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0000065881 Development of sensor and automation system for a fruit (honey oranges) sorter machine / Low Yean Yin.

DEVELOPMENT OF SENSOR AND AUTOMATION SYSTEM FOR

A FRUIT (HONEY ORANGES) SORTER MACHINE

LOW YEAN YIN

MAY 2009

"I hereby declared that I have read through this report entitle "Development of Sensor

and Automation System for a Fruit(Honey Oranges) Sorter Machine" and found that has

comply the partial fulfillment for awarding the degree of Bachelor of Electrical

Engineering (Mechatronics)"

Signature

Supervisor's Name : Cik Aziah Bt Khamis

Date : 22APRIL2009

DEVELOPMENT OF SENSOR AND AUTOMATION SYSTEM FOR

A FRUIT (HONEY ORANGES) SORTER MACHINE

LOW YEAN YIN

This Report is Submitted In Partial Fulfillment of Requirements For The Degree of

Bachelor In Electrical Engineering (Mechatronics)

Faculty of Electrical Engineering

University Teknikal Malaysia Melaka

APRIL 2009

I hereby declared that this report entitle "Development of Sensor and Automation System

for a Fruit (Honey Oranges) Sorter Machine" is a result of my own research except for the

cited in the references. The report has not been accepted for any degree and is not

concurrently submitted of any other degree.

Signature Y l

Name : LowYeanYi

Date : 22 APRIL 2009

ACKNOWLEDGEMENT

Upon submitting this report, I would like to thank Cik Aziah Binti Khamis, my

supervisor of Projek Sarjana Muda (PSM 11), for her guidance and participation in

conducting my project. Her knowledge and insights were invaluable in identifling the

ways to solve my problems regarding to my project. I would also like to thank En. Ahmad

Zaki for advise and provide me good idea and knowledge to complete my final project.

Next I would like to express appreciation to all my teammates and fiiends as

appreciation for their cooperation, support and encouragement.

ABSTRACT

The main objective of this project is to design and implement of a Portable h i t (honey

oranges) sorter. The project purposes are to select a best sensor type for a fruit sorter

machine and to develop a fully Programmable Integrated Circuit (PIC) controlled

automation system for a f i t sorter machine. Automation system is widely used in many

fields to provide comfortable to human and to reduce the need for human intervention.

Besides, automation plays an increasingly important role in the global economy and in

daily experience. Therefore the automation system build should automatically sort the

fruits accordingly to their size. The system is fully applied the application of sensor and the

micro-controller. The sensor will detect the presence of the fruit and then send the signals

back to the microcontroller. After the controller receive the signals from the sensor, the

micro-controller begin to count fiom one to ten.

ABSTRAK

Objektif utama projek ini adalah merekabentuk seterusnya manghasilkan mesh mudah alih,

pengasing buah lirnau mengikut saiz. Projek ini memberi penekanan terhadap aspek sensor

dan rekabentuk mesin. Pengawal mikro merupakan satu kaedah kawalan yang digunakan

dalam projek ini. Sistem yang dibangunkan ini berupaya untuk mengenalpasti saiz bagi

setiap buah limau dengan mengaplikasi penggunaan isyarat. Isyarat keluaran akan dihantar

ke pengawal mikro. Pengawal mikro akan mengira bilangan buah limau dari satu hingga

sepuluh.

