Design and implementation of 4 DOF Robotic Arm for

health applications

A midterm capstone project report submitted in partial fulfillment of the requirement for
the award of the degree of

Bachelor of Engineering
in
Electronics and Computers Engineering

Submitted by:

(102215191) Khushpreet Singh

(102215284) Harshit Tripathi
(102215295) Piyush Goyal
(102215029) Rakshit Aggarwal
(102215019) Sidharth Jindal

CPG No. 41
Under Supervision of
Dr. Gaganpreet Kaur (Assistant Professor, ECED)
Dr. Anil Arora (Assistant Professor, ECED)

Department of Electronics and Communication Engineering Thapar Institute of

Engineering and Technology, Patiala
February 2025
 DECLARATION

We hereby declare that the capstone project group report title “Design and
implementation of 4 DOF Robotic Arm for health applications” is authentic record of our
own work carried out at “Thapar Institute of Engineering and Technology, Patiala” as a
Capstone Project in sixth semester of B.E. (Electronics and Computer Engineering),
under the guidance of “Dr. Gaganpreet Kaur” and “Dr. Anil Arora”, during January to
July 2025.

Date: 12th August 2025

Name Roll Number Signature

Khushpreet Singh 102215191
Harshit Tripathi 102215284
Piyush Goyal 102215295
Rakshit Aggarwal 102215029
Siddharth Jindal 102215019

i
 ACKNOWLEDGEMENT

We would like to express our sincere gratitude to our mentors, Dr. Gaganpreet Kaur
and Dr. Anil Singh, for their constant guidance, encouragement, and invaluable insights
throughout the course of this project. Their technical expertise, constructive feedback,
and unwavering support have been instrumental in shaping our work and leading it
towards successful completion.

We are also deeply thankful to Dr. Kulbir Singh, Head, Electronics and Communication
Engineering Department, and to the entire faculty and staff of the department. We extend
our heartfelt appreciation to our friends for their timely help, valuable suggestions, and
moral support at every stage of this endeavour.

Finally, we express our deepest gratitude to our families for their unending love, patience,
and encouragement. Their belief in our abilities and their sacrifices have been a constant
source of motivation, enabling us to put forth our best efforts. To everyone who
contributed directly or indirectly to this work, we extend our sincere thanks.

Date: 12th August 2025

Name Roll Number Signature

Khushpreet Singh 102215191
Harshit Tripathi 102215284
Piyush Goyal 102215295
Rakshit Aggarwal 102215029
Siddharth Jindal 102215019

ii
 ABSTRACT

This capstone project presents the design and partial implementation of a four degrees-of-freedom
(4-DOF) robotic arm control system utilizing an FPGA platform. The system is developed on the
ZedBoard Zynq-7000 SoC, which provides a hybrid architecture combining a Processing System
(PS) and Programmable Logic (PL). This heterogeneous platform enables hardware acceleration,
parallelism, and low-latency control, thereby addressing the performance limitations of
conventional microcontroller-based robotic controllers.

In this work, the PL is employed to implement dedicated stepper motor driver logic,
ensuring precise pulse generation, real-time synchronization, and deterministic actuation.
The PS will be responsible for higher-level computations and supervisory control,
resulting in an efficient hardware–software co-design. Inverse kinematics has been
implemented to facilitate trajectory planning, enabling smooth and accurate positioning
of the robotic arm’s end-effector. A distance calculation algorithm has been successfully
validated on the hardware, while system configuration and boot integrity have been
confirmed through the ZedBoard’s status indicators.

The preliminary outcomes of this project highlight the potential of FPGA-based robotic
control systems in domains requiring precision, reliability, and safety. Future extensions
will focus on full integration of camera-based vision processing and autonomous
operation, particularly targeting healthcare assistance and rehabilitation robotics.

iii
 LIST OF TABLES

Table No. Caption Page No.

Table 2.1 Justification for FPGA Over microcontrollers 4-5
Table 2.2 Research Overview on Robotic Arms in Healthcare 6–7
Table 4.1 Undergraduate Subjects Covered 15
Table 6.1 Work Breakdown Structure and Gantt Chart 19
Table 6.2 Individual Contribution in the project 19

iv
 LIST OF FIGURES

Table No. Caption Page No.

