mct & automation mamgl 207 manual

7/21/2019 Mct & Automation MAMGL 207 Manual

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SHANMUGHA

ARTS,SCIENCE,TECHNOLOGY & RESEARCH ACADEMY

SASTRA - University

THANJAVUR613 402

SCHOOL OF MECHANICAL ENGINEERING

MAMGL207

MECHATRONICS and AUTOMATION

LAB

Manual


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Index

Exercise

TitlePage

no

Pneumatics

1Design a pneumatic circuit using a double acting cylinder to draw a liquidmetal from a smelting crucible by a casting ladle and cast in moulds. Theraising and lowering of the ladle should be controlled by push buttons.

2Design a pneumatic circuit using a double acting cylinder and 5/2 Handoperated valve to open a main gate of a factory.

3 Design a simple pneumatic circuit to open and close the bus door.

4 Design a pneumatic circuit using AND and OR gate

5 Design a circuit using Time delay valve

6Design a pneumatic circuit using a double acting cylinder, roller operatedvalve, 3\2 push button and 5\2 single pilot valve to control the cylinderposition.

7Design a circuit to control the double acting cylinder using double pilot valve.The double pilot valve has to be controlled by only one push button.

Electro pneumatics

8

Washers for injection pump are to be cleaned in a cleaning bath. The doubleacting cylinder is used to dip washers in and out of the cleaning bath.Write a program to count the 10 strokes of the cylinder and stop the cycle.

9Design a circuit using LSM controller to control the A.C. Non servo motorclockwise and anti-clockwise with time delay.

10 Exercises on sequencing conveyors, single and double acting cylinders.


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6 Dof Serial Manipulator & WORKSPACE Software

11A Study Exercise and Calibration of Home position

11B D-H table Formation

11C Straight Line Programming

12A Design a Turntable (Rotary Joint) and Linear slide(Translational joint)

12B Design and simulate a 3-dof RRR serial manipulator

12C Path Planning for Welding Application using 6 dof serial manipulator

MAPS & Mobile Robot

13A Study Exercise of Mini-Automation and Production and System

13B Study of Mobile Robot Pioneer P3 AT

13C To develop a Map of an unknown environment


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Exercise 1: Design a Pneumatic circuit using double acting cylinder and two push

buttons.

Task

Design a pneumatic circuit using a double acting cylinder to draw a liquid metal from a smelting

crucible by a casting ladle and cast in moulds. The raising and lowering of ladle is controlled by

push buttons.

Apparatus required:

FRL unit

T-connector

3/2 Push buttons ( 2 nos)

5/2 Air-Air valve

Double acting cylinder

Connecting hose

Procedure:

A Double acting cylinder is used to draw the metal from the crucible and cast

the mould.

5/2 Air air valve is used to control the forward and return stroke of the

cylinder

The pilot ports X and Y of the 5/2 valve are controlled by two 3/2 push button

valves.

The air which is stored in the reservoir of the compressor enters the FRLunit and passes through the pressure ports of two 3/2 push buttons and 5/2

Air-air valve.

When the push button 1 is pressed, the working port of the push button 1 will

lead the supply to the pilot port X of the 5/2 air-air valve. Thus the spool in

the 5/2 valve moves and connects the working port A to the rod end of the

cylinder. The cylinder extends and the pressure at the piston side is

exhausted through the port S to the atmosphere.

When the push button 2 is pressed, the working port of the push button 2 will

lead the supply to the pilot port Y of the 5/2 air-air valve. Thus the spool inthe 5/2 valve moves and connects the working port B to the Piston side of

the cylinder. The cylinder retracts and the pressure at the rod end is

exhausted through the port R to the atmosphere.

The circuit which is designed is simulated in the P- Simulation Software


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The components are connected in the pneumatic board with the connecting

hoses as per the circuit.

