Mechanical Engineering project

Capstone Project

Lovely Professional University (Punjab)

Project Domain: Mechatronics

Sub-Domain: Material Handling

Project Title: Nut Sorting Machine

Project Mentor: Mr. Harinder Pal Singh

Asst. Professor - LSME, Lovely Professional

University, Punjab

Project Undertaken By: Manpreet Singh 11001082

January-May

2014

NUT SORTING MACHINE

CAPSTONE PROJECT

Submitted in Partial Fulfillment of the

Requirement for Award of the Degree

Of BACHELOR OF TECHNOLOGY/MASTER OF TECHNOLOGY

In

MECHANICAL ENGINEERING

By

Manpreet Singh 11001082

Under the Guidance of

Mr. Harinder Pal Singh

DEPARTMENT OF MECHANICAL ENGINEERING

LOVELY PROFESSIONAL UNIVERSITY

PHAGWARA, PUNJAB (INDIA) -144402

2014

Capstone Project | SME ii

School of Mechanical Engineering | Lovely Professional University

Lovely Professional University Jalandhar, Punjab

CERTIFICATE

I hereby certify that the work which is being presented in the Capstone project entitled “Nut

Sorting Machine” in partial fulfillment of the requirement for the award of degree of

Bachelor of technology and submitted in Department of Mechanical Engineering, Lovely

Professional University, Punjab is an authentic record of my own work carried out during

period of Capstone under the supervision of Mr. Harinder Pal Singh, Assistant Professor,

Department of Mechanical Engineering, Lovely Professional University, Punjab.

The matter presented in this dissertation has not been submitted by me anywhere for

the award of any other degree or to any other institute. .

Date: Manpreet Singh 11001082

This is to certify that the above statement made by the candidate is correct to best of

my knowledge.

Date: Mr. Harinder Pal Singh

Supervisor

The B-Tech Capstone project has been held on

Signature of Examiner

Capstone Project | SME iii


Acknowledgement

Final year Capstone project comes as one of the most valuable phase in the making of an

engineer. The very concept accentuates the correlation of theoretical concepts with the

practical dimensions of their application. This remains to be the key reason for it holding

utmost significance in the development of a promising engineer. As a part of the process, it

becomes particularly important to get the right kind of environment, offering genuine support

& cooperation for successful accomplishment of the anticipated intent. An exact

reciprocation was extended to us by Lovely Professional University, Punjab during the period

Sep-Dec, 2013.

A project is branded by the contributing members associated with it. That being said, I would

by no means overlook any opportunity to acknowledge the efforts of a few esteemed

individuals who have impressed upon their persona as nothing short of exemplified

inspiration & motivation, truly acting as impetus to our project.

Dr. Gurpreet Singh Phull: HOS, SME, Lovely Professional University

Mr. Harinder Pal Singh – Project Mentor: Asst. Prof., SMEM, Lovely Professional University

Mr. Sunil Setia – Asst. Prof., Lovely Professional University

Mr. Jaiinder Preet Singh: COD – SME, Lovely Professional University

Mr. Piyush Gulati: COD – SME, Lovely Professional University

Mr. Rajiv Kumar: Capstone Project Coordinator - Lovely Professional University

Capstone Project | SME iv


Taking into consideration a project of this scale, ‘Every drop of water counts’, hence we

convey our heartfelt gratitude & appreciation to ‘Logitech Electronics’ for providing us this

excellent opportunity to share their embedded system workshop to work to automation.

Lastly, at this dependent juncture in life, all developments may appear to be the consequence

of one’s own actions but in fact are disguised outcomes concealing the invaluable efforts, co -

operation, patronage & boundless encouragement endowed by our Families. Words fall short

to affirm credibility to articulate their consistent role in each & every success of an

individual. Bearing the same reflection, we would like to communicate our indebted

thankfulness to our Families, without the unimpeded support none of this would

have been remotely possible.

Manpreet Singh 11001082 B Tech ME Hons

Capstone Project | SME v


Preface

In order to address way to cater with the limited man power, increasing competition and

decreasing profits caused by invention of latest technology, three key policy avenues are

considered to be appropriate to meet the challenge of sustainable manufacturing industry for

the future: reduction of human power; shift to automation; and, improvement of material

handling systems.

From the viewpoint of reducing human effort and improvement in material handling system

automation has become very important need. In fact, automation is not a recent invention. It

has a history as old as that of the conventional machining. However, taking the negative effects

of conventional machining into account, automation has been recognized by many in the

nascent manufacturing industry. Developed industries are increasingly supportive in this

department because automotive manufacturing development is vital economic opportunity.

To integrate automation in the current urban manufacturing system, a series of appropriate

measures should be taken not only in the machining and packing, but also in material handling.

This not only reduces manufacturing cost but also increase quality of the manufactured

products.

Thus in order to provide industries the same benefit we have tried to make a nut sorting

machine based on the principles of electronic and mechanical science.

Capstone Project | SME vi


Abstract

One of the exciting work that a mechanical engineer would like to do in the field of

Mechatronics can be The Nut Sorter Project.

The goal of the project is to design a Mechatronics system that can sort nut of different sizes

and types. It would also be able to detect other objects in the process and reject them. The

project will be aimed to provide the industry a real machine for direct use in packaging

department at very economical price

The components of this nut sorter will be

sensors,

stepper and DC motors and

some basic electronic components.

The project will be emphasized to function at optimum speed, accuracy and design.

This sorter works based on the shadow a nut casts. Depending on the size of the shadow, the

nut is dispensed into the respective bin.