TABLE OF CONTENT

CHAPTER CONTENT PAGE

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

TABLE OF CONTENT

LIST OF TABLES

LIST OF FIGURES

LIST OF ABBREVIATIONS

LIST OF APPENDICES

1 INTRODUCTION

1.1 Introduction

1.2 Problem Statements

1.3 Project Objectives

1.4 Project Scope

1.5 Thesis outline

2 LITERATURE REVIEW

2.1 Introduction

2.2 The Compac System

2.2.1 Weight Sorting- Precision Weight Sizing

2.2.2 Color, Shape- InVision5000 Color and Dimension

iv

v

vi

vii

X

xi

xiii

xiv

System

2.2.3 Single Lane Sorters

2.3 Sensors

2.3.1 Keyence PSOl Series Photoelectric Sensor

2.3.2 Namco's Capacitive Proximity Sensor

2.3.3 Limit Switch

2.3.4 Omron Photoelectric Switch

3 Methodology

3.1 Introduction

3.2 Literature Review

3.3 Automation System Design and Sensor Choosing

3.4 Programming

3.5 Designation of the Circuit

3.6 Circuit Construction and Troubleshooting

3.7 Assembly and Troubleshooting

3.8 PIC16F877A USB Burner

4 Analysis and Discussion

4.1 Introduction

4.2 Automation System Overview

4.3 Sensor Choosing

4.4 Controller Choosing

4.5 Software Implementation

4.5.1 Programming of One Counter in One PIC 16F877A

4.5.2 Simulation of One Counter in One PIC16F877A

4.5.3 Programming of Three Counters in One PIC1 6F877A

4.5.4 Simulation of Three Counters in One PIC16F877A

4.6 Hardware Implementation

4.6.1 Placement of Sensor

4.'6.2 The Controller Board

4.7 Comparison between One Counter and Three Counters in

One PIC1 6F877A

5 Conclusion

5.1 Conclusion

5.2 Future Development

REFERENCES

APPENDICES

LIST OF TABLES

TABLE TITLE PAGE

2.1 Limit switch specifications 10

2.2 Ornron Photoelectric Switch Specifications 11

3.1 Components used in the PIC1 6F877A USB Burner 27

3 -2 Comparison of photoelectric sensor, capacitive sensor, limit 32

switch and Ornron photoelectric switch

4.1 Components used in one controller board 4 1

4.2 Comparison between One Counter and Three Counters in One 44

PIC 16F877A

LIST OF FIGURES

FIGURE TITLE PAGE

Honey oranges production for the first eight year of plantation

Sizer operation screen

Weighing apple

InVision operating screen

Two lane W s i o n grade for apple

Single lane Sorter

Keyence PSOl Series photoelectric sensor and sensor amplifier

Tubular sensor

Limit switch

The operation of Omron Photoelectric Switch

Omron Photoelectric Switch (Model E3Z-T61)

The circuit diagram for photoelectric switch

Project Methodology

The process of honey oranges sorting process

PIC reference

Prototype of the fiuit sorter machine

The path to build a new project in mikroC compiler

The checkbox to start a new project

A new worksheet created

Program, code are typed at the worksheet

The program codes are being build

The mikroC Compiler shows no error

The electronic devices library

The electronic devices selected are shown in the left column in the

Proteus software

The machine code are loaded into the PIC to test its simulation

Circuit testing and troubleshooting at the breadboard

Click to open the Wiiic800 Software

The software detects the PIC16F877A

The WinPic800 Software

The *.hex file is opened

The program is completely burn into the PIC1 6F877A

Image of the Burner

Fruit sorter machine top view

Fruit sorter machine side view

Fruit sorter Prototype

Automation system side view

PIC 16F877A

Circuit diagram of one counter in one PICl6F877A

Circuit diagram of 3 counters in one PIC16F877A

The sensor is placed at the drop point of each chute

The placement of the detector and the emitter at the small size

chute

The emitter will sends a signal to the detector

The h i t blocked the signal fiom the emitter

The controller board

Circuit symbol for a relay

The image of a 1 2V relay

The connection id a 5V voltage regulator

The image of the voltage regulator and 9V battery connector

LIST OF ABBREVIATIONS

ADC

BJT

CPU

HEX

L

LED

M

MIMO

NC

NO

PCB

PIC

RAM

ROM

S

SLS

XL

Analog to Digital Converter

Bipolar Junction Transistor

Central processing unit

Hexadecimal

Large

Light-Emitting diode

Medium

Multi inputs multi outputs

Normally CIose

Normally Open

Printed Circuit Board

Programmable Intelligent Computer

Random Access Memory

Read Only Memory

Small

Single Lane Sorters

Extra Large

LIST OF APPENDICES

APPENDIX TITLE PAGE

A GANTT CHART 49

B PIC1 6F877A DATASHEET 5 1

C 7805 DATASHEET 59

D PIC 16F877A USB BURNER CIRCUIT 62

E THE ACTUAL CIRCUIT OF THE CONTROLLER 64

BOARD

CHAPTER 1

INTRODUCTION

1.1 Introduction

Honey orange is one of the popular citrus species cultivated by smallholder fanners

along the coastal and midland areas in Malaysia. There is a great amount of honey oranges

produced every year. The produced honey oranges are either sort by human or machine.

Besides, one of the best automation systems is controlled by using microcontroller.

