Introduction

Industrial automation is reshaping modern manufacturing by minimizing human error,

increasing productivity, and reducing operational costs. This project proposes a
ROS‐based robotic arm tailored for industrial applications. The arm is designed with
4–5 degrees of freedom (DOF) and is driven by five MG996R servo motors, ensuring
precise and flexible movement. The system is controlled by the Raspberry Pi Pico
2W—a compact, efficient microcontroller that provides wireless connectivity and low
power consumption. Integration with ROS (Robot Operating System) not only
simplifies the development of control algorithms but also enhances the system’s
scalability for complex automation tasks.

To ensure reliability, the project includes a custom PCB designed with EasyEDA. This
board connects the Raspberry Pi Pico 2W to the servo motors, incorporates a robust
5V regulator, and features a screw terminal for battery connection. Mechanical
components are designed using AutoCAD, ensuring precision in the physical structure
through either 3D printing or laser-cut metal fabrication. This approach balances cost,
durability, and ease of assembly, making the robotic arm ideal for educational labs and
small-scale industrial environments. The synergy between cutting-edge electronics,
intuitive software design, and precise mechanical engineering creates a comprehensive
platform that serves as an excellent testbed for robotics research and automation
applications.

ii
Problem Formulation

Industries are increasingly reliant on automated systems to enhance efficiency and

accuracy in production processes. However, high-cost commercial robotic arms and
their complex control systems restrict adoption by smaller businesses and academic
institutions. Existing solutions often involve proprietary hardware and software,
limiting customization and adaptation to specific industrial tasks. Moreover,
integration with modern communication protocols and ROS frameworks is seldom
addressed in affordable systems.

The primary challenge is to develop a low-cost, adaptable robotic arm that leverages
open-source tools and widely available components. The design must simplify both the
hardware and software aspects, allowing for straightforward upgrades and
modifications. By using the Raspberry Pi Pico 2W, a custom EasyEDA PCB, and
AutoCAD for mechanical design, this project targets the development of a modular
system. The design aims to reduce costs without sacrificing performance by
integrating efficient power management, precise servo control, and robust mechanical
design. This project addresses the key problems of cost, complexity, and customization
in robotic arm systems, thereby democratizing advanced automation technologies for
educational and small-scale industrial applications.

iii
Objectives

The main objectives of the project include:

 Design and Development: Create a robotic arm with 4–5 DOF capable of
executing industrial tasks such as pick-and-place, assembly, and inspection.
 Microcontroller Integration: Utilize the Raspberry Pi Pico 2W to manage
servo operations and communicate with ROS, ensuring real-time control and
wireless connectivity.
 Custom PCB Fabrication: Design a PCB using EasyEDA that integrates five
MG996R servo motors, a 5V regulator, and a screw terminal for battery
connection, ensuring stable power delivery and easy wiring.
 Mechanical Structure: Develop a sturdy and precise mechanical framework
using AutoCAD. The design will support either 3D-printed parts or laser-cut
metal sheets, emphasizing modularity and ease of fabrication.
 Software Integration: Implement a ROS-based control system to manage
kinematics, motion planning, and feedback control, making the system flexible
for a range of industrial applications.
 Cost Efficiency and Scalability: Maintain a low-cost solution that is scalable
and adaptable, ensuring that both educational institutions and small industries
can benefit from advanced robotic technologies.

Each objective is addressed through a combination of hardware design, PCB layout,

and software integration, ensuring that the final system meets performance, reliability,
and cost-effectiveness requirements.

iv
Tools Required

Developing this robotic arm requires a combination of hardware and software tools
that ensure precision, reliability, and efficiency:

Software Tools:

 EasyEDA:
o PCB Design: Used for creating the schematic and layout of the custom
PCB. EasyEDA provides an intuitive interface, component libraries, and
simulation tools to validate the design before fabrication.
o Integration: Easy to share projects and collaborate with peers, ensuring
that the electrical design meets the requirements of the robotic arm.
 AutoCAD:
o Mechanical Design: Employed for designing the chassis, joints, and
overall mechanical framework of the robotic arm. AutoCAD’s precision
drawing tools help create detailed blueprints, which can be used for 3D
printing or laser cutting.
o Drafting: Enables the creation of detailed assembly drawings and parts
lists, ensuring that each component fits seamlessly in the final assembly.
 ROS (Robot Operating System):
o Control Software: Provides a framework for writing control algorithms,
managing sensor data, and integrating the robotic arm into automated
industrial systems.
o Simulation: Allows testing of motion planning and kinematics in a
simulated environment before real-world deployment.
 Programming Environment:
o Python/C++ IDEs: Essential for coding on the Raspberry Pi Pico 2W,
interfacing with ROS, and developing custom control algorithms.