Capstone Project | SME vii


Executive Summary

As part of our Final Year Mechanical Engineering project, we studied the problems faced by

the assembling industries related to the material handling of the parts used like hardware which

are difficult to sort mechanically and selected topic as well as completed individual research

and study on the theories of the topic. After thorough study was conducted we were able to

design and develop our own working model of the automatic nut sorting machine. We’ve

explored the machine frame and body fabrication, motor, storage system, guiding system, and

electrical and control systems. The team has come to the conclusion that it is best for both the

short and long term that we work on improving the material handling system.

For this conceptual design, the deliverables are as follows:

· Fabrication model refinement.

· Suitable material & equipment selection & procurement.

· Prototyping & development.

· Model, diagram and documentation of the Electrical System.

· Complete or refine circuit protection for the electrical and control systems.

· Combining & simplifying the multiple fragmented control circuits.

· Exceptional performance feature – Sensor based handling

The merits of the design will include much enhanced user ability to control and use,

higher efficiency, reduced chances for circuit failure, and a knowledge database that will be

passed to future projects to be undertaken.

Capstone Project | SME viii


Abbreviations & Symbols

AC: Alternating Current

DC: Direct Current

LED: Light Emitting Diode

CCD: Charged Coupled Device

LDR: Light Dependent Resistor

IC: Integrated Circuit

VR: Voltage Regulator

PCB: Printed Circuit Board

MCU: Microcontroller

ROM: Random Access Memory

CMOS: Complementary Metal Oxide Semiconductor

POT: Potentiometer

Op AMP: Operation Ampliphier

Capstone Project | SME ix


List of Figures

Figure 1.1 Different types of products undergo sorting in the industry……………….. 3

Figure 1.2 Nut Sorter……………………………………………………………….. 4

Figure 1.3….……………………………………………………………………………… 5

Figure 1.4..………………………………………………………………………………… 5

Figure 1.5……………………………………………………………………………….… 6

Figure 1.6……………………………………………………………………………… 6

Figure 1.7………………………………………………………………………………… 6

Figure2.1: Block Diagram Microcontroller……………………………………………… 13

Figure2.2: Pin Diagram AT89C51………………………………………………………… 14

Figure2.3: Types of resistors ………………………………………………………...…… 15

Figure2.4: Variable Resistor…………………………………………………………… 16

Figure2.5: Polar Capacitor………………………………………………………………… 16

Figure2.6: Non Polar Capacitor…………………………………………………………… 16

Figure2.7: Electrolytic Capacitor……………………………………………………… 17

Figure2.8: Ceramic capacitor…………………………………………………/………… 17

Figure2.9: IN4001 Diode……………………………………………………………… 18

Figure2.10: OP-AMP as comparator …..………………………..…………………… 19

Figure2.11: Pin Diagram of LM324…………………………………………………… 19

Figure2.12: Primary and Secondary windings of Transformer………………………… 20

Figure2.13: Symbol of Transistor…………………………………………………… 21

Figure2.14: Description of terminals of Transistor……………………………………… 21

Figure2.15: Types of LED S…………………………………………………………….. 21

Figure2.16: Pin description of LM7805………………………………………………… 22

Figure2.17: Circuit Diagram of Power Supply…………………………………………… 22

Figure2.18: DC Motor and its internal structure……………………………………… 24

Figure2.19: H-Bridge circuit……………………………………………………………… 25

Capstone Project | SME x


Figure2.20: The two basic states of an H bridge………………………………………… 25

Figure 2.21; Servo Motor drive…………………………………………………………. 27

Figure 2.22: General LDR…………………………………………………………….. 27

Figure 3.1 Basic Transformer………………………………………………………….. 28

Figure 3.2 Circuit Diagram of Power supply…………………………………………… 28

Figure 3.3 Sensor LDR and LED as in the Machine…………………………………… 29

Figure 3.4 General layout of comparator circuit………………………………………… 29

Figure 3.5 Comparator as used in the Machine………………………………………… 30

Figure 3.6 General Layout of the LM 8051…………………………………………….. 30

Figure 3.7 Microcontroller as used in the Machine……………………………………… 31

Figure 3.8 Guide Tube …………………………………………………………………… 31

Figure 3.9 General layout of Circuit diagram…………………………………………… 32

Capstone Project | SME xi


List of Tables

Table 1.1…………………………………………………………………………………..5

Table 1.2…………………………………………………………………………………..6

Table 1.3…………………………………………………………………………………..6

Table 1.4 Project Charter………………………………………………………………….11

Table 2.3: Logic table for DC motor……………………………………………………...26

List of Flow Charts

Flow Chart 1.1 General Layout of the Nut Sorting Machine…….………………………...3

Flow Chart 1.7……………………………………………………………………………...9

Table of Contents

Acknowledgement III

Preface V

Abstract VI

Executive Summary VII

Abbreviations & Symbols VIII

List of Figures IX

List of Tables XI

List of Flow Chart XI

Table of Contents 1

1.) Introduction 3

1.1) Sorting 4

1.2) Some of the examples used in industries 5

1.3) Problem Statement 7

1.4) Scope Of the Machine 7

1.5) Project Objective 8

1.6) Flow Chart 9

1.7) Complete Work Plan 10

2.) Literature 12

2.) Hardware Description 12

2.1) Microcontroller (mcu) 12

2.2) Resistors 15

2.3) Capacitors 16

2.4) Diode 17

2.5) LM324 (OPERATIONAL AMPLIFIER) 18

2.6) Transformer 19

2.7) Transistor 20

2.8) LED 21

2.9) Voltage Regulator 22

2.10) Power Supply 22

2.11) DC Gear motor 24

2.12) Servo Drive 26

2.13) LDR 27

3.) Working of the machine 28

3.1) Transformer 28

3.2) Power Supply 28

3.3) Sensor LDR 29

Capstone Project | SME 2


3.4) Comparator 29

3.5) Microcontroller 30

3.6) Guide 31

3.7) Program for algorithms of

microcontroller

33

4.) Conclusion & Discussion 36

4.1) Application 36

4.2) Advantage 36

4.3) Future Scope 36

4.4) Conclusion 37

5.) References & Bibliography 38



Introduction

With the rising competition in the every industry the need of automation is becoming very

