PNEUMATIC BASED SORTING SYSTEM USING TEMPERATURE SENSOR

Transcription

1 Introduction Chapter outline 1.1 What is sorting? 1.2Where it is used? 1.3Why it is required? Benefits?

2 2 1.1 What is sorting System? There are lots of definitions of sorting as below: 1. A group of persons or things of the same general character; a kind. 2. Character or nature: books of all sorts. 3. One that exemplifies the characteristics of or serves a similar function to another: "A large dinner-party... made a sort of general introduction for her to the society of the neighborhood" (George Eliot). 4. A person; an individual: The clerk is a decent sort. 5. To separate from others: sort out the wheat from the chaff. 6. An act or instance of sorting: did a sort on the columns of data. 7. To arrange according to class, kind, or size; classify. See Synonyms at arrange. 8. To clarify by going over mentally: She tried to sort out her problems. 1.2 Where it is used? In Mechanical industries different types of sorting system are used e.g. size sorting, color sorting, pressure sorting, humidity sorter etc. Sorting systems are used in, 1). Pharmaceutical industries 2). Agriculture industries. 3). Material Handling. 4). Casting industries. 5). Power plants. 6). Compressor Manufacturing Unit (Ingersoll Rand). 7). Shipping industries. 8). Defense.

3 3 9). Plasma Research Unit. 10). Indian space & research Organization. 1.3 Why it is required? Generally sorting systems acquire very less floor space, easy to operate, user friendly, accurate, reliable & precise. Ultimately these factors are necessary fast production, inspection & to decrease lead time. In nut shell sorting systems have these factors. That is why sorting systems are necessary for industries. Fig1.1 Matrial Handling Systeam

4 4 1.4 Benefits 1). Increasing in productivity. 2). Fast quality inspection. 3). 100% Chances to achieve six sigma. 4) Decrease in lead time. 5). Faster Production. 6). Sorting system can work for 24 hours continuously. 7). Better safety as they have emergency alarm system. 8). Engineer need not to continuously monitor the system as system itself is very intelligent.

5 5 2 Project Definition Chapter outline 2.1 How we got this idea? 2.2 Project Details. 2.3 How we are working on this Project.

6 6 2.1 How we got this idea? When we saw video of Apasara Manufacturing and Detect system on basis of pneumatics systems.we like it and We all wanted to make a semi automatic mechanical inspection system. Our key interest was in pneumatic systems & material handling systems. But in industries people are not using core pneumatic system, they are using ElectroPneumatic system. So at the end we decided to work on Pneumatic based sorting system using temperature sensor. Ultimately with help of this project we could learn ElectroPneumatic systems as well as sensor technology. So we can say that we learn Fluid machines as well as electrical things also. 2.2 Project Details: First of all we have to put our machined objects on the conveyor running by motor. Temperature sensor will sense the temperatures of objects. According to our logic fed in microcontroller, signal will be sent to the direction control valve via microcontroller. At the end direction control valve will pass the pressurized air to the pneumatic actuator and accordingly object will be removed. In this way this system will sort machined objects according to its temperature. 2.3 How we are working on this Project? This project is made of lots of different streams. Things are to be done or design as below in the form of project details. Very first we have to learn designing a motor conveyor. After that we have to design belt with appropriate materials & dimensions. Then motor with desired rpm, torque & current capacity. Finally we can have conveyor belt system for our temperature sorter. Second we have to learn ElectroPneumatic system. Deciding direction control valves, actuators, filter units, lubricator units, pressure regulator & Simulation of the system for faster design.

7 7 Third we have to learn about temperature sensors, its characteristics, its interfacing circuits, interfacing with solenoid valves etc.then at the last we have to learn about the microcontroller used in CNC. Ultimately we will program the microcontroller and according to its program it will control the system Our Project can be divided into four parts: 1) Pneumatic Systems (Fluid Mechanics). Fig2.1Basic pnumeatic systeam 2) Motor Conveyor (Design + Material Handling). Fig2.2 Conveyer belt

8 8 3) Temperature Sensor (Sensing Technology). Fig2.3 Temperature Sensor 4) Infrared senser Fig2.4 Infrared senser

9 9 5) Automation. Fig2.5 Automation.