A Pressure of 2 bar is applied through the FRL unit and by pressing the

push button the cylinder extends and retracts

Circuit Diagram:

Result:

Thus the circuit is simulated in the software; the connections are made on the board and tested

with pneumatic supply

Note: Exercise 1 may be taken as model exercise for exercises 2 to 7

Double Acting cylinder

3/2 Push Button

Valve3/2 Push Button

Valve

5/2 Air-Air Control

ValveFRL unit


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6

Exercise 2: Design a simple pneumatic circuit using 5/2 hand operated valve

Task

Design a circuit to operate the main gate of a factory from the security room using a handoperated valve.

Identify the apparatus required:

Design the circuit:

Write the procedure:

Furnish Result:

Exercise 3: Design a simple pneumatic circuit to open and close the bus door.

Task

Design a circuit to operate the door of a bus assuming the control is present with the driver andthe bus instructor.


Design the circuit:


Furnish Result:

Exercise 4: Design a pneumatic circuit using AND and OR gate

Task

The door of a room containing safe deposit boxes is operated by a spring return cylinder. The

door remains closed by a spring force. There are 3 toggle switches namely S1, S2, S3 available

at the safe deposit room (for user), guard room and reception respectively for operating the

door. The user is acknowledged by the guard constantly monitoring the safe deposit boxes. In

the absence of the guard, the entrance lobby receptionist monitors it.


Design the circuit:


Furnish Result:


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7

Exercise 5: Design a circuit using Time Delay, AND gate& OR gate

Task

Embossed name plates are to be produced from a thin metal sheet. The double acting cylindershould extend when both push button S1 and S2 are pressed simultaneously. The return stroke

is to occur only after the forward end position and achieving a desirable pressure limit. Thecylinder should immediately retract if Emergency push button S3 is pressed


Design the circuit:


Furnish Result:

Exercise 6: To perform sequencing operation with Single acting cylinder and Doubleacting cylinder combined together.

Task

Assume the paint tins are moving on a conveyor. At a certain position, the operator uses a pushbutton valve to place the caps on the tin. A double acting cylinder lifts up the tin and cap ispressed by a single acting cylinder. Make the circuit to perform this operation by a push buttonvalve.


Design the circuit:


Furnish Result:

Exercise 7: Design a circuit to control the double acting cylinder using double pilot valve.

The double pilot valve has to be controlled by only one push button.

Task

Design the circuit:


Furnish Result:


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8

ELECTRO PNEUMATICS

Exercise 9: Design a circuit using LSM controller to actuate a Double acting cylinder

Task

Washers for an injection pump have to be cleaned in a cleaning bath. The double acting cylinder is used

to dip a container with washers in and out of the cleaning bath. For good cleaning, the washers have to

be immersed in the bath for count of 10 strokes. Write a program to perform this sequence.

Program:

// i, - input(sensor)

//x,y - output(actuator)

dim a as integer

dim b as integer

for a = 1 to 5

if inp(i) = 1 then

b= outp(x,1)

b=outp(x,0)

delay(1000)

b=outp(y,1)

b=outp(y,0)

delay(1000)

endif

next

Design the circuit:Write the procedure:

Furnish Result:

Exercise 9: Design a circuit using LSM controller to servo motor control

Task

Controlling the A.C non servo motor in clockwise and anticlockwise direction with time delay in repeated

cycles

Program:

Design the circuit:


Furnish Result:


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9

Exercise 10: Sequencing using electro-pneumatics with single and double acting cylinders.

Task

Two cylinders are used to transfer parts from a stack on to a chute. When a push button is pressed the

cylinder 1.0 extends pushing the parts from the stack, to the conveyor and positions it to transfer by 2 nd

cylinder on to the out feed chute. A servo motor runs the conveyor system. Once the part is transferredthe first cylinder retracts followed by the second. The speed of both the cylinders is adjustable.