Microcontrollers are multiple inputs and multiple outputs (MIMO) device. The

microcontrollers available are PIC, 8051 (Intel, Atmel, Philips, Maxim), 280 (Zilog),

68HCll (Freescale) etc. The microcontrollers are used for embedded applications such as

automotive, electrical appliances, remote control and etc.

1.2 Problems Statement

There are 400 honey lemon tree can be plant per hectare (400 trees per ha). There

are no productions during the first three year of planting. The honey oranges production is

fiom the fourth year. There are 7,030 kgha of honey oranges produce during the fourth

year, this amount is increased to 15,914 kg/ha in the fifth year, 20,734 kg/ha during sixth

year, 19,990 kg/ha during the seventh year and 18,597 kg/ha during the eight year. There

are quite great amount of honey oranges produce every year. The honey oranges produce

can be sort by human or h i t sorter machine. Since the fruit sorter machines that are

available in the market are expensive and bulky. So, it is not affordable for the small-scale

industries not afford to buy the product. Then a cheaper and simpler sorter machine is

designed to overcome this problem. Also, l l l y PIC controlled fruit sorter machine is a

good solution to overcome this problem.

7,030 11 5,914 120,734 11 9,990 11 8,g57 7.7. I... I

Figure 1.1 Honey oranges production for the first eight year of plantation

1.3 Project Objectives

The project objectives are defined as follows:-

1. To select the best sensor type for a fruit sorter machine.

2 To develop an automation system for a fiuit sorter machine.

3 To use the PIC to control the automation system for a fiuit sorter machine.

1.4 Project Scope

The project scopes are defined as follows:-

1. This h i t sorter machine is design to sort one type of product at a time.

2. The fiuits are sort based on their shape (circular commodities).

3. The automation system is implemented by using PIC controller.

4. The microC compiler is used to program the PIC and the proteus software is used to

run the simulation of the PIC.

1.5 Thesis Outlined

In this report, Chapter 1 discussed about the overview of the project included

introduction of the project, the problems statement, project objectives and project scope.

Then Chapter 2 discussed about the literature review on the previous project. These

included the studies of the Compac System. The Compac system will be divided into few

sorting system, there are weight sorting, color and shape sorting and the single lane sorters.

Besides that, there are also the studies of the sensors included Keyence Photo Sensor,

Namco's Capacitive Proximity Sensor, limit switch and Omron Photoelectric Switch. After

that, Chapter 3 discussed about the project methodology. The project methodology is the

step to do the project. The project begin with literature review, the automation system

design and sensor choosing, programming, circuit construction and troubleshooting, follow

by the assembly and troubleshooting. Next, Chapter 4 discussed about the analysis and

discussion of the project. These included the automation system overview, the sensor

choosing, the controller choosing. Besides that, it is divided in to two parts which are

software and hardware implementation. For the software implementation, these included

the programming and simulation of one counter and three counters in one PIC16F877A.

For the hardware implementation, these included the placement of sensor and the

controller board. M e r that, this chapter also discussed the comparison between one

counter and three counters in on PIC16F877A. Finally, Chapter 5 discussed about the

conclusion and the future development.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

The literature review of this project is the review of the automation system that

available in the market. The reviews are by done by refer to the technical journal, reference

books and internet searches.

2.2 The Compac System

Compac use a unique carrier system, advanced software electronics and precise

measurement systems to sort produce by weight, size, color, shape, density, blemish or

defects, taste, internal characteristics and more. The automation system used is Invision

5000 system. InVision5000 system uses high definition camera to snap multiple images of

each W t as it rotate under the camera. Dedicated computers and software captured and

analyzed images from the camera. The operator then sorts fruit into different operator

defined classifications base on the fi-uit's surface color, diameter, etc.

2.2.1 Weight Sorting - Precision Weight Sizing

Compac sorting machines use an electronic weighmg system that is unique to

Compac and is unsurpassed in accuracy. The Compac carriers feature four individual

weigh points. This is very important to compensate for f i t shape or position such as pears,

avocados, kiwif i t . Two load cells per lane then gather weight information from each

weigh point and process approximately 250 readings in less than 1110th of a second for

each fruit. Unique mathematical algorithms are an important but hidden part of the

electronics that ensure Compac sizers provide superior precision for greater return on your

investment. This system is specifically designed for accurate high speed weighing of

produce from 25 to 2000 grams. The fruit carriers and load cell runners are designed so

that each carrier is being measured for over 95% of the weigh cycle, giving maximum time

for precision weighing, even at high speeds of 10 to 15 fruit per second per lane. The

weight of every single empty carrier is recorded and used as an individual tare weight and

is updated every time that the carrier is weighed empty. This compensates for changes

through the packing day, effectively calibrating itself automatically.

