items to-and-fro. A good example could be of
Amazon.

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4.3.3. Software Design Process (4 Points)
To configure the Software aspects of our robot, C programming language
was used to code our Algorithm Design structure. Choosing C language
was the result of the many demands of our Software requirements. It has
high speed execution and, more importantly, can make use of special
machine-dependent instructions that is vital when coding embedded
systems like our Industrial Robot. For the GUI commnication, we have the
softeare DGUS which too uses the C Language. Furthermore the diverse
range of libraries available for an even wider scope of electronic
components makes it suitable for our technical specifications.

The Atmega2560 Microcontroller will be coded in C language to interact

and control with the peripheral units through the Arduino Mega software for
serial communication as outlined in the Algorithm Design Process (above).

In the Program the following libraries have been used in the sub-
program routines

1) Touch-screen Display library <DWIN.h>

2) XBEE serial wireless communication <XBee.h>
3) Initializing serial communication on digital pins of Arduino
<SoftwareSerial.h> (For Maikrt QR code sensor)
4) Sensor Library <QTRsensors.h>

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 4.4. External Interfaces (Points)

External Vehicle Control Interface:-

Our Robot will be equipped with a touch-sensitive capacitive Dwin screen
that will output a requirement-tailored graphical user interface (GUI)
rendered in the software “DGUS” (Dwin Graphic Utilized Software) V7.6.

Functions and Status details related to the Vehicle’s trajectory, energy

levels, motion, etc. will be displayed with the appropriate inputs for
parameters to intervene in the vehicle’s natural course of action, aided by
user-friendly icons. Data transfer with Arduino Board will be made using
UART (Universal Asynchronous Receiver/Transmitter) for serial
communication.

Subcomponents for Image Processing and Data Transfer: The Dwin

T5L touchscreen is based on the T5L0 ASIC. This chip has 1MBytes of Nor
Flash, 512K Bytes of which are used to store the user database. The
display has a resolution of 800x480 pixels and can display 262K colors. It
uses an FPC50_0.5mm RGB interface for the LCD and either an IIC
interface for capacitive touch or an FPC4_1.0mm for resistive touch.
Communication Protocols and Modules: The Dwin T5L touchscreen
uses a TTL/RS232 interface for communication. The interface is connected
via a 10Pin_1.0mm connection wire. The device can download data via an
SD card or an online serial port.

5. SECURITY (10 POINTS)

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Battery
We have ensured that batteries are securely mounted within the robot to
prevent movement or vibration that could cause damage or dislodgement. To
achieve this, we have implemented robust mounting systems that securely
anchor the batteries to the internal structure of the robot, minimizing the risk of
shifting during operation or transportation. Additionally, we have utilized
shock-absorbing materials and fastening mechanisms to further enhance
stability and reduce the potential for damage. Furthermore, regular
inspections are conducted to verify the integrity of the mounting
arrangements, ensuring that any necessary adjustments or reinforcements
are made to maintain the secure positioning of the batteries.
With the 16 AWG silicone cable, the security of the power cables connected
to the battery is increased.
Additionally, we have established clear procedures for responding to battery-
related incidents such as leaks, spills, or overheating, including training team
members on how to safely handle these situations. Based on the battery
location and the surrounding components of the robot, we designed
enclosures made of plastic to physically separate the batteries from other
components. To increase safety precautions, we incorporated ventilation
openings in the enclosures to allow for proper airflow around the batteries and
prevent overheating. Furthermore, we designed the enclosures to allow for
easy access to the batteries for maintenance and inspection purposes, either
by incorporating removable panels or access doors that can be opened as
needed. We have clearly labeled the enclosures to indicate the presence of
batteries and any relevant safety information or precautions that need to be
followed when accessing or handling them. The enclosures are periodically
inspected to ensure they remain intact and free from damage, and any
necessary repairs or replacements are promptly carried out to maintain the
integrity of the isolation measures.