10 Literature survey Chapter outline 3.1 History of sorting 3.2 Component list. Description Of Components

11 11 3.1History of sorting Sorting system is the part of material handling systems & also part of inspection system. So we could go through the history of material handling system. While there is no way to determine the origin of material handling as a concept, the industry of material handling goes hand-in-hand with commercial trade. As long as trade has been occurring, there has been a need to somehow handle the goods being exchanged. The roots of modern material handling begin with the industrial revolution. Skids and pallets were introduced early in the 20th century to replace wooden boxes, crates, barrels, and kegs, which had previously been used to store and transport goods. Before the mechanization of material handling, barrels had the advantage of being able to be tipped on their side and rolled as a means of transport. Textile sacks had been the primary means for storage and transport of granular products such as flour or feed. The pallet soon replaced many of these other types of unitizing equipment and became an integral part of the material handling industry. Corrugated containers became another monumental piece of material handling equipment. Corrugated paper was invented in the 1850s, and around the turn of the century, corrugated shipping containers began to replace their wooden counterparts. This new type of container greatly reduced packaging and shipping costs by switching to more inexpensive and lighter paper-based packaging materials. Fig3.1 History of sorting

12 Project Components: 1) 78 RPM 12 Volts DC motor for conveyor. 2) FRL unit for pneumatic system. 3) Storage cylinder (1.5 mm thick). 4) 10 meter Hoses (0.25 inch diameter). 5) 5/2 direction control valve with 12 volts solenoid (3 pieces). 6) Double acting pneumatic actuator (20 mm bore 75 mm stroke 3 pieces). 7) Relay circuits (4 circuits 12 volts). 8) Temperature sensor (LM35 5 volts 3 sensors). 9) 12 volts DC power supply. 10) Bread board (1 piece).

13 Component Description Pneumatic Component Description FRL Unit Specifications: Medium: Compressed air Mounting position: Vertical ± 5 Pressure range max.: 10 Bar Temperature nominal: -10 to 60 Fig3.2 Frl unit There are three types of air preparation processes. Filtering contaminants out of the air Regulating the air pressure level Lubricating the air

14 Filter: Fig3.3 As air flows under pressure, it carries particles called contaminants. These particles will cause damage to components throughout a pneumatic system Regulator Fig3.4 A pressure regulator has two functions.

15 15 To adjust the supply pressure to a desired level To maintain a constant air pressure Lubricator: Fig3.5 Pressurized air that enter the input port also enter the pilot line /2 Direction Control Valve:

16 16 A solenoid valve has two main parts: the solenoid and the valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the valve mechanically. A direct acting valve has only a small flow circuit, shown next page. Fig3.6 Direction Control Valve The media controlled by the solenoid valve enters the valve through the inlet port (Part 2 in the illustration above). The media must flow through the orifice (9) before continuing into the outlet port (3). The orifice is closed and opened by the plunger (7). The valve pictured above is a normally-closed solenoid valves. Normally-closed valves use a spring (8) which presses the plunger tip against the opening of the orifice. The sealing material at the tip of the plunger keeps the media from entering the orifice, until the plunger is lifted up by an electromagnetic field created by the coil.