Figure 2.1 Sizer operation screen.

Figure 2.2 Weighing apple

2.2.2 Color, Shape InVision5000 Color and Dimension System

Compac's InVision 5000 system provides detailed, accurate color, size and shape

sorting for produce. Compac InVision 5000 captured multiple images of each fruit at

standard production speeds of up to 15 fruit per second. InVision 5000 is unique because

the software is easy to use with advanced features if the user needs the application. The

InVision 5000 also can capture up to 25 images of each fi-uit for improved accuracy and it

can handle dark and light fruit types automatically. Besides, the InVision 5000 provides

features such as grading and imaging. The color grading can sort the fi-uits up to 16 user

defined colors. For example, the average color of the fi-uit is from green to red for

tomatoes, yellow shades for lemon, etc. The shape is sort base on few shapes such as

elongation, flatness and symmetry.

Figure 2.3 InVision operating screen

Figure 2.4 Two lane Invision grade for apple

2.2.3 Single Lane Sorters

Compac Single Lane Sorters (SLS) have the unique ability to pack off both sides to

save valuable floor space. With capacities from 1 to 15 tons per hour, SLS solutions are

ideal for smaller packers or to add flexibility to larger facilities. The singulation options

are to suit budget, capacity and fruit requirements. The pack off both sides is to maximize

flexibility with minimal floor space.

Figure 2.5 Single Lane Sorter

2.3 Sensors

2.3.1 Keyence PSOl Series Photoelectric Sensor

A photoelectric sensor, or photoeye, is a device used to detect the presence of an

object by using a light transmitter, often infrared, and a photoelectric receiver. The

Keyence PSOl Series Photoelectric Sensor is one example of the photoelectric sensors. The

PSOl photoelectric sensor with one touch calibration amplifier can detect object at ultra

long 4 meter detecting distance. It is a fully-automatic one-touch calibration sensor

amplifier. The wire-saving connection system of the sensor and the sensor amplifier make

the sensor to become an extremely compact body.

Figure 2.6 Keyence PSOl Series Photoelectric Sensor and Sensor Amplifier

2.3.2 Namco's Capacitive Proximity Sensor

Capacitive proximity sensors are special design to sense non-metallic products.

Capacitive proximity sensors can be adjusted so that they will ignore or "see through" an

object in order to detect a second object behind it as long as the object foreground is not

metallic, the sensor will actually be able to sense products such as powder, granular

material, etc. Capacitive sensors operate by detecting the change in capacitance between

the capacitive sensor and the intended target. Capacitance is an electrical property between

two separate materials, and its strength varies with distance and the properties of the

materials. Namco's capacitive sensors have sensing ranges up to 70rnm. Namco capacitive

proximity sensors are available in three housing styles and can detect many different liquid

and solid materials including oil, water, soaps, beverages, chemicals, powders, and grains.

Their versatility and range make them ideal for a variety of food industry applications.

Detecting product level inside a hopper or storage tank is an easy task for the sensor as is

sensing the contents of a sealed package to make sure it contains the proper amount of

product. At the end of the production line Namco's capacitive sensors can be used to make

sure cases are full of packaged product and to detect shipping pallets for automatic case

loading applications. Besides that, the Namco's capacitive proximity sensors can use to

detect the plastic body too. Generally, plastic body capacitive sensors are more suitable for

applications where chemical or water resistance is desired. This would include food

applications. Metal body sensors are more appropriate where physical strength and rigidity

are needed as well as in high vibration applications. Figure 2.7 shows two types of

Namco's capacitive proximity sensor.

(a) Threaded tubular sensor

(b) Smooth tubular sensor

Figure 2.7 Tubular Sensor

2.3.4 Limit switch

A switch is a mechanical device used to connect and disconnect an electric circuit

at will. Switches cover a wide range of types, from subminiature up to industrial plant

switching megawatts of power on high voltage supply and distribution lines. In

applications where multiple switching options are required mechanical switches have long

been replaced by electronic switching devices which can be automated and intelligently

controlled. Table 2.1 shows the feature of few types of limit switch. These features are

very important during the wiring of the sensor to the hardware. The Figure 2.9 is the image

of the single pole, single throw limit switch.