-Wiring

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For the wiring part we have used efficient wiring management system to
ensure safety. Uninsulated cables are not used and care is taken to ensure
that no conductors are left exposed. Places where high current flows are
marked on the circuit board. The cables were carried in cable channels in ac-
cordance with the standards. The current drawn by the motors is monitored
instantly, high current draw status is monitored with current sensors and pro-
grammed to be turned off when desired. Such a system within the robot's
enclosure supports and organises wiring harnesses. It provides a structural
framework for routing cables and allow for easy access during installation and
maintenance. It also allows for managing large quantities of cables and
accommodating complex routing configurations.
which is particularly useful. We have also ensured additional protection for
specific sections of wiring harnesses or individual cables by encasing wires in
a protective sheath, shielding them from mechanical stress, environmental
hazards, and electromagnetic interference. It is especially beneficial in areas
where cables are exposed to high levels of vibration, abrasion, or moisture.In
the circuit we have also added circuit breakers to safeguard against
overcurrent conditions that could lead to overheating, fires, or damage to
electronic components.

-Mechanics
For the mechanical part we installed protective guards around the edges of
the robot to minimize the impact of collisions with objects or surfaces. For this
purpose we used durable rubber to absorb energy and reduce the likelihood
of damage to both the robot and its surroundings.Likewise for the safety of the
lifting mechanism we added mechanical brakes that can be used to support
the weight of the arm and object in the event of a power failure. Mechanical
brakes arrest the energy of a machine or object via force, most commonly
friction. It locks down the manipulator ensuring no motion until the operator
comes back to safe zone. Also helps in paralysing the robot when there is
chance of inter link collisions. Since they operate purely based on mechanical
principles, they do not rely on electrical or electronic components, making
them less susceptible to malfunctions or power failures.

-Extras
Additionally we also ensured there is an easily accessible emergency stop
button that immediately halts the robot's motion in case of an emergency.
Furthermore we have also established clear procedures and protocols for
handling emergencies.For this purpose we have designate a team of two
trained individuals responsible for responding to emergencies ,when operating

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 ,who are familiar with emergency procedures and trained in first aid.. We have
also ensured that all the members are trained and aware of any security
precautions for which purpose we have had workshops conducted to provide
training to all the team members to take appropriate measures in case of any
emergency and increase awareness.
Variations were reduced by providing a clean and organized working environ-
ment in the workshop. Made suitable for 5S. Personal protective equipment
such as glasses and gloves were used in the workshop.
During and during testing, a fire extinguishing kit must be available. A fire-re-
sistant bag designed to withstand temperatures up to 1000 ° C, a fire extin-
guisher, fire protection glasses and safety gloves must be available.

6. TEST (5 POINTS)

The team has not conducted any physical tasks on the robot so far for testing
it for all of its required capabilities. However, we suerly plan to carry out these
tests very soon in the future as they essential and very helpful to asses
whether the robot requires any furhter work done on it. So here’s our plan for
these tests:

Types of tests Plan

We plan to test different parts of the robot by
putting them under certain harsh conditions to
Robot’s durability test test whether it can withstand heavy loads and
hard collisions(In case they take place).

We plan to check all the sensors that we’ll be

using for their correct values. We’ll do this by
Sensor Working test
connecting them to a computer and check their
values in some IDE from a code.
We have planned to thoroughly test the
communicating devices as these are very
Testing communication crucial for the task to run smoothly. So we plan
devices to regularly test these devices by connecting to
our computers

7. EXPERIENCE (5 POINTS)

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Accidents during Design, Production, and Testing Stages:

1. Mechanical Failures: During the initial design phase, we faced several

mechanical failures related to the lifting mechanism. The mechanism failed to
withstand the stress of lifting weights up to 80kg, resulting in breakdowns and
potential safety hazards.

2. Electrical Malfunctions: In the testing phase, we encountered electrical

malfunctions in the line-following and wall-tracking systems. These
malfunctions led to erratic movements and collisions, posing risks to the
robot's operation and surroundings.

3. Software Glitches: Software glitches were also a significant challenge.

The QR code reader system experienced bugs that caused misinterpretation
of codes, leading to incorrect actions and operational errors.

Mistakes Made and Lessons Learned:

1. Underestimation of Load Capacity: One of the critical mistakes was

underestimating the load capacity required for the lifting mechanism. This
oversight led to frequent breakdowns and forced us to reevaluate and
reinforce the mechanical structure to handle heavier loads effectively.