important. Automation in industries began many years ago but in earlier days it was focused to

production of precise jobs, but now when the industries are not only looking to maintain

quality but also reducing cost of production the need of automation is begin released in very

aspect not only in manufacturing but in packaging and material handling.

Moving to the fasteners packaging and handling, fastener industry produces huge variety of

jobs not only different in physical or chemical properties but having small variation in size

with all other parameters remaining same, in this scenario the need of creating cheap and

reliable equipment is becoming of prime importance.

Now getting particularly to nut they can be of huge variety only by change in the hole

diameter, which if mingled can become very cumbersome job.

To provide automation we observed that with change in diameter the height og nut also

changes and this can be used to detect the dimensional variation by using very cheap and

reliable sensor and in accordance to this idea we designed the automated nut sorter machine

Flow Chart 1.1 General Layout of the Nut Sorting Machine

Figure 1.2 Nut Sorter Machine

Transfo

rmer

Compar

ator

Sensor

Power

Supply

Microco

ntroller

AC to DC

converto

r

Gear

Motor

Servo

Motor

Rotor

Guide

C

o

n

t

a

i

n

e

r



Sorting

Sorting is any process of arranging items according to a certain sequence or in different sets,

and therefore, it has two common, yet distinct meanings:

1. Ordering: arranging items of the same kind, class or nature, in some ordered sequence,

2. Categorizing: grouping and labeling items with similar properties together (by sorts).

The main purpose of sorting information is to optimize its usefulness for specific tasks.

Sorting can be of any product and can be done by using various methods.

In this report sorting of fastener – Nut is given main emphasis.

Sorting In fasteners industries

Optical sorting machine can also be used to do automatic sorting. The optical sorting machine

product line offers users flexibility over a wide range of parameters that can be measured as

well as sorting machines that are designed specifically for certain objects such as screws, rivets

or bolts. One sorting system from the optical sorting machine product line is designed to

discriminate metallic objects based on hardness. Each optical sorting machine offers powerful

technology to any production line.

Figure 1.2 Different types of products undergo sorting in the industry

Inspection parameters

• Diameter, Hole diameter • Length

• Width • Height, Thickness

• Surface defect • Deformed, Broken

• Different shape • Crack

• Burrs, Chips • Across Corner

• Across Flat • Chamfer angle

• Included angle • Arc radius

• Concentricity • Roundness

• With coating • With mark



• With cut/tapering • Parallel edge length

• Broken pin, Recess depth • With thread

• Fine or coarse thread • Thread numbers

• Pitch • Slanted thread

• Minor diameter • Major diameter

• Hardness • Recognition of different materials

• Heat treatment

Some of the examples used in industries

Optical Sorting Machine QSS-C07

This optical sorting machine measures all the standard parameters (see above). It is designed

for nuts, rivets, rollers, washers, studs and objects that can sit stably on a conveyor belt.

Table 1.1

Figure 1.3 Figure 1.4



Optical Sorting Machine QSS-D07

This optical sorting machine measures all the standard parameters (see above). It is designed

for screws, bolts, bolts and nuts, bolts and washers.

Table 1.2

Figure 1.5 Figure 1.6

Automatic Sorting Machine QSS-V08

This automatic sorting machine measures hardness,

differences in material (composition) and whether or

not the object has been heat treated or not.

Table 1.3

Figure 1.7



Problem Statement

To evaluate & analyse the viability of automation system in sorting fasteners which are time

consuming to sort mechanically.

Fasteners are the basic hardware for any sector of fabrication or construction society. Fasteners

are used in all the industries for its specific use.

There are various size of fasteners used in the industries and due to the close variation in

dimensions they can easily be mixed if not taken care and once they are mingled it can be

cumbersome and time consuming to sort them.

Scope of the Machine

The machine can solve the problem of time consumption and

Waste of resources in face of labor cost

The machine can be used

In the industry where it is manufactured , at the packaging sector.

Where it is used as hardware in large quantity like in fabrication of machine

Construction of buildings and towers where nuts of close dimension are used



Objectives of the study

Project Title

Design & Development of an Efficient industrial NUT SORTING MACHINE.

Project Objective

General Objective

1. To cater to the issue of competition in mechanical industry the need for automation is assess

by all the industry

2. To identify the key policy avenues considered to be appropriate to meet the challenge

of sustainable manufacturing and packaging industry for the future.

3. To provide alternative for industries aiming toward reducing human effort and

improvement in material handling system by implementing automation

4. Sustainable and practical automation solutions for the future industrial environment.

Technical Objectives

1. Design & Analysis.

2. Prototyping, fabrication & development.

3. Adding functionality for enhanced utility.



System Flow Chart

Flow Chart 1.2

Concept Selection



Complete Work Plan

Project Charter

Project Title Business Unit

Nut Sorting Machine

Mechatronics

and

Material Handling

Project Support Structure Business Case

Project

Mentor

Mr. Harinder Pal Singh, Asst.