17 Double Acting Pneumatic Cylinder: Fig3.7 Double Acting Pneumatic Cylinder General Once actuated, compressed air enters into the tube at one end of the piston and, hence, imparts force on the piston. Consequently, the piston becomes displaced (moved) by the compressed air expanding in an attempt to reach atmospheric pressure. Compressibility of gasses One major issue engineers come across working with pneumatic cylinders has to do with the compressibility of a gas. Many studies have been completed on how the precision of a pneumatic cylinder can be affected as the load acting on the cylinder tries to further compress the gas used. Under a vertical load, a case where the cylinder takes on the full load, the precision of the cylinder is affected the most. A study at the National Cheng Kung University in Taiwan, concluded that the accuracy is about ± 30mm, which is still within a satisfactory range but shows that the compressibility of air has an effect on the system.

18 18 Fail safe mechanisms Pneumatic systems are often found in settings where even rare and brief system failure is unacceptable. In such situations locks can sometimes serve as a safety mechanism in case of loss of air supply (or its pressure falling) and, thus abate any damage arising in such a situation. Due to the leakage of air from input or output reduces the pressure and so the desired output. Although pneumatic cylinders will vary in appearance, size and function, they generally fall into one of the specific categories shown below. However there are also numerous other types of pneumatic cylinder available, many of which are designed to fulfill specific and specialized functions. Single-acting cylinder Single-acting cylinders (SAC) use the pressure imparted by compressed air to create a driving force in one direction (usually out), and a spring to return to the "home" position. More often than not, this type of cylinder has limited extension due to the space the compressed spring takes up. Another downside to SACs is that part of the force produced by the cylinder is lost as it tries to push against the spring. Because of those factors, single acting cylinders are recommended for applications that require no more than 100mm of stroke length. Double-acting cylinders Double-acting cylinders (DAC) uses the forces of air to move in both extends and retract strokes. They have two ports to allow air in, one for outstroke and one for in stroke. Stroke length for this design is not limited. However, the piston rod is more vulnerable to buckling and bending. Addition calculations should be performed as well.

19 Electrical Component Description Relay circuit A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits, repeating the signal coming in from one circuit and re-transmitting it to another. Relays were used extensively in telephone exchanges and early computers to perform logical operations. A type of relay that can handle the high power required to directly control an electric motor or other loads is called a contactor. Solid-state relays control power circuits with no moving parts, instead using a semiconductor device to perform switching. Relays with calibrated operating characteristics and sometimes multiple operating coils are used to protect electrical circuits from overload or faults; in modern electric power systems these functions are performed by digital instruments still called "protective relays".

20 Temperature Sensor LM35: Fig3.7 Temperature Sensor LM35 is a precision IC temperature sensor with its output proportional to the temperature (in o C). The sensor circuitry is sealed and therefore it is not subjected to oxidation and other processes. With LM35, temperature can be measured more accurately than with a thermistor. It also possess low self heating and does not cause more than 0.1 o C temperature rise in still air. The operating temperature range is from -55 C to 150 C. The output voltage varies by 10mV in response to every o C rise/fall in ambient temperature, i.e., its scale factor is 0.01V/ o C Infrared senser: An infrared sensor is an electronic device that emits and/or detects infrared radiation in order to sense some aspect of its surroundings. Infrared sensors can measure the heat of an object, as well as detect motion. Many of these types of sensors only measure infrared radiation, rather than emitting it, and thus are known as passive infrared (PIR) sensors.

21 21 All objects emit some form of thermal radiation, usually in the infrared spectrum. This radiation is invisible to our eyes, but can be detected by an infrared sensor that accepts and interprets it. In a typical infrared sensor like a motion detector, radiation enters the front and reaches the sensor itself at the center of the device. This part may be composed of more than one individual sensor, each of them being made from pyroelectric materials, whether natural or artificial. These are materials that generate an electrical voltage when heated or cooled. These pyroelectric materials are integrated into a small circuit board. They are wired in such a way so that when the sensor detects an increase in the heat of a small part of its field of view, it will trigger the motion detector's alarm. It is very common for an infrared sensor to be integrated into motion detectors like those used as part of a residential or commercial security system. Most motion detectors are fitted with a special type of lens, called a Fresnel lens, on the sensor face. A set of these lenses on a motion detector can focus light from many directions, giving the sensor a view of the whole area. Instead of Fresnel lenses, some motion detectors are fitted with small parabolic mirrors which serve the same purpose. An infrared sensor can be thought of as a camera that briefly remembers how an area's infrared radiation appears. A sudden change in one area of the field of view, especially one that moves, will change the way electricity goes from the pyroelectric materials through the rest of the circuit. This will trigger the motion detector to activate an alarm. If the whole field of view