Figure 3.1 Concept Diagram of the Robotic Arm 12
Figure 3.2 Mechanical Structure of the Robotic Arm 12
Figure 3.3 Shoulder Joint of the Robotic Arm 13
Figure 3.4 Base Joint of the Robotic Arm 13

v
 LIST OF ABBREVATIONS

4DOF Four Degrees of Freedom

FPGA Field-Programmable Gate Array
HDL Hardware Description Language
UART Universal Asynchronous Receiver/Transmitter
PWM Pulse Width Modulation
GPIO General-Purpose Input/Output
I/O Input/Output
SoC System on a Chip
PS Processing System
PL Programmable Logic
AI Artificial Intelligence
ARM Advanced RISC Machine
DC Direct Current (Power Supply)
CPU Central Processing Unit
ISO International Organization for Standardization
IEEE Institute of Electrical and Electronics Engineers

vi
 TABLE OF CONTENTS

DECLARATION............................................................................................................ i
ACKNOWLEDGEMENT.............................................................................................. ii
ABSTRACT..................................................................................................................... iii
LIST OF TABLES.......................................................................................................... iv
LIST OF FIGURES......................................................................................................... v
LIST OF ABBREVIATIONS........................................................................................ vi
CHAPTER 1- INTRODUCTION................................................................................. 1
1.1 Project Overview.................................................................................................... 1
1.2 Motivation.............................................................................................................. 2
1.3 Assumptions and Constraints................................................................................. 2
1.4 Novelty of Work..................................................................................................... 3
CHAPTER 2 – LITERATURE SURVEY................................................................... 4
2.1 Literature Survey.................................................................................................... 4
2.2 Research Gaps........................................................................................................ 7
2.3 Problem Definition and Scope............................................................................... 7
CHAPTER 3 – FLOW CHART.................................................................................. 11
3.1 System Architecture............................................................................................... 11
3.2 Analysis.................................................................................................................. 14
3.3 Tools and Technologies Used................................................................................ 15
CHAPTER 4 – PROJECT DESIGN AND DESCRIPTION..................................... 16
4.1 Description............................................................................................................. 16
4.2 U.G. Subjects......................................................................................................... 17
4.3 Standards Used...................................................................................................... 18

vii
CHAPTER 5 – OUTCOME AND PROSPECTIVE LEARNING............................ 19
5.1 Scope and Outcomes.............................................................................................. 19
5.2 Prospective Learnings............................................................................................ 19
5.3 Conclusion.............................................................................................................. 20
CHAPTER 6 – PROJECT TIMELINE....................................................................... 21
6.1 Work Breakdown & Gantt Chart............................................................................ 21
6.2 Individual Gantt Chart............................................................................................ 21
REFERENCES............................................................................................................... 22

viii
 INTRODUCTION

1.1 Project Overview

In today’s rapidly evolving technological landscape, the relationship between innovation
and human creativity has played a crucial role in shaping advancements in robotic arms.
The progression from basic electromechanical systems to AI-driven autonomous robots
reflects the broader evolution of digital and mechanical engineering, while their
integration across industries has transformed task execution by enhancing efficiency,
precision, and automation.

The robotics field is rapidly advancing, with automation transforming various industries,
particularly healthcare. Robotic systems assist medical professionals by enhancing
precision, reducing human exposure to hazardous environments, and improving
procedural efficiency. Field Programmable Gate Array (FPGA) based robotic control
offers high- speed processing, real-time decision-making, and efficient motion control,
making it ideal for applications requiring accuracy and reliability. This capstone project
focuses on developing a 4 Degree of Freedom (4DOF) robotic arm controlled using
FPGA for real-time operations. Unlike conventional microcontrollers, FPGA enables
parallel processing and precise motion control, enhancing automation in medical
procedures. The robotic arm uses stepper motors for accurate positioning and smooth
joint movement, and incorporates a camera module for object detection to support routine
assistance activities. By enhancing efficiency, reducing manual effort, and improving
overall task execution in controlled environments, the project seeks to bridge the gap
between robotics and intelligent automation in healthcare.

The potential applications include assisting healthcare professionals in remote

diagnostics, reducing manual intervention in high-risk environments, and optimizing
workflow in hospitals. Through this innovation, the project seeks to bridge the gap
between robotics and intelligent automation, demonstrating the viability of hardware
accelerated FPGA-controlled robotic systems in healthcare.