Professor, LSME - Lovely

Professional University, Punjab From the viewpoint of competition in mechanical

industry the need for automation is assess by all the

industry. It is also important from the viewpoint

of reducing human effort and improvement in

material handling system automation has

become very important need

To integrate automation in the current urban

manufacturing system, a series of appropriate

measures should be taken not only in the

machining and packing, but also in material

handling

Project

Team

Manpreet Singh & Abhishek

Planning Manage-

ment

Decision

Making

Mandeep Singh & Sushant

Procure-

ment Execution Logistics

Darshprit Singh

Finance Content

Database

Procure-

ment

Collective

Misc Resource Execution

Technical

Aid

Logistic Electrical, Ludhiana,

Punjab

Shubham Yadav, Btech ME

(4th Yr) LPU, Punjab

Problem Statement

To evaluate & analyze the viability of a personal cost effective two-wheel plug-in electric vehicle

prototype for short distance applications such as campus mobility.

Project Objective

1.) To cater to the issue of limited fossil fuel availability, increasing CO2 emissions and air & noise

pollution caused by conventional vehicles with combustion engines.

2.) To identify the key policy avenues considered to be appropriate to meet the challenge of sustainable

urban transport for the future.

3.) Reduction of travel distance; Transition to environment friendly transport modes; and, Improvement

of fuel and vehicle technologies.



Project Scope

Is Is Not

To review the work advancements till date on

subject matter & proceed accordingly.

To review work advancements in alternatives such

as mechanical sorter, optical sorter,etc.

To design & analyse a prototype to assess

feasibility for long term applications.

To design & analyse a prototype to assess

feasibility for long range applications.

To maintain efficiency, cost-effectiveness. To optimize efficiency, escalate cost.

Deliverables Support Required

Design & Analysis. Mr.

Harinder

Pal Singh

Asst. Professor, SME, LPU

Prototyping, fabrication & development. Design & Analysis (Estimate 3-4 days)

Added functionality for enhanced utility.

Road Map

Activity Plan Timeline

Project Start Saturday, September 7, 2013 Targeted Months

Status Project End Friday, December 13, 2013 February March April

Define

Project topic selection, finalisation

Complete

Literature review & related content

Complete

Brainstorming - Idea development

Complete

Detailed concept selection & design

Complete

Measure Costing & budgeting

Complete

Analyse

Analysis - Design & failure

On going

Prototype fabrication, development

On going

Identification of real time problems

On going

Improve

Contingent design modifications

Planning

Correction of problems identified

On going

Control

Mentor-Team interaction sessions

On going

Aesthetics & finishing

Planning

Conclusion & future scope

Planning

Documentation & report

On going

Report revision & presentation

Complete

Prepared by: Gravity Group ME

(4th Yr), LPU, Punjab Date: 24-4-14

Validated by: Mr. Harinder Pal Singh

Asst. Prof, SMEM, LPU, Punjab

Table 1.4 Project Charter



Literature

HARDWARE DESCRIPTION

Material Used

1. Microcontroller

2. Transformer

3. LDR

4. Servo Drive

5. Capacitor

6. Voltage Regulator (7805)

7. Resistors

8. LED

9. LM324 (Comparator)

10. IC bases

11. Transistors

12. Gear Motors(100rpm)

13. Ribbon wire

14. Soldering Iron

15. Soldering Wire

16. Multimeter

17. PCB

18. Screw & Nuts

The detailed description of the components is given:

2.1 MICROCONTROLLER (MCU)

The Intel 8051 is an 8-bit microcontroller available in DIP (dual in-line package) form.8051

can all be programmed using 8051 assembly language as well as embedded C++. Once the

microcontroller is programmed it acts as the brain of the system. We are stepping towards the

automation we need a body that centrally controls the full device and in this project we use



microcontroller 8051 for the same purpose. The block diagram of a typical microcontroller,

which is a true computer on a chip is shown in fig 2.1. The design incorporates all of the

features found in micro-processor CPU, ALU, PC, SP, and registers. It also added the other

features needed to make a complete computer: ROM, RAM, I/O,timer & counters,and clock

circuit.

Figure2.1: Block Diagram Microcontroller

2.1.1 8051 MICROCONTROLLER

The AT89C51 is a low-power, high-performance CMOS 8-bit microcontroller with

8Kbytes of in-system programmable Flash memory. The device is manufactured using Atmel’s

high-density non-volatile memory technology and is compatible with the industry-standard

80C51 instruction set and pin out. The on-chip Flash allows the program memory to be

reprogrammed in-system or by a conventional non-volatile memory programmer. By

combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip, the

Atmel AT89C51 is a powerful microcontroller which provides a highly-flexible and cost-

effective solution to many embedded control applications. The AT89C51 provides the

following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog

timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt

architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the

AT89C51aa is designed with static logic for operation down to zero frequency and supports

two software selectable power saving modes. The Idle Mode stops the CPU while allowing the

RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power-

down mode saves the RAM contents but freezes the oscillator, disabling all other chip

functions until the next interrupt or hardware reset.