22 22 changes temperature, this will not trigger the device. This makes it so that sudden flashes of light and natural changes in temperature do not activate the sensor and cause false alarms Electronic Component Description: A)3.3.1 Microcontroller Arduino A microcontroller (sometimes abbreviated µc, uc or MCU) is a small computer on a single integrated circuit containing a programmable input/output peripherals. Program memory in the form of NOR FLASH or OTP ROM is also often included on chip, as well as a typically small amount of RAM. Microcontrollers are designed for embedded applications, in contrast to the microprocessors used in personal computers or other general purpose applications. Microcontrollers are used in automatically controlled products and devices, such as automobile engine control systems, implantable medical devices, remote controls, office machines, appliances, power tools, toys and other embedded systems. By reducing the size and cost compared to a design that uses a separate microprocessor, memory, and input/output devices, microcontrollers make it economical to digitally control even more devices and processes. Mixed signal microcontrollers are common, integrating analog components needed to control nondigital electronic systems. Arduino is a tool for making computers that can sense and control more no. of Inputs and outputs. It is based on a simple microcontroller board, and a development environment for writing software for the board. Arduino can be used to develop systems, taking inputs from a variety of switches or sensors, and controlling a variety of lights, motors, and other physical outputs.

23 23 In order to use Arduino with the MATLAB environment, one program named adio.pde (analog digital input output) must be transferred to the Atmel atmega168 microcontroller. This program is compatible with Matlab through class Arduino. Arduino class helps us to make real time working Object in which we can make changes in order to communicate with the I/O devices. These programs are provided by Matlab developer team as additional package. The programs can run only in Matlab 2008 or higher versions.

24 Role in our project. Chapter outline 4.1 Role of Conveyor-belt. 4.2 Role of Pneumatic Components. 4.3 Role of Electrical Components. Role of Electronics Components.

25 Role of Conveyor-Belt. (1)It is a material handling device. (2)It transfer object from one plac e to another via belt. (3)It maintain a transport load of object in required quqntity. (4)It handlling the object with automation with minimum man power or without man power 4.2 Role of Pneumatics Role of FRL unit. 1) It will filter the pressurized air coming from compressor. 2) It will also work as a pressure regulator, so it can regulate the pressure of filtered air. 3) It will provide lubrication to the regulated air so pneumatic component can live long lasting. 4). It is a safety unit for whole pneumatic system Role of Direction Control valve 1) It will sense an electrical signal coming from relay unit. 2) It will sense pass an air signal to the pneumatic actuator. 3) It will give a direction to the air signal as well electrical signal. 4) It will work as a gate between an electrical signal and air signal. 5) It will be acting as a crucial element for this unloading pneumatic system Role of Pneumatic Actuator 1) It will accept the air signal coming from Direction control valve. 2) It will quickly unload the object running on the conveyor. 3) Also after unloading the object quickly regain its original position and ready for the next operation.

26 Role of Electrical Components Temperature Sensor: 1) It will continuously sense temperature of an object running on a conveyor. 2) It will give an analog signal to the microcontroller unit. 3) Ultimately it gives an input signal in the form of temperature to the temperature sorting system Role of Relay in Our Project 1). Giving Supply to the direction control valve. 2). Interfaced with Arduino. 3). Breaking +5volts to +12 volts DC. 4). Conveyor Motor Forward &reverse motion. 4.4 Role of Electronics Components. 1). It will sense take signal from Temperature Sensor. 2). It will give fast outputs to the relay unit. 3). Communication between system & computer like CNC machines. 4). Displaying results on Serial LCD. Why Arduino??? 1)Very easy programming. 2)Small in size. 3)Easy to learn for mechanical students. 4)Easy to interface with other devices. 5)USB to USB communication.