Program:

// i, j,k - input(sensor)

//x,y,z - output(actuator)

dim a as integer

dim b as integerfor a = 1 to 5

if inp(i) = 1 then

b= outp(x,1)

delay(1000)

b=outp(x,0)

delay(1000)

if inp(j) =1 then

b= outp(z,1)

delay(1000)

b= outp(y,1)

delay(1000)

b=outp(y,0)if inp(k) =1 then

b= outp(z,0)

delay(1000)

endif

endif

endif

next

Design the circuit:


Furnish Result:


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10

6 DOF SERIAL MANIPULATOR

11A. Study Exercise and Cal ibrat ion of Home p osi t ion

Configuration : Vertically Articulated Five-bar LinkageNo. of Axes : 6 (3 axes waist-shoulder-elbow with 3 axes Roll-Pitch-Roll wrist)Link 1 : 300 mmLink 2 : 300 mm

Vertical Height : 400 mmJoint Actuators : DC Servo geared motorsTransmission : Joint 1 : Gear Train

Joint 2 & 3 : Ball screwJoint 4, 5 & 6 : Timing belt

Gripper : Pneumatic / Electrical

Robot : 35 kg

Control : 20 kg

Joint Motion

ManipulatorJoint 1 : 300 degreesJoint 2 : 60 degreesJoint 3 : 60 degreesJoint 4 : 300 degreesJoint 5 : 180 degreesJoint 6 : 300 degrees


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11B. Denav it - Har tenberg Table Methodology

OBJECTIVE

1. To establish the axes and construct the DH-Table for solving the forward kinematics

or inverse kinematics

PROCEDURE

Assign frames to each links

Nominate the X-axes and Z-Axes for each frame

Formulate the transformation of frames in order to create the D-H table

D-H Table:

d a

1. 1 d1 0 90

2. 2 + 90 0 a2 0

3. 3 0 0 90

4. 4 d3+ d4 0 -90

5. 5 - 90 0 0 90

6. 6 d5+ d6 0 0

Z2Z4

Z0

Z3

Z5

Z6

Z1


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11C. Solv ing Forward K inematics

OBJECTIVE

1. To determine 0T6

from the D-H table and verify the Cartesian coordinates of the end-

effector, for a particular set of joint values

PROCEDURE

For each row the total transformation matrix is computed

D-H Table:

0T1

d a

1. 1 d1 0 90

2. 2+90 0 a2 0

3. 3 0 0 90

4. 4 d3+ d4 0 -90

5. 5-90 0 0 90

6. 6 d5+ d6 0 0

Calculate 0T6 which is given as 0T

6 =0T1 x 1T

2 x 5T6

The calculated position vector in the matrix 0T6 is compared with the Cartesian

coordinates of the end-effector, for a particular set of joint values

T1 = [ cos(teta1) 0 sin(teta1) 0;

sin(teta1) 0 -(cos(teta1)) 0;

0 1 0 d1;

0 0 0 1];


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13

12A. Design a Turntable using a Rotary Joint

AIM:

To create a turn table in workspace software and simulate its rotation by having an

object fixed at its edge.

PROCEDURE:

Creating the shell:

1. The basic shape of a turn table is two cylinders mounted one above the other

2. Bottom cylinder is the table base with larger diameter compared to the other. The

dimension of the base is radius-10units, height-100units.

3. Click on the object to select it and go to the position. The values are given such

that the base is aligned to the inertial frame.

4. Now, the top cylinder is given dimensions radii -50units, height-10units.

5. The top cylinder is aligned with the upper face of the table base.

6. A small object (box) of dimensions 5x5x5units is fixed over the top as shown in

the diagram and the object is positioned at the edge of the table top.

7. The general layout of the turntable mechanism has been created but the partneeds to be attached to the turntable top, as shown in figure 1.

8. Select the object Part as the attachment child. From the Modify main menu,select Attach. Click on the object Top as the attachment parent.

Creating the Mechanism and Defining the Rotational Joint:

The next stage of the construction is to create the mechanism, create the jointand specify the type of joint.