2.1.2 FEATURES

1. 8K Bytes of In-System Programmable (ISP) Flash Memory

2. Endurance: 1000 Write/Erase Cycles

3. 4.0V to 5.5V Operating Range

4. Fully Static Operation: 0 Hz to 33 MHz

5. Three-level Program Memory Lock

6. 256 x 8-bit Internal RAM

7. 32 Programmable I/O Lines



8. Three 16-bit Timer/Counters

9. Eight Interrupt Sources

10. Full Duplex UART Serial Channel

11. Low-power Idle and Power-down Modes

12. Interrupt Recovery from Power-down Mode

13. Watchdog Timer

14. Dual Data Pointer

15. Power-off Flag

16. Fast Programming Time

17. Flexible ISP Programming

2.1.3 PIN CONFIGURATION OF 8051 MICROCONTROLLER

Figure2.2: Pin Diagram AT89C51



2.1.4 WHY 8051 ?

1. Meeting the computing needs of the task efficiently and cost effectively

2. Speed, the amount of ROM and RAM, the number of I/O ports and timers, size,

packaging, power consumption.

3. Easy to upgrade.

4. Availability of software development tools

5. Assemblers, debuggers, C compilers, emulator, simulator, technical support.

2.2 RESISTORS

The flow of charge (or current) through any material, encounters an opposing force similar in

many respect to mechanical friction. This opposing force is called resistance of the material. It

is measured in ohms. In some electric circuits resistance is deliberately introduced in the form

of the resistor.

2.2.1 CARBON RESISTORS:

Carbon resistors are divided into three types:

a. Carbon composition resistors are made by mixing carbon grains with binding material

(glue) and moduled in the form of rods. After this an insulating material seals the

resistor. Resistors are available in power ratings of 1/10, 1/8, ¼ , 1/2 , 1.2 watts and

values from 1 - 20 ohms.

b. Carbon film resistors are made by deposition carbon film on a ceramic rod. They are

cheaper than carbon composition resistors.

c. Cement film resistors are made of thin carbon coating fired onto a solid ceramic

substrate. The main purpose is to have more precise resistance values and greater

stability with heat. They are made in a small square with leads.

Figure2.3: Types of resistors

2.2.2 VARIABLE RESISTORS:

A variable resistor is a device that is used to change the resistance according to our needs in an

electronic circuit. It can be used as a three terminal as well as a two terminal device. Mostly



they are used as a three terminal device. Variable resistors are mostly used for device

calibration

It has a resistive element as the track and a sliding contact called the wiper. The wiper is

connected with the help of another sliding contact to another terminal. The position of the

wiper depends on the type of POT used. For a panel POT, the wiper is kept in the middle. The

resistive element has a terminal on both the ends and can be linear or logarithmic. It is usually

made up of carbon or a mixture of ceramic and metal or even graphite.

Figure2.4: Variable Resistor

2.3 CAPACITORS

A capacitor can store charge, and its capacity to store charge is called capacitance. Capacitors

consist of two conducting plates, separated by an insulating material (known as dielectric). The

two plates are joined with two leads. The dielectric could be air, mica, paper, ceramic,

polyester, polystyrene, etc. This dielectric gives name to the capacitor like paper capacitor,

mica etc.

Types of Capacitors- Capacitors are of two types Fixed and Variable capacitor.

Fixed types of capacitor are further of two types:-

POLAR CAPACITOR: Those capacitor have polarity are known as polar capacitor.

Electrolytic capacitor are the example of polar capacitors.

Figure2.5: Polar Capacitor

NON POLAR CAPACITOR: Those capacitor have no polarity are known as non-polar

capacitor. Ceramic capacitor are the example of non polar capacitors

Figure2.6: Non Polar Capacitor

ELECTROLYTIC CAPACITOR: Electrolytic capacitors have an electrolyte as a dielectric.

When such an electrolyte is charged, chemical changes takes place in the electrolyte. If it’s one



plate is charged positively, same plate must be charged positively in future. Non-electrolyte

capacitors have dielectric material such as paper, mica or ceramic. Therefore, depending upon

the dielectric, these capacitors are classified.

Figure2.7: Electrolytic Capacitor

CERAMIC CAPACITOR: Such capacitors have disc or hollow tabular shaped dielectric made

of ceramic material such as titanium dioxide and barium titanate. Thin coating of silver

compounds is deposited on both sides of dielectric disc, which acts as capacitor plates. Leads

are attached to each sides of the dielectric disc and whole unit is encapsulated in a moisture

proof coating. Disc type capacitors have very high value up to 0.001uf. Their working voltages

range from 3V to 60000V. These capacitors have very low leakage current. Breakdown voltage

is very high.

Figure2.8: Ceramic capacitor

2.4 DIODE

Diodes are semiconductor devices which might be described as passing current in one direction

only. Diodes have two terminal, an anode and a cathode. The cathode is always identified by a

dot, ring or some other mark. Diode is a unidirectional device. In this current flows in only one

direction.

Diodes can be used as voltage regulators, tuning devices in RF tuned circuits, frequency

multiplying devices in RF circuits, mixing devices in RF circuits, switching applications or can

be used to make logic decisions in digital circuits. There are also diodes which emit "light", of

course these are known as light-emitting-diodes or LED's.

A rectifying diode of the 1N4001-07 ( 1A) type or even one of the high power, high current

stud mounting types. You will notice the straight bar end has the letter "k", this denotes the

"cathode" while the "a" denotes anode. Current can only flow from anode to cathode and not in

the reverse direction, hence the "arrow" appearance. This is one very important property of

diodes.



The principal early application of diodes was in rectifying 50 / 60 Hz AC mains to raw DC

which was later smoothed by choke transformers and / or capacitors. This procedure is still

carried out today and a number of rectifying schemes for diodes have evolved, half wave, full

wave and bridge, full wave and bridge rectifiers.