Page 1 of 24
1.2 Motivation
Integrating robotics into healthcare is no longer a futuristic vision but an immediate
necessity. We're facing a sharp increase in the number of patients, along with more
complicated care needs, all while dealing with a global shortage of skilled healthcare
workers. Routine assistance tasks, though essential, can take up a lot of staff time and
lead to physical fatigue, reducing efficiency in critical care delivery. It can reduce the
quality of care for patients. By automating these tasks, we can help healthcare workers
spend more time on what matters by using their judgment, showing care, and making
decisions.

FPGA-based control offers a significant advantage by providing real-time, parallel

processing for precise and responsive motion control. Leveraging this ability in a 4DOF
robotic arm creates a reliable, adaptable solution for controlled environments such as
hospital wards and rehabilitation centers.

This capstone project offers a multidisciplinary learning experience by integrating digital

system design, Verilog programming, robotics, machine vision, and control theory. It
develops problem-solving skills, promotes innovation in assistive technology, and
provides hands-on expertise in hardware acceleration-based implementation. The
knowledge gained is highly relevant to advancing fields such as automation, embedded
systems, and intelligent healthcare solutions.

1.3 Assumption and Constraints

1.3.1 Assumptions

 The project will be implemented on the Xilinx Zynq-7000 FPGA Board, utilizing
both its FPGA fabric and ARM cores for hardware–software co-design.
 It is assumed that the hardware peripherals (stepper motors, camera) will be
compatible with the Zynq-7000’s interfaces and can be integrated without major
hardware redesign.

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  The robotic arm will operate in a controlled environment with minimal
interference from external factors such as lighting variations, dust, or temperature
fluctuations.

1.3.2 Constraints

 Limited availability of resources to learn and work on the FPGA technology

restricts extensive experimentation and exploration of advanced features within
the project timeline.
 Limited access to a DC power supply in the lab requires waiting for equipment
availability, restricting testing time outside scheduled hours.
 Budgetary constraints limit procurement of higher-grade sensors, actuators which
could have otherwise enhance system capabilities.
 The project faces a steep learning curve due to the complexity of advanced FPGA
logic design and ARM co-processing integration, which is challenging to master
fully within the available schedule.

1.4 Novelty Of Work

This project uses the Xilinx Zynq-7000 system on chip, which combines an FPGA and an
ARM processor on a single chip. This allows real-time control of the 4 Degree of
Freedom robotic arm using hardware acceleration, while the on-board processor handles
tasks like camera-based object detection. Unlike systems that require separate
microcontrollers or CPUs, this integrated design reduces delays and improves
performance. It also simplifies the overall system, making it more efficient and scalable
for assistive robotics applications. This combined hardware and software approach is a
notable advancement over traditional multi-device robotic systems.

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 LITERATURE SURVEY

2.1 Literature Survey

This literature survey presents a review of key advancements and research efforts related
to robotic arms, with a focus on FPGA-based implementations, control techniques, and
applications in healthcare and automation. It highlights various methodologies, hardware
platforms, and system designs that have been explored to improve precision, efficiency,
and real-time responsiveness. The following table summarizes significant studies that
justify the use of FPGA technology over microcontrollers for robotic arm control, as well
as research specifically targeting 4 Degree of Freedom robotic arms in healthcare
environments.

Table 2.1: Justification for FPGA Over microcontrollers

Ref. Year Objective Methodology Key Findings Limitations
No.
Develop an FPGA- FPGA (Verilog), FPGA-based control Relies on Arduino,
based robotic arm with Mobile App improves precision introducing processing
[16] 2024 mobile integration for (Bluetooth), DC and real-time delays; FPGA could
real-time agricultural Motors (L293D response; mobile app provide real-time AI
applications driver), IR Sensors. enhances processing and sensor
accessibility. fusion.
Develop a robotic arm FPGA (Zynq-7000 FPGA-based image Hardware-dependent,
using FPGA-based SoC), Ubuntu Linux, processing enables lacks FPGA-
[20] 2016 image processing and Stereo Vision, real-time robotic accelerated deep
stereo vision for OpenCV, PWM control without a PC. learning for real-time
movement control. Servo Control. image tracking.
Design and develop an FPGA (Verilog Improves precision Limited real-time
[19] 2023 FPGA-based HDL), PID control, and efficiency, adaptability, lacks
controller for precise parallel execution. reduces latency, FPGA-driven sensor
robotic arm motion optimizes energy fusion for faster
using Verilog HDL. consumption. motion control.
Improve FPGA (Intel Stratix- Achieved 14–16x CPU bottleneck for
reinforcement learning V), Reinforcement speedup in training; training, FPGA could
[4] 2024 efficiency for robotic Learning (DDPG), improved policy handle both training
arms using FPGA Python, PyTorch. learning transfer. and execution
acceleration. efficiently.
Develop an FPGA- FPGA (Spartan-3), High flexibility, Relies on MATLAB
based controller for a VHDL, MATLAB standalone design, GUI, reducing real-
[18] 2016 6-DOF robotic arm GUI, Wireless accurate positioning. time efficiency; FPGA
using inverse Control, Inverse could enable
kinematics. Kinematics. embedded AI-based
path planning.