2. Inadequate Testing Protocols: We realized that our initial testing

protocols were inadequate in identifying potential issues comprehensively. We
learned the importance of rigorous testing at each development stage to
uncover and address hidden flaws before deployment.

3. Overreliance on Software: Relying too heavily on software solutions

without robust hardware backup mechanisms proved to be a mistake. We
learned the importance of balancing software and hardware capabilities to
ensure reliable and resilient performance in real-world scenarios.

Overcoming Challenges and Experiences Gained:

1. Iterative Design Process: Through a process of iterative design, we

addressed mechanical weaknesses by reinforcing critical components and
optimizing the lifting mechanism for enhanced durability and load-bearing
capacity.

2. Enhanced Testing Procedures: We revamped our testing procedures to

include stress testing under simulated real-world conditions. This
comprehensive approach helped us identify and rectify potential issues early
on, ensuring a more robust and reliable final product.

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 3. Holistic Approach to System Integration: We adopted a holistic
approach to system integration, ensuring seamless interaction between
mechanical, electrical, and software components. This approach minimized
compatibility issues and enhanced overall system efficiency and performance.

In conclusion, the development journey of our industrial robot for Teknofest

was characterized by challenges, accidents, and invaluable learning
experiences. By acknowledging and overcoming mistakes, we gained insights
that not only improved our robot's functionality but also enriched our
understanding of the complexities involved in robotics engineering.

8. TIME, BUDGET AND RISK PLANNING (5 POINTS)

Time
Responsibilit Start End Milesto
Task
ies Month Month ne
System Analysis and design A and b January February Yes
Robot chassis design and Februar
C and D April No
production y
Material selection E and F March May No
Drive system and motion
A and B April June No
mechanism design
External sheet metal
manufacturing model Cand D June July Yes
design and production
GUI design and
Eand F January January yes
communication
Electronics and mechanicla
A and B no
assembly January January
Trial track creation Cand D January January yes
PDR Writing A and B January January no
Algorithm design E and F January January yes
Programming A and B January January no
Track tests C and D January January yes
E and F January January

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 Budget
COMPONE MANUFACTU
MODEL FEATURES PRICE
NTS RER
MECHANICS
MachineT MachineT Has a good 6000TL
torque and
Motor
good enough
RPM.
Self- Self- Finally cut by
Manufactured Manufactured ourselves 1000TL
Aluminium
for its use as
Sheets
base and other
uses
Amazon Amazon Has good grip 2500TL
and has a
Wheels
diameter of
10cm
Self- Self- Self- 1000TL
Manufactured Manufactured Manufactured
Angles to join the base
and other parts
verticaly
Toothed wheel
or gear that
Sprockets.com Sprockets.com interlocks with 1000TL
a chain, track,
Sprockets
or other
perforated or
indented
material.
Chain Mechanical
devices
consisting of
AliBaba AliBaba inter connected 400TL
links that
transmit power
or convey

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 materials in a
linear or
rotational
motion
Armaghan Armaghan To join two or 800TL
Engineering Engineering more parts
Nuts/bolts
works works together
securely
RoboClaw Pololu Pololu Max Voltage: 6500TL
Motor Driver 34V
Max Current:
60A
Arduino Arduino Arduino Atmega 2560 300TL
Mega controller
Wires Locally Locally ----- 300TL
Manufactured Manufactured
ZigBee Digi Digi Able to 630TL
International International communicate
wirelessly,
Range:10-100m
ZigBee Sparkfun Sparkfun Connects 400TL
Board Zigbee to PC
LCD DWIN DWIN Has a touch 800TL
Display / screen and a
Control software
Panel
Batteries Mania / Turnigy Mania / Supplies 24V 2400TL
Turnigy and 3.3A
Buzzers Locally Locally Produces 50TL
Manufactured Manufactured sound when
given
command
Indicator Locally Locally Indicates 40TL
LEDs Manufactured Manufactured direction of
movement
Emergency Locally Locally Can cut off the 150TL
Buttons Manufactured Manufactured power supply
to the robot
HX711 Pololu Pololu Amplifies the 100TL
Module signal of the
load cell
Qtr Line Pololu Pololu Sends Infrared 340TL
following waves to