The cylinder Base is selected and the Mechanism is created from the Createmain menu.


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The Turntable has been defined as a mechanism, with 1 auxiliary joint variable. A rotationaljoint is created by at the origin of the parent object (Base). This can

be seen represented by a co-ordinate frame and a graphical representation ofthe rotational joint, as shown in figure 2.

Learning a GP:

1. Go to view pendant learn GPs of the joint between object and the table

top.

2. Create a new path file say, TURN and keep adding various GPs.

3. On clicking simulation, the turn table rotates with the given GP like +90, +180, -

30, -60, etc

4. If the speed of the simulation is fast, the speed can be controlled by using

simulator options say, 100ms.

RESULT:

A model of turn table is drawn in workspace and its rotations are simulated successfully

with an object attached to its corner.


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Design a Turntable using a Rotary Joint

AIM:

To create a translational joint (slider mechanism) using Workspace 5 software and

simulate the translations of the slide.

PROCEDURE:

The mechanism to be created is a translational mechanism, i.e. slide in a guideway.

1. Three cuboids of suitable dimensions named as, guideway, tool and the slide,

are created

2. CUBOID 1 (guideway):

Construct a cuboid of dimensions 100x20x20 and align it to the inertial

frame as follows,

X=50; Y=10; Z=10R=0 (roll); P=90 (pitch); Y=0 (yaw)

CUBOID 2 (tool-creating slot):

A cuboid of dimensions 65x10x10 is made and placed over CUBOID 1

(guideway).

Using the BOOLEAN operation (subtract), the necessary slot is created

by subtracting tool (child object) from the parent object.

Hence the slot for the slide in the guideway is created.

CUBOID 3 (slide):

Now, another cuboid named SLIDE, is created to fit at the centre of the

slot and give appropriate inside and outside movement while defining its

mechanism parameters.

Once defining the construction of the model, attach the slide onto the

guideway by MODIFY option.

Create the joint, specify the mechanism as translational. Give the suitable

GPs from the VIEW options. Create a new path file as SLIDE and give

the motion.

Simulate the mechanism.

RESULT:

Thus the slider mechanism is created using Workspace 5.


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12B.Design and simulate a 3-dof RRR serial manipulator

AIM:

To simulate a robotic arm as a model by using workspace software.

PROCEDURE:

First we have to create the shell of the robot.

Creating the shell of the robot:

1. Create a cylinder with the dimensions length=80 units and radius=120 units. The

coordinates are given as (0,0,40)

2. The coordinates are set. Then name the cylinder as obj0.

3. From the CAD window of the project view, under the layer branch, left click the

(+) icon on layer 0.

4. Browse in the list and click on the obj0 to select the object.

5. Change the name to ROBOT1. Make sure that the name entered is in capital letters

6. The second object is created with the following dimensions

7. Length=250 radius=70 centroid (0,0,230)

8. Change the name to LINK1. Select clear selection on the CAD view point.

9. Similarly LINK2 and LINK3 are created as per the dimensions in table

10.Before simulation edit the joints and necessary movement from the Robot main

menu, left-click Edit Joints. For the base frame( X=0, Y=0, Z=0), pitch and roll is

zero.


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Setting the kinematics of the robot:

1. From the Robot main menu, left-click Kinematics.A Floating dialog is activated2. Change the Templates field to 3R.

3. Left-click OK to the dialog shown below.

Give the necessary GPs to check the orientation of the arm and then simulate it.

RESULT:

Thus a robotic arm is simulated in workspace5 software.


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12C. Automatic tool path generation for welding operation

AIM:

To create a welding path automatically for a Welding robot

PROCEDURE:

1. From the workspace directory, select the automatic path model folder and go to

the file automatic path.wsp.

2. Select CREATE SUPER CHAIN FACE FEATURE.

3. Select the top face of the flat part and click add button from the feature section of

the dialog box.

4. Select Exterior Wire and press OK.

5. Go to CREATE followed by PATH and then change the path name to PART 1,

and then select GENERIC AUTOMATED and press OK.