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 Develop a control FPGA (Lattice iCE40 Efficient real-time Lacks predictive
system for a 6-DOF HX1K), Open-Source control with open- control, limited sensor
[23] 2024 robotic arm using Tools (Yosys, source FPGA. processing; FPGA
open-source FPGA Nextpnr), PWM could improve motion
tools. Control. stability.
Develop an automated 4-DOF Arm, RC Reduced calibration No adaptive motion
underwater robotic Transmitter, Servo & error (0.0734 pixels), correction, lacks
[7] 2024 arm for camera DC Motors, Polyvinyl improved camera FPGA-powered real-
calibration in Chloride Structure. accuracy. time image processing
aquaculture. for underwater
calibration.
Develop a 5-DOF Arduino, IoT Successfully IoT-based control
robotic arm (RemoteXY), Forward implemented forward introduces latency,
[9] 2025 integrating forward Kinematics (DH kinematics; precise FPGA could handle
kinematics and IoT- Representation). movement tracking. real-time processing
based control. onboard.

Develop a wireless EMG Sensors, RF-433 Achieved 99.62% Limited EMG signal
[6] 2024 EMG-controlled Wireless Control, accuracy in motion processing, FPGA
robotic arm for Arduino UNO, SG90 tracking. could enable faster and
human-computer Servo Motors. more precise muscle-
interaction. based control.

Compare algebraic Algebraic Method (DH 99.9% accuracy in No FPGA-based

and software-based Transform), Software theoretical vs. real- acceleration, resulting
[17] 2024 approaches for (RoboAnalyzer), world validation. in slower kinematic
kinematics in a pick- Arduino, Servo calculations and
and-place robotic arm. Motors. trajectory planning.

Develop a cost- SCARA Robot, Delta High-speed Pick- and- PLC-based system lacks
effective SCARA DVPSV2 PLC, Place (1.2–2.5 sec per reconfigurability,
[5] 2024 robotic arm for pick- Forward & Inverse cycle). FPGA could enable
and-place applications Kinematics, Stepper real-time motion
using PLC. Motors. updates and flexibility.

Develop a robotic arm Arduino, LabVIEW, High-precision motion, Predefined motion

[1] 2019 for medical surgeries SolidWorks, Servo & wireless control patterns, lacks FPGA-
to enhance precision Stepper Motors, enhances flexibility. driven real-time
and efficiency. Bluetooth Control. surgical precision and
AI integration.

Develop a robotic arm YOLOv3, ROS 94% classification No FPGA-accelerated

for medical waste MoveIt, accuracy, 82.1% AI for image
[21] 2022 segregation using AI Speech Recognition robotic arm accuracy. processing, affecting
and voice commands. (Google Cloud API), real-time medical waste
5- DOF Arm. sorting.

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 Table 2.2 : Research Overview on Robotic Arms in Healthcare