27 Circuit Diagram & Operation Chapter outline 5.1 Relay Circuit Diagram & Operation. 5.2 Motor Circuit & Operation. 5.3 Block Diagram Air Signal Flow Diagram

28 Relay Circuit Diagram & Operation: Automatic actuation of pneumatic cylinder requires automatic actuation of solenoid. For that we need to write a program in the controller according to our position step diagram. Program will be thus transferred from microcontroller to the solenoid via a relay circuit, which ensures protection of the controller under fluctuating current. Fig5.1 Relay Circuit Controller output is in the form of bit. This output is fed to the relay circuit. Relay circuit is provided for safety of controller and switching of solenoids. Switching of the solenoids is actually taken care by a general purpose transistor. Diode prevents reverse flow of current.

29 29 Fig 5.2 Actual Snap of Relay Circuit When D0 is set, transistor will be forward bias enabling the flow of current through collector to emitter. The normally open contact closes & supplies power to solenoid. Solenoid actuates pneumatic DCV & it actuates pneumatic cylinder. 5.2 Motor Circuit & Operation:

30 30 Operation: In our project motor conveyor should run forward as well as reverse. To do so we have to use two relays & 4 contacts as given in above figure. When arduino will give supply to the first relay it will trigger only two forward contacts so conveyor will run forward. When arduino will give supply to the second relay it will trigger only two reverse contacts so conveyor will run reverse. 5.3 Block Diagram Temperature Sensor 5/2 Direction Control Valve Relay Circuit Pneumatic Cylinder Fig5.3 Block Diagram

31 Air Signal Flow Diagram: Compressor FRL 5/2 DCV Fig5.4 Air Signal Flow Diagram Double Acting Pneumatic Cylinder

32 Simulation Using Automsim Premium Simulator. Chapter outline 6.1Introduction to this software. Making Simulation of our project.

33 Introduction to this software: Integrated multi-instrument automation and experiment control with real-time data collection and data processing through a single application. Automation Studio software accelerates experimental workflows and improves R&D productivity by automating and controlling multiple laboratory instruments. The system handles data collection/storage, real-time data processing, data analysis, searching and reporting all within a single, easy-to-use application. Execute simple and complex protocols Create multiple custom interfaces. Run protocols and receive real-time feedback on process variables using an intuitive graphical user interface (GUI) that graphically renders the instrument. The simple instrument interface makes it straightforward for non-specialist, walk-up operators to execute standard, predefined tasks incorporating laboratory best practices. It is also easy to configure more complex interfaces for use by specialists executing More demanding workflows.

34 Making Simulation of our project: Fig 6.1 (a) Fig 6.1(b)

35 Programme Of Arduino 7.1 Programming Specification Of Arduino.

36 Programming: int a=8,b=9,c=10,d=2,e=3; int pin0=0; int pin1=1; int tempc1=0,tempc2=0; int samples1[8]; // variables to make a better precision int samples2[8]; int maxi = -100,mini = 100; // to start max/min temperature int i; int j; int val1=0; int val2=0; void setup() { Serial.begin(9600); // start serial communication pinmode(a,output); // Motor Forward pinmode(b,output); // S1 pinmode(c,output); // S2 pinmode(d,input); // IR 1 pinmode(e,input); // IR 2 } void loop() {