1N400X series Diode:-

2.4.1 FEATURES

i. Diffused Junction

ii. High Current Capability and Low Forward Voltage Drop

iii. Low Reverse Leakage Current

iv. Lead Free Finish

Figure2.9: IN4001 Diode

2.5 LM324 (OPERATIONAL AMPLIFIER)

LM324 is a 14 pin IC consisting of four independent operational amplifiers (op-amps)

compensated in a single package. Op-amps are high gain electronic voltage amplifier with

differential input and, usually, a single-ended output. The output voltage is many times higher

than the voltage difference between input terminals of an op-amp.

These op-amps are operated by a single power supply and need for a dual supply is eliminated.

They can be used as amplifiers, comparators, oscillators, rectifiers etc. The conventional op-

amp applications can be more easily implemented with LM324. Application areas include

transducer amplifiers, DC gain blocks and all the conventional op amp circuits which now can

be more easily implemented in single power supply systems. For example, the LM324-N series

can be directly operated off of the standard +5V power supply voltage which is used in digital

systems and will easily provide the required interface electronics without requiring the

additional ±15V power supplies.



Figure2.10: OP-AMP as comparator Figure2.11: Pin Diagram of LM324

2.5.1 OP-AMP COMPARATOR CIRCUIT WORKING

A comparator circuit compares two voltages and outputs either a 1 (the voltage at the plus side;

VDD in the illustration) or a 0 (the voltage at the negative side) to indicate which is larger.

Comparators are often used, for example, to check whether an input has reached some

predetermined value. In most cases a comparator is implemented using a dedicated comparator

IC, but op-amps may be used as an alternative. Comparator diagrams and op-amp diagrams use

the same symbols.

Figure shows a comparator circuit. The circuit does not use feedback. The circuit amplifies

the voltage difference between Vin and VREF, and outputs the result at Vout. If Vin is greater

than VREF, then voltage at Vout will rise to its positive saturation level; that is, to the voltage

at the positive side. If Vin is lower than VREF, then Vout, will fall to its negative saturation

level, equal to the voltage at the negative side. In practice, this circuit can be improved by

incorporating a hysteresis voltage range to reduce its sensitivity to noise

2.6 TRANSFORMER

Transformer works on the principle of mutual inductance. We know that if two coils or

windings are placed on the core of iron, and if we pass alternating current in one winding, back

emf or induced voltage is produced in the second winding. We know that alternating current

always changes with the time. So if we apply AC voltage across one winding, a voltage will be

induced in the other winding. Transformer works on this same principle. It is made of two

windings wound around the same core of iron. The winding to which AC voltage is applied is

called primary winding. The other winding is called as secondary winding. Transformers are of

two types Step Up transformer and Step Down transformer.



Figure2.12: Primary and Secondary windings of Transformer

STEP UP TRANSFORMER: These transformers are used to increase the voltage level at the

output means Voltage at secondary winding is more than the primary winding. In this

transformer secondary winding has more number of turns than primary winding. These types

of transformers are generally used in power station.

STEP DOWN TRANSFORMER: These transformers are used to decrease the voltage level at

the output winding means voltage of secondary winding is less than the primary winding. In

this transformer secondary winding has less number of turns than primary winding. These

types of transformers have major applications in electronics industry.

2.7 TRANSISTOR

The schematic representation of a transistor is shown. Note the arrow pointing down towards

the emitter. This signifies it's an NPN transistor. A transistor is basically a current amplifier.

Say we let 1mA flow into the base. We may get 100mA flowing into the collector. Note: The

currents flowing into the base and collector exit through the emitter (sum off all currents

entering or leaving a node must equal zero). The gain of the transistor will be listed in the

datasheet as either βDC or Hfe. The gain won't be identical even in transistors with the same part

number. The gain also varies with the collector current and temperature.



Figure2.13: Symbol of Transistor

Figure2.14: Description of terminals of Transistor

2.8 LED

LED means light emitting diode. Its function is similar to the diode. But these are not made up

from silicon or germanium. These are generally used as a indicating device. There are variety

of LEDs are available in market depending upon their size and colour.

Figure2.15: Types of LED S



2.9 VOLTAGE REGULATOR

The LM78XX 3-terminal positive voltage regulators employ internal current-limiting, thermal

shutdown and safe-area compensation, making them essentially indestructible. Heat sinking is

provided; they can deliver over 1.0A output current. They are intended as fixed voltage

regulators in a wide range of applications including local (on-card) regulation for elimination

of noise and distribution problems associated with single-point regulation.

Figure2.16: Pin description of LM7805

2.9.1 FEATURES

1. Output current up to 1 A

2. Output voltages of 5; 6; 8; 9; 12; 15; 18; 24 V

3. Thermal overload protection

4. Short circuit protection

2.10 POWER SUPPLY

Power supply is the essential part of any device or project. We are using microcontroller and

LED. These components needs +5V DC supply. So we need a power supply circuit of +5V

DC. Power supply circuit includes step down transformer, rectifier circuit, filter circuit and

regulator circuit. An indicating component is also attached with the power supply to indicate

the power ON condition of power supply unit.

Figure2.17: Circuit Diagram of Power Supply



Now the aim is to design the power supply section which converts 230V AC in to 5V DC.