Ref.
Year Objective Methodology Key Findings Limitations
No.
Develop a robotic Arduino, LabVIEW, Achieved high No FPGA
arm to assist in Stepper Motors, precision with micro- implementation, lacks
[11] 2022 surgical procedures Bluetooth Control stepping control, force sensors for
by improving improved surgical feedback, requires
precision and accuracy. real-world clinical
reducing human error. testing.
Perform non-contact ROS (Robot Operating Achieved 0.005 mm No FPGA, lacks AI-
lung assessments for System), Inverse accuracy, fast inverse driven patient
[2] 2020 COVID-19 patients, Kinematics, Bluetooth kinematics execution assessment, needs
reducing healthcare Stethoscope, Thermal (200ms per position). clinical validation.
worker exposure. Camera
Minimize human Arduino, Linear Automated swab Requires manual
[8] 2022 interaction during Actuator, collection, reduced control, lacks AI-based
COVID-19 swab Potentiometer patient processing optimization.
collection and Control, Camera time by 30%.
automate report Module
generation.
Develop a Impedance Control, Successfully Lacks AI-driven
robotic platform RGB-D Camera, localized objects, ultrasound image
[ [15] 2024 for intraoperative Force/Torque performed real- quality enhancement,
ultrasound Sensor, Ultrasound time 3D needs real-world
scanning to Probe reconstruction for surgical testing.
improve guided scanning.
precision and
safety.
Assist surgeons YOLOv5, Deepgram Achieved 99.4% Struggles in high-noise
[14] 2022 in retrieving Speech Recognition, accuracy in OR conditions, lacks
instruments Raspberry Pi 4B, surgical tool real-time tracking of
through voice Electromagnet detection, reduced moved instruments.
control, retrieval errors.
minimizing
contamination
risk.
Integrate Stepper Motors, CNC Successfully Lacks laparoscopic
industrial System, Potentiometer validated robotic tool integration,
[10] 2023 robotics into Control, Web motion for restricted motion range
surgery to Application surgical tasks, for certain procedures.
improve CNC platform
precision and enabled stable
reduce surgeon movements.
fatigue.
Enable remote ESP32 Real-time cloud-based Internet dependency
robotic surgeries Microcontroller, IoT, robotic control, introduces latency,
[3] 2022 using cloud Cloud-Based Remote allowing remote lacks haptic feedback
computing and IoT. Control, Servo Motors surgeon access. for precision.
Improve laparoscopic Cable-Driven Reduced hand Needs real-world
and endoscopic Parallelogram tremors, improved testing, lacks AI-based
[13] 2011 procedures by Mechanism, Maxon DC precision with cable- adaptability for
enhancing dexterity. Motors, MATLAB driven control. complex surgeries.
Simulation

Page 6 of 24
 Conduct contactless Raspberry Pi 3, Successfully Limited to temperature
temperature screening MLX90614 Infrared automated thermal screening, lacks AI for
[22] 2022 in hospitals and public Temperature Sensor, screening, prioritizing high-risk
spaces. Arduino Nano, DC reducing human individuals.
Motors exposure.
Automate oral swab Raspberry Pi 4B, Dlib Successfully Requires patients to stay
collection to minimize Facial Landmark performed still, lacks real- world
[12] 2023 healthcare worker Detection, Servo autonomous swab deployment testing.
exposure. Motors, Adafruit Servo collection with
Hat facial recognition.

2.2 Research Gaps

Despite advances in the development of robotic arm platforms, several important research
gaps are remaining. Addressing these gaps is essential for realizing robust, efficient, and
scalable robotic arm systems that effectively combine motion control and intelligent
perception. A thorough review of recent literature and current designs reveals that most
existing solutions are limited by fragmented architectures, suboptimal hardware choices,
and scalability constraints. The following specific research gaps have been identified:

1. Lack of Unified Architecture: Most of the current robotic arm systems

implement motor control, image processing, and decision-making as separate
modules on independent hardware units. This fragmented approach results in
increased latency, synchronization challenges between subsystems, and higher
system complexity, thus hampering real-time performance and reliability.

2. Absence of Low-Latency Hardware: Widely used microcontrollers like Arduino

or ESP32 are not optimized for low-latency or parallel task processing. Their
limited computational capability restricts the simultaneous execution of complex,
real-time tasks, such as concurrent motion control and image-based feedback
needed for advanced robotic applications.

3. Non-Scalable and Fragmented Designs: The separation of different system

functions across various modules leads to excessive wiring, greater software
interdependencies, and increased maintenance overhead. This fragmented and
rigid structure makes it difficult to expand the system or introduce new features
and functionalities in response to evolving requirements.

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 4. Limited Scalability and Modularity: Many existing designs require major
hardware changes to add new sensors, increase the number of degrees of freedom,
or implement additional features. In contrast, FPGA-based architectures
inherently support modularity, allowing seamless integration of future upgrades
with minimal redesign effort.