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 sensors determine the
colour of
surface
Sharp IR Sends Infrared 190TL
sensors Pololu Pololu waves to
determine the
distance till the
obstacle
Embedded Maikert Maikert Scans Qr 250TL
Qr Code Codes
scanner
Pl50 Load Daraz Daraz Measures 300TL
cell weight
TOTAL PRICE 25450TL

Risk Planning
Chances or
Risk
Risk Effect current status of Solution
ID
risk
R1 Out of High Ongoing Contingency Funds
Funds
Medium Mitigated
Low Unresolved
Resolved

9. ORIGINALITY AND LOCALITY (5 POINTS)

Problem-solving strategy: In Our industrial robot, we have implemented a

unique solution for the given tasks and the criteria provided in the rulebook.
Though many of the components themselves may not be unique, their
selection, combination, and tailoring for purpose remains original to our team

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and is a result of the creative approach each of the members adopted to carry
out his part in this robotic project. The following is a description of the many
aspects of our robot where this originality was put into practice:

Original Mechanical Structure: Robot features L-shaped base with lifting

mechanism for 25kg weight, Load cells connected to a signal amplifying
module (HX711 Module) , driven by high-torque DC motor. Drive system
includes two 24V gear motors linked to sprockets and 10cm diameter tires for
smooth movement. Internal system incorporates power supply, GUI, sensors,
and circuitry for comprehensive functionality. This structure is original to our
team.
Original Mechanical Design: All the designing processes were carried out
by the relevant team members in Solidworks software. These included the
designing of the aluminium base, L-shaped angles, motor brackets, nuts,
bolts, and screws etc with many of the ready-recieved components getting
redesigned and adjusted for efficient assembly. The physical produton of
these designs was done in the Labs managed by our institute and machined
on the same work-benches.

Original Algorithm Design: There were 3 main Algorithms developed by our

Team to fulfill the tasks given (Complete description provided in Algorithm
Design)

1) PD Controller (Line-following): Adjusts output based on error,

accumulated error over time, and rate of change of error. Provides precise
and responsive control, minimizing oscillations and steady-state error. All
variables, parameters, and functions developed originally by our team
2) Motion Control Algorithm (Main Drive): To enable smooth and powerful
motion and take calculations of individual motor-speeds and change them
to achieve desired transation, rotation etc. Perfected and adjusted
originally for the specific motors our robot uses.
3) Single Conditional Algorithm (Detecting Obstacles): Developed
indigeneously using input from mounted IR sensors and gauged distance
triggers different prompts to robot based on object distance, time period of
detection. Logical flow of commands and feedback-orientation made
originally.

Local GUI Screen Design: Our team robot uses a mounted Dwin Touch-
screen to provide user-friendly command interface. The designing of the
visual icons, declaring suitable parameters connected to various touch-
senstitve prompts from screen and setting up transmission protocls and
commands, creating live input-output real-time channels was all done by the
team members in charge of this aspect.

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 Local Cicuit-Board Design: Circuit that controls all input/output channels
and component-processor interaction of the robot. The design was made in
the Proteus printed circuit design program.

Micro-controller Shield: The Arduino Mega is fitted with a self-developed

moto-driver shield to improve functionality and enable smoother interaction
and tidier wiring.The design was made in the Proteus printed circuit design
program.

10. COMMERCIALIZATION POTENTIAL (5 POINTS

Market Analysis
1. Size of the Market:
- Global Market:
 The global industrial robotics market size is projected to reach $30.19
billion by 2023, with a compound annual growth rate (CAGR) of 12.8% from
2022 to 2028.
- Regional breakdown:

 North America accounts for around 23.68% of the market share, driven by the
adoption of automation in manufacturing and logistics.
 Europe and Asia-Pacific follow closely, with about 52.2% and 24.12% market share,
respectively, attributed to the growth of smart factories and e-commerce.

2. Growth Potential:
- Factors driving growth include:

 Increasing labor costs and the need for efficiency in material handling processes.