Since 230V is too high to reduce it to directly 5V DC, therefore we need a step down

transformer that reduces the line voltage to certain voltage that will help us to convert it in to a

5V DC. Considering the efficiency factor of the full wave, we came to a conclusion to choose a

transformer, whose secondary voltage is 3-4 higher than the required voltage. Thus a step

down transformer of 9 V and 500 mA is used to step down the AC power supply. This

transformer can provide current up to 750 mA. Our circuit load is below 750 mA. So there will

not be any loading effect on transformer. Output of transformer is given to the rectifier circuit.

We are using a central tapped full wave rectifier. In this rectifier we are using 1N4007 PN

diode to rectify AC voltage. Output of this rectifier is not purely DC. Output of rectifier is

rippled DC. So we need some filtering section to rectify these ripples. Output voltage of

rectifier can be calculated by:-

Vout = (Vin * √2)- (Forward voltage drop of diode)

1N4007 is a silicon semiconductor material based diode. So in this case forward Voltage drop

is .7 V. Final output of this rectifier be:-

Vout= (12*√2)- .7

Vout= 16.1 V

Total Voltage= Voltage across resistor+ Voltage across LED

LED and resistor are connected in series so same current will flow. Means 8mA current will

flow through the resistor.

Now Total Voltage is =5V

Voltage across resistor is =1.6v

Current is = 10mA

So our equation will be

5V= (10mA * resistance) + 1.6V

3.4V=10mA * resistance

Resistance =3.4/10mA

= 450 ohm

Thus we can calculate the any series resistor for any input voltage and LED.



2.11 DC GEAR MOTOR

DC motor is a device powered from direct current (DC) that converts the current into

mechanical energy and rotates. Here the motor is used to move the lfr through the path. The dc

motor used here is a 100 rpm.

2.11.1 PRINCIPLE OF OPERATION

In any electric motor, operation is based on simple electromagnetism. A current-carrying

conductor generates a magnetic field; when this is then placed in an external magnetic field, it

will experience a force proportional to the current in the conductor, and to the strength of the

external magnetic field. We know opposite (North and South) polarities attract, while like

polarities (North and North, South and South) repel. The internal configuration of a DC motor

is designed to harness the magnetic interaction between a current-carrying conductor and an

external magnetic field to generate rotational motion.

Figure2.18: DC Motor and its internal structure

In this project the dc motor acts as the very integral part to deliver the output. Once we obtain

the signals to the motor driven IC the end effector ,through we will obtain the desired result is

the dc motor.



2.11.2 H-BRIDGE CIRCUIT

An H bridge is an electronic circuit which enables a voltage to be applied across a load in

either direction. These circuits are often used in robotics and other applications to allow DC

motors to run forwards and backwards.

The term H bridge is derived from the typical graphical representation of such a circuit.The

term H bridge is derived from the typical graphical representation of such a circuit. An H

bridge is built with four switches (solid-state or mechanical).

When the switches S1 and S4 are closed (and S2 and S3 are open) a positive voltage will be

applied across the motor. By opening S1 and S4 switches and closing S2 and S3 switches, this

voltage is reversed, allowing reverse operation of the motor.

Figure2.19: H-Bridge circuit

Using the nomenclature above, the switches S1 and S2 should never be closed at the same

time, as this would cause a short circuit on the input voltage source. The same applies to the

switches S3 and S4. This condition is known as shoot-through.

Figure2.20: The two basic states of an H bridge



S1 S2 S3 S4 Result

1 0 0 1 Motor moves right

0 1 1 0 Motor moves left

0 0 0 0 Motor free runs

0 1 0 1 Motor brakes

1 0 1 0 Motor brakes

1 1 0 0 Stop

0 0 1 1 Stop

1 1 1 1 Stop

Table2.1: Logic table for DC motor

The H-bridge arrangement is generally used to reverse the polarity of the motor, but can also

be used to 'brake' the motor, where the motor comes to a sudden stop, as the motor's terminals

are shorted, or to let the motor 'free run' to a stop, as the motor is effectively disconnected from

the circuit.

2.12 SERVO DRIVE

A servo drive system consists of a servo drive and a servo motor. The main task of a servo

drive (also called "servo amplifier", "servo inverter", "servo controller", or just "controller") is

the control of the motor current. In addition, ESR servo drives offer a broad spectrum of

functionality .



While most of the electrical drive systems are operated at constant speed, a servo drive has a

rather "hectic" life. Often it has to accelerate to the rated speed within a few milliseconds only

to decelerate a short time later just as quick. And of course the target position is to be reached

exactly with an error of a few hundredths of a millimeter.

Figure 2.21; Servo Motor drive

2.13 LDR LIGHT DEPENDENT RESISTANCE

LDRs or Light Dependent Resistors are very useful especially in light/dark sensor circuits.

Normally the resistance of an LDR is very high, sometimes as high as 1000 000 ohms, but

when they are illuminated with light resistance drops very less time taken

Figure 2.22 General LDR



Working of the Machine

Main parts of machine with their role and working using real picture

Transformer

First the power from main AC house hold supply which is 220 V is given to transformer which

steps down the voltage to 12 V.

Figure 3.1 Basic Transformer

Power Supply

Then the stepped down voltage is given to power supply circuit for changing the AC supply to

DC supply

Figure 3.2 Circuit Diagram of Power supply



Light emitting

source

LDR

SENSOR

Sensor

Here the sensor used is LDR which works on the principle of variable resistance when the light

directed to the LDR panel is obstructed by the nut the light intensity decreases for the sensors

on which the shadow of nut falls according to the height to the nut and this decreases the

resistance and gives signal to comparator circuit

Figure 3.3 Sensor LDR and LED as in the Machine

Comparator

The comparator LM324 compares the voltage difference the sends the output to the

microcontroller in the form of high or low.