5. Lack of Parallel and Scalable Processing: Current systems seldom utilize the
synergistic potential of ARM processing cores alongside FPGA fabric. An
optimized, unified design allows ARM cores to handle high-level control tasks
while assigning compute-intensive parallel processes—such as vision
processing—to the FPGA, thereby enabling effortless expansion for more sensors
or complex robotic operations.

2.3 Problem Definition and Scope of the Project

2.3.1 Problem Definition

Traditional robotic arms often lack the real-time adaptability, precision, and
computational power necessary for critical medical applications. Microcontroller-based
robotic systems typically experience high latency, limited flexibility, and operational
inefficiencies that restrict their effectiveness in healthcare automation. This project seeks
to overcome these limitations by developing an FPGA-controlled 4 Degree of Freedom
(4DOF) robotic arm capable of high-speed processing, precise motion control, and real-
time decision-making.

Key challenges to address include achieving seamless real-time motion control, effective
integration of sensors, and implementing intelligent decision-making capabilities, all
while keeping the system cost-effective. The intended outcome is a scalable, efficient
robotic automation platform with diverse potential applications in healthcare, such as
diagnostics, rehabilitation, and telemedicine. This project aims to identify and optimize
these use cases to enhance healthcare delivery and patient safety.

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2.3.2 Scope of the Project

This project's scope includes designing, developing, and implementing a 4 DOF robotic
arm specifically tailored for healthcare applications. The following are the main areas of
concentration for the project:

1. Mechanical and Control System Development: -

 A 4 DOF robotic arm will be designed and fabricated, incorporating lightweight

yet durable materials suitable for medical environments.
 Stepper Motors will be used to achieve smooth, accurate, and repeatable
movements.
 Kinematic and dynamic analysis will be conducted to ensure the arm meets
required range of motion, payload capacity, and stability for health-related tasks.

2. Software Integration and User Interface: -

 A control system will be implemented to manage the arm's motion and coordinate
with sensors for precise feedback and operation.
 A user-friendly interface will be developed to allow healthcare personnel to
control the arm manually or through semi-autonomous modes.
 Safety algorithms and limit switches will be integrated to prevent unintended
motion and ensure compliance with medical safety standards.

3. Remote Operation and Assistive Features: -

 Networking capabilities (e.g., Wi-Fi, Bluetooth) will be explored to enable remote
control of the arm for telemedicine or remote rehabilitation assistance.
 The system will be capable of performing repetitive therapeutic movements,
assisting in rehabilitation exercises, and handling lightweight medical
instruments.
 Feedback will be used to enhance precision and provide adaptive control in
sensitive operations.

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4. Validation and Testing: -
 Extensive testing will be carried out to verify accuracy, repeatability, and load-
handling capabilities under different operating conditions.
 Performance metrics like response time, motion smoothness, and safety
compliance will be assessed.

5. Deployment and Documentation: -

 Detailed documentation will be prepared covering hardware architecture, control
algorithms, maintenance guidelines, and safety protocols.
 A prototype robotic arm will be deployed in a simulated healthcare setting to
demonstrate capabilities and gather feedback for further optimization.

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 FLOW CHART

3.1 System Architecture

The system architecture is designed around the Zynq-7000 SoC, which uniquely
combines a Processing System (PS) and Programmable Logic (PL) within a single
chip.
 Processing System (PS): The PS comprises a dual-core ARM Cortex-A9
processor along with standard peripherals such as DDR controllers, UART,
Ethernet, and GPIO. In this project, the PS handles high-level tasks including
trajectory planning, inverse kinematics computation, supervisory control, and
coordination between different motion modules. By centralizing decision-making
within the PS, the system achieves flexibility and programmability similar to
conventional embedded processors.

 Programmable Logic (PL): The PL is the reconfigurable FPGA fabric that

enables parallel execution of time-critical tasks. Dedicated motor driver logic
blocks are implemented here to generate precise step pulses for the stepper
motors, ensuring accurate angular displacement and synchronization. The PL’s
inherent parallelism reduces latency by processing multiple signals
simultaneously, unlike sequential microcontroller execution. The PS and PL
communicate via AXI interconnects, enabling seamless data transfer and
command execution between software and hardware domains.

 Stepper Motors (SMs): The robotic arm is made up of four stepper motors
corresponding to its four degrees of freedom (DOF). Each stepper motor is
actuated through the driver logic in the PL, which produces clocked pulse
sequences that directly control motor rotation and direction. This ensures fine-
grained angular positioning, which is essential for precise robotic movements.