37 37 val1=digitalread(d); val2=digitalread(e); digitalwrite(a,high); digitalwrite(b,low); digitalwrite(c,low); Serial.println("Motor is runnig"); if(val1==high) { Serial.println("IR1 Detected"); Serial.println("Motor Stop"); digitalwrite(a,low); // motor stop for(i=0;i<=7;i++) { samples1[i] = ( 5.0 * analogread(pin0) * 100.0) / ; tempc1 = tempc1 + samples1[i]; delay(1000); } tempc1 = tempc1/8.0; // better precision Serial.println(float(tempC1)); if (tempc1>=25) {

38 38 digitalwrite(b,high); Serial.println("Cylindder1 Forwrad"); delay(4000); digitalwrite(b,low); Serial.println("Cylindder1 Retracted"); delay(2000); } tempc1=0; delay(100); // delay before loop } else if(val2==high) { Serial.println("IR2 Detected"); digitalwrite(a,low); Serial.println("Motor Stopped"); for(j=0;j<=7;j++) { samples2[j] = ( 5.0 * analogread(pin1) * 100.0) / ; tempc2 = tempc2 + samples2[j]; delay(100); }

39 39 tempc2 = tempc2/8.0; // better precision Serial.println(float(tempC2)); if (tempc2<=50) { digitalwrite(c,high); Serial.println("Cylindder2 Forwrad"); delay(4000); digitalwrite(c,low); Serial.println("Cylindder2 Retracted"); delay(2000); } tempc2=0; delay(100); // delay before loop } Serial.println(" Second Loop Started"); delay(1000); }

40 40 Specification Microcontroller Operating Voltage ATmega168 5V Input Voltage (recommended) 7-12 V Input Voltage (limits) Digital I/O Pins 6-20 V 14 (of which 6 provide PWM output) Analog Input Pins 6 DC Current per I/O Pin DC Current for 3.3V Pin Flash Memory SRAM EEPROM Clock Speed 40 ma 50 ma 16 KB (of which 2 KB used by bootloader) 1 KB 512 bytes 16 MHz Components FIG.7.1 COMPONENT OF ARDUINO

41 Design And Modification 8.1 Design Of Conveyor 8.2 problem Related To Design. Implemention

42 Desgin Of Conveyor. It Is Group Of Device With No Lifting Gear Used For Moving Horizontal Load In A Continous Flow.

43 PROBLEM RELATED TO DESIGN 1)It Does Not Provide Proper Gripping 2)There Is A Slaging In Belt After Long Duration. 3)There Is A No Providing Mechanism For Belt Tighting 4)Belt Are Play On Roller. 5)More Vibration Generated So Shaft Of Roller Will Twisted.

44 Implemention:

45 45 Sectional View:

46 Advantages, Applications, Limitations &Future Scope 9.1 Advantages. 9.2 Limitations. 9.3 Application. 9.4 Conclusion Future Scope

47 47 9.1Advantages: 1)Increasing Productivity. 2) Decreasing Lead Time. 3)Good Reliability. 4)Better Accuracy than human being. 5)Consumes very less time. 6)Precision sensing. 9.2limitations: 1)Temperature sensors take lots of time for accurate sensing. 2)Air leakage problems in pneumatics. 3)Higher current from battery lead failure of solenoid valve. 4)Noisy system without silencers. 5)Temperature sensor is having nonlinear characteristics after a certain temperature. 9.3 Applications: 1)Casting industries. 2)Machining industries. 3)Pharmaceutical industries. 4)Different metallurgical applications.

48 Conclusion: After designing the current sorting system, it can be concluded that, 1). System works on advanced Technology. 2). User Friendly. 3). Easy Programming. 4). Quick Pneumatic Operation. 5).Less Floor space. 6). Better than conventional temperature sorting systems. 7). Accurate & Reliable results. 9.5 Future Work: 1) Making Graphical User Interface for this software. 2) Making conveyor with gear system & using servo motors. 3) Use of higher degree of freedom temperature sensor. 4) Flow control valve in pneumatic system. 5) Production analysis of this system. 6) Quality, Inspection & agronomical analysis 7) Finding Reliability of this system.

49 49 Reference websites:

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