Hardware Tools:

 Raspberry Pi Pico 2W:

o Microcontroller: Acts as the central control unit for the robotic arm,
providing wireless connectivity and processing capabilities.
 PCB Fabrication Tools:
o Soldering Station: For assembling the custom PCB components.

viii
 o Multimeter and Oscilloscope: Used for testing and debugging the
electrical circuits.
 Mechanical Fabrication Tools:
o 3D Printer/Laser Cutter: Depending on the chosen material (plastic for
3D printing or metal for laser cutting), these tools will be used to create
the mechanical components.
 General Tools:
o Screwdrivers, Wire Strippers, and Measurement Tools: Essential for
assembly and troubleshooting.

By integrating these tools, the project ensures high-quality design, seamless

fabrication, and reliable performance. The combination of EasyEDA and AutoCAD
allows for a smooth transition from conceptual design to physical implementation.

ix
7. Components List
Electronic Components:

 Raspberry Pi Pico 2W:

o Role: Serves as the primary microcontroller with built-in Wi-Fi for remote
control and integration with ROS.
o Features: Compact size, low power consumption, and robust processing
capabilities.
 MG996R Servo Motors (x5):
o Role: Actuate the joints of the robotic arm.
o Features: High torque, precise control, and compatibility with PWM
signals.
 Custom PCB:
o Role: Connects the Pico to the servos, integrates a 5V regulator, and
features a screw terminal for battery connection.
o Design: Created using EasyEDA, featuring robust trace widths and proper
power filtering.
 Voltage Regulator (5V):
o Role: Steps down the battery voltage to a stable 5V supply.
o Options: Linear regulators like LM7805 or efficient buck converters such
as MP1584.
 Passive Components:
o Capacitors: 100µF (input) and 10µF/0.1µF (output) for voltage
stabilization.
o Resistors, Diodes, and Connectors: Ensure proper signal conditioning and
circuit protection.

Mechanical Components:

 Frame Material:
o Options: 3D-printed plastic parts or folded laser-cut metal sheets,
designed in AutoCAD for precision.
 Mounting Hardware:
o Bolts, screws, and brackets: Secure the servos and mechanical joints.
 Screw Terminal Block:
o Role: Provides a reliable and user-friendly connection for the battery.

x
8. Plan of Execution

The execution plan for the project is broken down into several phases, each ensuring
thorough design, testing, and integration:

Phase 1: Conceptualization and Research

 Literature Review: Study existing robotic arm designs, ROS integration, and
power management strategies.
 Requirement Analysis: Define project specifications, performance criteria, and
cost constraints.
 Initial Design: Sketch the basic block diagram and mechanical layout using
AutoCAD.

Phase 2: Hardware Design and Prototyping

 PCB Design:
o Use EasyEDA to develop the schematic and PCB layout.
o Validate design with simulations and peer reviews.
 Mechanical Design:
o Create detailed CAD drawings in AutoCAD for the arm structure.
o Prototype key components using 3D printing or laser cutting.
 Component Procurement:
o Order the Raspberry Pi Pico 2W, MG996R servos, voltage regulators, and
all necessary passive components.

Phase 3: Software Development and Integration

 Microcontroller Programming:
o Develop and test PWM control routines on the Raspberry Pi Pico 2W.
o Integrate ROS communication protocols.
 Control Algorithms:
o Implement kinematics, trajectory planning, and sensor feedback loops.
 Testing:
o Simulate motion in ROS before physical integration.
o Debug and refine control signals.

xi
Phase 4: System Assembly and Testing

 PCB Assembly:
o Solder components onto the custom PCB.
o Integrate the PCB with the Raspberry Pi Pico 2W and servo motors.
 Mechanical Assembly:
o Assemble the mechanical structure using parts designed in AutoCAD.
o Secure all components with proper mounting hardware.
 System Integration:
o Connect the power supply and test voltage regulation.
o Conduct full system tests, calibrate servo movements, and fine-tune ROS
parameters.