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 Figure – 3.1 Concept Diagram of the Robotic Arm

Figure – 3.2 Mechanical Structure of the Robotic Arm

Page 12 of 24
Figure – 3.3 Shoulder Joint of the Robotic Arm

Figure – 3.4 Base Joint of the Robotic Arm

Page 13 of 24
3.2 Analysis

The analysis of the 4-DOF robotic arm control system focuses on hardware–software
partitioning, latency minimization, parallel execution, and synchronization efficiency. In
this architecture, the Processing System (PS) is responsible for high-level tasks,
providing the target coordinates of the end-effector based camera-derived measurements.
The Programmable Logic (PL) handles trajectory planning, stepper pulse generation, and
synchronized motor control, exploiting FPGA parallelism to execute multiple motor
commands concurrently. This offloading of time-critical tasks significantly reduces
response latency and ensures deterministic actuation, which is essential for precise
robotic motion.

Preliminary evaluation confirms that the system maintains smooth and accurate end-
effector movement, with minimal timing errors across all axes. By performing trajectory
computation and pulse generation in hardware, the design achieves high-throughput
operation and precise synchronization, which would be difficult to accomplish in a purely
software-based or microcontroller-driven system.

Comparative analysis highlights that FPGA-based control provides superior scalability,

allowing additional degrees of freedom or sensors to be incorporated without significant
performance degradation. The system also exhibits higher precision and responsiveness,
making it suitable for applications that demand reliability, such as healthcare assistive
robotics, rehabilitation devices, and industrial automation. Overall, this hardware–
software co-design demonstrates the advantages of leveraging the Zynq-7000 SoC for
real-time robotic control, combining flexible software computation with deterministic
hardware acceleration.

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3.3 Tools and Technologies Used

 Hardware Components:
 ZedBoard Zynq-7000 SoC (ARM Cortex-A9 + FPGA)
 Stepper Motors (4 DOF) for robotic arm joints
 Stepper Motor Drivers (4 units, powered by 24 V supply)
 See3CAM_CU30_CHL_TC_BX USB Camera

 Design Tools:
 Xilinx Vivado (HDL design, synthesis, bitstream generation)
 Vitis (software development)
 PetaLinux (for embedded Linux integration)

 Programming Languages:
 Verilog (hardware logic)
 C/C++ (software control),

 Mathematical Tools: MATLAB/NumPy (for inverse kinematics simulation)

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 PROJECT DESIGN AND DESCRIPTION

4.1 Project Description

The proposed project involves the design and implementation of a 4 Degree of Freedom
(4DOF) robotic arm tailored for healthcare-related assistive tasks. The core control
system is built on the Xilinx Zynq-7000 platform, leveraging its hybrid architecture that
combines Programmable Logic (PL) and Processing System (PS) for efficient hardware–
software co-design.

A USB camera connected to the Zynq board captures real-time images for object
detection. The image processing pipeline runs on the Processing System (ARM cores),
which analyzes the camera feed and extracts the coordinates of target objects. These
coordinates are then transmitted to the Programmable Logic (FPGA fabric) where inverse
kinematics computations are performed to calculate the required joint angles (theta
values) for the robotic arm.

The calculated angles are used to generate precise motor control signals through FPGA-
based PWM controllers driving the stepper motors. This integration allows for smooth,
coordinated movement of the robotic arm, enabling it to pick and place objects
accurately. Real-time sensor feedback from encoders ensures closed-loop control,
maintaining positional accuracy and stability. The mechanical design prioritizes
lightweight and durable materials to ensure both strength and agility during operation.

This system architecture provides a scalable and modular framework that supports future
enhancements such as AI-driven motion planning and advanced sensor fusion. By
combining high-speed hardware acceleration with flexible software processing, the
project aims to deliver a robust, real-time robotic solution to support routine assistance
tasks in healthcare environments, improving operational efficiency and reducing manual
workload.