6. Select the feature FCO_00 and then edit the properties from APG dialog box.

7. Then select, USE MODIFIED CONFIG to change from FUT 0,0,0 to NUT 0,0,0

and give OK to all.

8. Right click on SK16 file to simulate the path on the object.

RESULT:

The automatic path (welding robot) is generated successfully in Workspace 5.


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Mini Automation and Production System (MAPS)

Specifications:

S.NO DESCRIPTION

1. Complete workstation mounted on an aluminum profileplate with operating console

2. Belt conveyor module

3. Horizontal transfer unit

4. Linear pick and place

5. Rotary indexing table

6. Filling module

7. Capping module transfer

8. Transfer module

9. Weighing module10. XY palletizer

11. vision inspection module

12. Siemens PLC Control Panel

108

54

36

8

12

2


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13A. Study Exercise

SIEMENS PLC: SPECIFICATIONS:

Make: Siemens S7-200 Series.

Base model: CPU 226 base unit24 Digital input / 16 Digital output (24V DC power ON)

Addressing I0.0 to I0.7, I1.0 to I1.7 and I2.0 to I2.7

Expansion model: 16 Digital input / 16 Relay output(24V DC power ON)

Addressing I3.0 to i3.7 and I4.0 to I4.7

Expansion analog input model:2 analog inputs 0-10 VDC (24V DC power ON)

Expansion analog Output model:2 analogs output 0- 10 VDC (24V DC power ON & 0-10V DC)

Software: Step 7 Micro win ver 4.0 (Windows 98/windows XP)With built in effective function blocks for modular programming.


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PLC(SIEMENS-S7-226)

Trunking

CONTROL PANEL LAYOUT

Bridge

rectifier

AnalogI/P

Terminals

16I/ 16O

24V,5V SMPS

Trunking

Stepper

driver

card(Y-Axis)

Optocoupler

Pneumatic

CPV valve

terminals

(Solenoid)

CONTROL PANEL LAYOUT(Inside view)

Trunking

AnalogO/P

CapacitorTransformer

Pneumatic

CPV valve

terminals

(Solenoid)

Relaycard

Trunking

Stepper

driver

card(X-Axis)

ExpansionModule

Trunking


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2.

I 2.2

8.

PLC INPUT ASSIGNMENT DETAILS

6.

Magnetic reed switch (at the cylinder Retractedposition in the LP&P Vertical arm)

3.

SlNo

Magnetic reed switch (at the cylinderRetracted position in the HTU)

Photoelectric sensor (at the Rotary indexingtable to detect the presense of material )

I 1.4

Inductive sensor (at the Conveyor starting position)

PLC AddressInput element Connected

Photo electric sensor (at the Conveyor endingposition)

13.

I 2.1

I 1.2

I 1.0

Magnetic reed switch at the capping unit cylinderretracted position

9.

I 1.7

HTU- Horizontal Transfer Unit

11.

Magnetic reed switch (at the cylinder Extendedposition in the HTU)

I 1.5

LP&P- Linear Pick and Place Unit

Magnetic reed switch at the filling unit cylinderextended position

All the inputs are of Normally open type

4.

14. I 2.5

I 1.3

Magnetic reed switch (at the cylinder retractedposition in the LP&P Horizontal arm)

Magnetic reed switch (at the cylinder Extendedposition in the LP&P Vertical arm )

Magnetic reed switch at the capping unit cylinderextended position

Magnetic reed switch at the filling unit cylinderretracted position

I 2.4

I 2.3

Inductive sensor to count no of stations passed ofthe rotary.(Below the rotary indexing table)

Magnetic reed switch (at the cylinder extendedposition in the LP&P Horizontal arm)

7.

I 1.1

I 2.0

12.

10.

I 1.6

5.

1.