Figure 3.4 General layout of comparator circuit



Figure 3.5 Comparator as used in the Machine

Microcontroller

The power converted to DC and output given by comparator is given to the microcontroller

where it applies algorithms to decide that the nut belong to which size range and gives output

to servo on which the guide is supported

Figure 3.6 General Layout of the LM 8051

Microcontroller also controls the motion of gear motor by cutting off power periodically to

stop the rotating disc so that the sensor can has sufficient data to read the change of light

intensity .

Comparator



Guide Tube

Container

Figure 3.7 Microcontroller as used in the Machine

Guide

The nut after recognized according to height falls to the container through the U shaped guide

by gravity method.

Figure 3.8 Guide Tube

Microcontrolle

r



Figure 3.9 General layout of Circuit diagram



Program for algorithms of microcontroller

Program L1 BIT P1.0 L2 BIT P1.1 L3 BIT P1.2 hall bit p1.3

dc1 bit p3.0 dc2 bit p3.1 servo bit p3.2 ORG 00h JMP START ORG 0003h RETI ORG 000Bh RETI ORG 0013h RETI ORG 001Bh RETI ORG 0023h RETI ORG 002Bh RETI ORG 30H JMP START START: jnb hall,action call dcmotor jmp start action: JNB L3,box3 JNB L2,box2 JNB L1,box1 jmp action dcmotor: clr dc1 setb dc2 call delay setb dc1



setb dc2 call delay2 ret box3: mov 70h,#03 call stepper jmp start box2: mov 70h,#02 call stepper jmp start box1: mov 70h,#01 call stepper jmp start stepper: mov a,70h clr c subb a,71h jz uu jc reverse jmp forward uu: nop mov p1,#00h ret reverse: mov r2,#02 mov a,78h ll: rr a mov 78h,a mov p1,a acall delay djnz r2,ll inc 70h mov a,70h clr c subb a,71h jz uu jmp reverse



forward: mov r2,#02 mov a,78h ll2: rl a mov 78h,a mov p1,a acall delay djnz r2,ll2 dec 70h mov a,70h clr c subb a,71h jz uu jmp forward delay: mov r7,0Ffh aa: mov r6,0ffh bb: nop NOP NOP djnz r6,bb djnz r7,aa ret delay2: mov r7,0fh aa2: mov r6,0ffh bb2: nop djnz r6,bb2 djnz r7,aa2 ret end



Advantages & Applications

1. It cater the issue of competition in mechanical industry by automation

2. It helps to meet the challenge of sustainable manufacturing and packaging industry

3. It provide alternative for industries aiming toward reducing human effort

4. It helps to achieve improvement in material handling system by implementing

automation

5. It generates sustainable and practical automation solutions for the future industrial

environment.

6. It can save a lot of time by doing sorting of nuts with little dimensional variation which

otherwise can be cumbersome

7. It saves a lot of cost inventory as the power required for the functioning of machine is

very less as compared to labor cost and also its speed of nut sort is more then that

achievable by humans.

8. In the industry where it is manufactured , at the packaging sector.

9. Where it is used as hardware in large quantity like in fabrication of machine

10. Construction of buildings and towers where nuts of close dimension are used

Future Scope

Fasteners are the basic hardware for any sector of fabrication or construction society. Fasteners

are used in all the industries for its specific use. The machine can improve or has added sorting

options to improve its future scope

Speed of the sorting

At present we can sort at the rate of 44 units per min. This speed may not be fit for industrial

use but it can be increased to more than ten folds by using high sensing capacity and more

accurate sensors, using high speed gear motor, using high speed servo drives which were not

used in this project due to cost inventory limitation

Colour of nut to be sort

The machine can also have a sensor to detect the color of the nut which will allow us to sort

nuts of different nut with their count displaying on LCD screen

Material of the nut to be sort

The machine can also have a sensor to detect the material property by scanning their grain

structure and sort the nut ex nut with bronze alloy can easily be sorted from nut manufactured

from stainless steel or other alloy



Conclusion

After completion of the project, the following points have come to light:

The machine can sort 44 units of nut for every minute

This speed can be increased many folds by taking high speed and accurate sensors, high

speed servo drives and gear motor

The machine can be very useful in the sector fasteners packaging and handling

By using this machine huge variety of jobs produced by fasteners industry which are

not only different in physical or chemical properties but have small variation in size

with all other parameters remaining same, the sorting of mingled nuts will become

cheap

reliable

less time consuming

Thus our aim to achieve realistic and practical sorting with the observation that with change in

diameter the height of nut also changes and this can be used to detect the dimensional variation

by using very cheap and reliable sensor designed as the automated nut sorter

machine is achieved



References & Bibliography

1. Printed Circuit Board Designer's Reference; Basics by Chris Robertson

2. Working of LDR; http://www.engineersgarage.com/electronic-components/ldr-light-

dependant-resistor

3. Electronic and PCB work ; http://www.technologystudent.com/

4. Mechanism of servo drive ; http://www.esr-pollmeier.de/en/FAQ.php

5. MIKELL P. GROOVER et al., Industrial Robotics: Technology, Programming, and

Applications (1986)

6. How to design robotic arm; http://www.societyofrobots.com/robot_arm_tutorial.shtml

7. Existing technology; http://www.worldoftest.com/optical-sorting.htm

http://www.amazon.com/s/ref=ntt_athr_dp_sr_1?_encoding=UTF8&field-author=Chris%20Robertson&ie=UTF8&search-alias=books&sort=relevancerank