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4.2 U.G. Subjects Used
Table – 4.1: Undergraduate Subjects Covered
Subject Code Subject Name Description
UEC513 Embedded Systems Focuses on the design and development of hardware-
software integrated systems, including
microcontrollers, interfacing techniques, and real-time
applications.
UEC612 Digital System Design Covers the design of digital circuits using
combinational and sequential logic, hardware
description languages (HDL), and FPGA-based
implementations.
UEC509 Computer Architecture Studies the structure, functionality, and performance of
computer systems, including CPU organization,
memory hierarchy, and instruction set architectures.
UES018 Manufacturing Introduces various manufacturing processes such as
Techniques casting, machining, forming, and modern additive
manufacturing techniques for engineering components.
UEI501 Control Systems Explores the modeling, analysis, and design of
feedback control systems, stability concepts, and
controller design techniques.
UTA015 Engineering Drawing Teaches technical drawing skills including
orthographic projection, isometric views, tolerances,
and CAD-based drafting for engineering design.
UEC754 Image Processing and Focuses on techniques for image enhancement,
Computer Vision segmentation, feature extraction, and object
recognition, with applications in automation and
robotics.
UCS636 3D Modelling Covers concepts and tools for creating three-
dimensional digital models for engineering, and
simulation applications.

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4.3 Standards Used

 IEEE 802.3 (Ethernet Standard) – Used for wired communication and real-time
data transmission between robotic components.

 UART Communication Protocol – Applied for serial communication between

FPGA and peripheral modules.

 IEEE 754 Floating-Point Standard – Considered in computational algorithms

for maintaining numerical precision.

 PWM Control Standards for Motor Drivers – Followed to ensure compatibility

with servo and stepper motor control.

 ISO 8373:2021 (Robotics – Vocabulary) – Used for consistent terminology and

definitions during system design.

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 OUTCOME AND PROSPECTIVE LEARNING

5.1 Project Outcomes

 Designed and implemented stepper motor control logic on the FPGA’s

Programmable Logic (PL), integrating stepper motor driver circuits to achieve
precise movement.
 Implemented precise coordinated 4-DOF movement control of the robotic arm,
incorporating kinematics and trajectory planning for smooth and accurate motion
execution within the PL fabric.
 Integrated camera-based image processing with real-time data transmission via
Ethernet/UART, enabling object detection, tracking, and remote monitoring in
robotic applications.
 Successfully implemented distance calculation code and loaded the ZedBoard with
the boot file. The configuration was verified by the blue status LED on the board.
 Currently preparing for filing a patent to document the methodologies, technical
advancements, and unique contributions of this robotic arm system.

5.2 Prospective learnings

Through the design and implementation of the 4 DOF robotic arm for healthcare
applications, the following technical and practical skills will be gained:

1. Advanced FPGA Programming Skills – The project have enhanced proficiency

in hardware description languages like Verilog through the development and
integration of motor control logic, communication protocols, and image
processing on FPGA.

2. Control System Design – Gained experience in implementing precise motion

control, kinematics, and trajectory planning for robotic systems.

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 3. Sensor Integration and Data Handling – Skills will be developed in real-time
sensor data acquisition, processing, and communication UART or Ethernet
interfaces.

4. Image Processing and Computer Vision – Knowledge will be acquired in

implementing camera-based object detection, tracking, and analysis for
healthcare-related automation.

5. Research and Innovation Skills – The team will gain experience in documenting
technical findings, preparing patent drafts, and contributing to academic
publications.

5.3 Conclusion
The 4 DOF robotic arm for healthcare applications represents a significant advancement
in the integration of robotics, FPGA-based control, and vision-assisted automation for the
medical field. This system successfully combines precise motion control, real-time
monitoring, and advanced sensing to perform tasks that require both accuracy and
reliability in healthcare environments. By leveraging FPGA technology, the arm achieves
low-latency responses and high reliability, making it suitable for delicate operations such
as assisting in rehabilitation exercises, handling medical instruments, and supporting
telemedicine.

The inclusion of camera-based image processing enhances the system’s ability to detect,
track, and interact with objects, opening avenues for semi-autonomous operation. Once
fully implemented, the system has the potential to reduce human effort, improve patient
care precision, and provide valuable assistance in situations where direct human
intervention is limited or risky. This project lays a strong foundation for future
innovations in medical robotics and demonstrates the transformative role of automation
in healthcare.

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 PROJECT TIMELINE

6.1 Work Breakdown & Gantt Chart

Table 6.1 - Work Breakdown Structure and Gantt Chart

6.2 Individual Gantt Chart

Table 6.2 - Individual Contribution in the project

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