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 Advancements in AI, machine learning, and IoT technologies enhancing robot
capabilities.
 Industry 4.0 initiatives promoting automation and data-driven decision-making.

3. Segmentation:
- Segments within the market:

 The global material handling robot market size was valued at $28.8 billion in 2023 and
is projected to reach a value of $86.5 billion by 2032, fueled by demand from
warehouses and distribution centers.
 Inspection and maintenance robots are gaining traction in industries like automotive and
aerospace for quality control and asset management.

Competitor Analysis
1. Existing Competitors:
- Major players include:
 Fanuc, ABB, KUKA, and Universal Robots offering a range of autonomous robots
with advanced navigation and task execution capabilities.
 Firms like Fanakku Kabushikigaisha of Japan focusing on niche applications such as
collaborative robots for small-scale manufacturing.

2. Competitive Environment:
- Making our robot internationally competitive:
 Although there are already a few existing competitiors in the market for industrial
handling robots, we gave a good thought to it and therefore we are making use of a
full-aluminium body that makes our robot sleek and considerably lighter. As a
result, it will be less power consuming and produce more effecient results
enhancing productivity.
 Moreover, we have ensured making our robot highly secure-to-use by taking crucial
security measures such as placing the battery in an isolated and safe place, using
effecient wiring systems to avoid any short-circuiting or overheating and having nice
body to minimize any physical harm to the surroundings.

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 Marketing Strategy
1. Target Audience:
- Ideal customers:
 Medium to large enterprises in manufacturing, logistics, and e-commerce sectors.
 Companies seeking to optimize material handling processes and improve
productivity.

2. Reaching the Audience:

- Marketing approach:
 Online presence through a professional website showcasing product features, case
studies, and customer testimonials.
 Participation in industry events like Robotics Expo and Supply Chain Summit to
demonstrate the robot's capabilities and network with potential clients.
 Sponsoring national and international Technology-Related events like
NERC(Pakistan) and TeknoFest(Turkey) and participating in such events by
conducting workshops and classes.
 Exibiting our project in large tech expos like CES & SXSW and different technological
conferences.

3. Marketing Channels:
- Channels to leverage:
 Social media platforms for targeted advertising and engagement with industry
professionals.
Collaborations with system integrators and distributors to reach a wider customer
base and provide localized support.

11. BIBLIOGRAPHY (5 Points)

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Robots.com, “Lifting With Material Handling Robots”, January 23, 2016, ,

VEX Robotics, “Gears”,

EZ-Robot, “Programming Your Robot to Detect QR Codes”, No date, Accessed on April 6,

2023,

Fagerness, T., “How to Build a Robot - PCB Design”, November 02, 2015

Miller, L., “The Comprehensive Guide to Manufacture a PCB”, April 25, 2024

Instructables, “Basic Electronics Skills for Robotics”

Robot Room, “David Cook’s Robot Room: Robotics, Circuits, and Machining”

Science.org, “Fully 3D-printed soft robots with integrated fluidic circuitry”, 75.

Learn Robotics, “Create a PCB (Printed Circuit Board) Online”,

Saif M “16 DIFFERENT TYPES OF SPROCKETS AND THEIR USES” [PDF] Last Updated on: July 17, 2021.
Accessed on March 23, www.theengineerspost.com

Arnab Kumar Das, “Line Follower Robot : ESP32 – QTR-8RC – PID Line Follower Robot
V1”, arnabkumardas.com

Techbitar, “Arduino-based Line Follower Robot Using Pololu QTR-8RC Line Sensor”,
instructables.com

OSAMASLEEM, “Line follower robot performed with PID controller technique and by qtr-8A
sensor”, github.com

Tacuna Systems, “Load Cells & Force Sensors in Robotics”,

Sensing Systems Corporation, “Load Cells for Robotics and Automation: Enabling Precision
and Control in Robotic Systems”, sensing-systems.com

Beijing Dwin Technology Co., Ltd., “DGUS”,

Basicmicro, “RoboClaw Basics”

Robots.com, “Lifting With Material Handling Robots”,

MISUMI Mech Lab Blog, “Rotary to Linear Motion”

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