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MOBILE ROBOT PIONEER P3 AT

Adept Mobile Robot platform uses revolutionary high-performance microcontroller withadvanced embedded robot control software based on the new-generation 32-bitRenesas SH2-7144 RISC microprocessor, including the P3-SH microcontroller with

ARCOS, ARCS with PatrolBot


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13B. Study of Mobile Robot Pioneer P3 AT

SOFTWARE AND PIONEER SDK

Adept Mobile Robot platform operates as the server in a client-server environment: Its

microcontroller handles the low-level details of mobile robotics, including maintainingthe platforms drive speed and heading, acquiring sensor readings. To complete theclient-server architecture, Adept Mobile Robot platform requires a PC connection:software running on a computer connected with the robots microcontroller via theHOST serial link and which provides the high-level, intelligent robot controls, includingobstacle avoidance, path planning, features recognition, localization, navigation, and soon.

An important benefit of Adept MobileRobots client-server architecture is that differentrobot servers can be run using the same high-level client. Several clients also mayshare responsibility for controlling a single mobile server, which permits experimentationin distributed communication, planning, and control.

The Pioneer SDK is a collection of libraries and applications that come with everyPioneer mobile robot and with selected accessories. The standard Pioneer SDKbundled with every robot at no extra charge includes the open-source ARIA and

ArNetworking, the MobileEyes and Mapper3-Basic network GUI applications,SONARNL and MobileSim.

Features include 44.2368 MHz Renesas SH2 32-bit RISC microprocessor with 32K RAM and

128K FLASH

3 RS-232 auxilliary serial ports configurable from 9.6 to 115.2 kilobaud

1 HOST software control serial port

4 possible SONAR arrays (8 ultrasonic transducers in each arry)

16 digital inputs for bumper switches


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16 digital I/O lines for gripper or customer use

5 and 12 VDC power

Heading correction gyro port

2-axis, 2-button joystick port

User Control Panel

USER CONTROL PANEL

The User Control Panel gives access to the ARCOS-based onboard microcontroller. Itconsists of control buttons and indicators and an RS-232 compatible serial port(9-pin DSUB connector).

Power and Status Indicators

The red PWR LED is lit whenever main power is applied to the robot. The green STAT

LED state depends on the operating mode and other conditions. It flashes slowly when

the microcontroller is awaiting a connection with a client and flashes quickly when in joy-

drive mode or when connected with a client and the motors are engaged. It also flashes

moderately fast when the microcontroller is in maintenance mode.

Serial Port

The SERIAL connector, with incoming and outgoing data indicator LEDs (RX and TX,

respectively), is through where you may interact with the ARCOS microcontroller froman offboard computer for tethered client-server control and for microcontroller softwaremaintenance. The port is shared internally by the HOST serial port, to which we connectthe onboard computer or an Ethernet-to-serial device. Either the SERIAL or HOSTconnector may be used for client-server and maintenance mode communication withthe microcontroller.


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13C. Mapping of an Unknown Indoor Environment Using a SICK LMS100 Laser

Rangefinder

SOFTWARE NEEDED:

SOPAS, ARIA, Mapper3.

PROCEDURE:

Connect the SICK LMS100 to a power source from the Pioneer 3AT and through

Ethernet to the onboard PC after placing the device at the front of the robot.

On the onboard PC, run SOPAS and connect the device to it. Please note that during

the change of IP address, all other network connections of the PC must beswitched OFF.After the connection has established, under the Basic Settings tab, click

on start measure.

Run a relevant mapping program through ARIA (example: sicklogger.exe). There is a

high chance that ARIA will not be able to connect to the laser directly. Under such a

circumstance, use the -laserport .. command.

Example in command promt:

Sicklogger.exe testscan.2d -robotport com3 -laserport 192.31.22.1

After jogging the robot through the indoor environment, search for the name of the 2d

file given in cmd in the onboard PCs C: drive. Run the file on mapper3 to view and edit

the obtained map.

RESULT:

mct & automation mamgl 207 manual

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