Phase 5: Final Evaluation and Documentation

 Performance Testing:
o Evaluate the arm under various loads and tasks.
o Collect data on precision, response time, and reliability.
 Documentation:
o Prepare detailed reports, including circuit diagrams, CAD drawings, and
software documentation.
o Finalize the user manual and reference list.

This comprehensive plan ensures that each aspect of the project is systematically
addressed, from initial research to final integration, ensuring a robust and scalable
robotic arm.

xii
9. Applications

The versatility of the ROS-based robotic arm makes it applicable in various industrial
and educational scenarios:

Industrial Automation:

 Pick-and-Place Operations:
o Automate repetitive tasks in manufacturing lines.
o Precisely handle components, reducing human error and increasing
efficiency.
 Assembly Lines:
o Utilize the arm for assembling parts, where precision and repeatability
are crucial.
o Integrate with sensors for quality control and error detection.

Research and Development:

 Robotics Education:
o Provide students with hands-on experience in robotics, PCB design, and
ROS programming.
o Serve as a platform for experimenting with advanced control algorithms
and machine learning.
 Prototyping and Testing:
o Experiment with new robotic designs and integration techniques.
o Use ROS simulation environments to test different scenarios before real-
world implementation.

Medical and Service Applications:

 Surgical Assistance:
o Adapt the arm for precise, minimally invasive procedures in a controlled
setting.
o Develop teleoperated control systems for remote surgeries.
 Assistive Robotics:
o Implement in scenarios requiring precision handling, such as in
laboratories or service industries.
xiii
 o Enhance accessibility by automating tasks that require fine motor skills.

Educational Outreach:

 Workshops and Competitions:

o Use the robotic arm as a hands-on educational tool in robotics
competitions and training workshops.
 Community Projects:
o Encourage collaborative projects that integrate hardware, software, and
mechanical design, fostering innovation and technical skill development.

The adaptability of the design, coupled with the open-source ROS framework,
ensures that the system can be easily customized for a wide range of applications,
making it a valuable asset in both industrial and educational environments.

xiv
10. Estimated Cost
Component Quantity Estimated Cost (INR)
Raspberry Pi Pico 2W 1 800
MG996R Servo Motors 4 1600
2S Li-ion Battery 1 500
Frame Materials - 1500
Miscellaneous - 1200
Total Cost - 5600

xv
11. References
1. Datasheets & Manuals
o MG996R Servo Motor Datasheet
https://www.electronicoscaldas.com/datasheet/MG996R_Tower-Pro.pdf
o Raspberry Pi Pico 2W Datasheet
https://datasheets.raspberrypi.com/picow/pico-2w-datasheet.pdf
o Raspberry Pi Pico 2W Official Documentation
https://www.raspberrypi.com/documentation/microcontrollers/
2. ROS (Robot Operating System)
o ROS Official Documentation
https://docs.ros.org/en/iron/index.html
o ROS Tutorials for Beginners
http://wiki.ros.org/ROS/Tutorials
o Micro-ROS (ROS for microcontrollers like Pico 2W)
https://micro.ros.org/
3. PCB Design using EasyEDA
o EasyEDA Documentation and Tutorials
https://docs.easyeda.com/en/
o Getting Started with EasyEDA (Complete Beginner Guide)
https://www.electronicwings.com/note/easyeda-tutorial
4. Mechanical Design using AutoCAD
o AutoCAD Official Documentation
https://help.autodesk.com/view/ACD/2025/ENU/
o AutoCAD Beginner Tutorial (Youtube Playlist)
https://www.youtube.com/playlist?list=PL-
B9VZ3xFbcTo7CEMnKzEv2MGozXWkVyK
5. Robotic Arm Kinematics & Control
o Simplified Robotic Arm Kinematics (ROS-based)
https://automaticaddison.com/ros-robot-arm-kinematics-tutorial/
o Introduction to Robotics: Mechanics and Control by John J. Craig (Book)
6. General Robotics
o Robot Operating System (A Practical Introduction to ROS) by Wyatt Newman
(Book)
o Robotics and Automation Handbook by Thomas R. Kurfess (Book)
o IEEE Spectrum Robotics Channel
https://spectrum.ieee.org/robotics

xvi