Development Of Sensor And Automation System For A Fruit (Honey Oranges) Sorter Machine.
c
-
.
raf
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
1
ACKNOWLEDGEMENT
iv
ABSTRACT
v
ABSTRAK
vi
TABLE OF CONTENT
vii
LIST OF TABLES
X
LIST OF FIGURES
xi
LIST OF ABBREVIATIONS
xiii
LIST OF APPENDICES
xiv
INTRODUCTION
1.1 Introduction
1.2 Problem Statements
1.3 Project Objectives
1.4 Project Scope
1.5 Thesis outline
2
PAGE
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
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 PIC16F877A
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 PIC16F877A
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 PIC16F877A 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
41
4.2
Comparison between One Counter and Three Counters in One
44
PIC 16F877A
LIST OF FIGURES
FIGURE TITLE
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
PAGE
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 PIC16F877A
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 12V relay
The connection id a 5V voltage regulator
The image of the voltage regulator and 9V battery connector
LIST OF ABBREVIATIONS
ADC
Analog to Digital Converter
BJT
Bipolar Junction Transistor
CPU
Central processing unit
HEX
Hexadecimal
L
LED
M
MIMO
Large
Light-Emitting diode
Medium
Multi inputs multi outputs
NC
Normally CIose
NO
Normally Open
PCB
Printed Circuit Board
PIC
Programmable Intelligent Computer
RAM
Random Access Memory
ROM
Read Only Memory
S
Small
SLS
Single Lane Sorters
XL
Extra Large
LIST OF APPENDICES
APPENDIX TITLE
PAGE
A
GANTT CHART
49
B
PIC16F877A DATASHEET
51
C
7805 DATASHEET
59
D
PIC16F877AUSB 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.
1
7,03011 5,914120,734 9,990118,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, kiwifit. 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, S h a p e 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.
-
.
raf
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
1
ACKNOWLEDGEMENT
iv
ABSTRACT
v
ABSTRAK
vi
TABLE OF CONTENT
vii
LIST OF TABLES
X
LIST OF FIGURES
xi
LIST OF ABBREVIATIONS
xiii
LIST OF APPENDICES
xiv
INTRODUCTION
1.1 Introduction
1.2 Problem Statements
1.3 Project Objectives
1.4 Project Scope
1.5 Thesis outline
2
PAGE
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
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 PIC16F877A
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 PIC16F877A
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 PIC16F877A 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
41
4.2
Comparison between One Counter and Three Counters in One
44
PIC 16F877A
LIST OF FIGURES
FIGURE TITLE
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
PAGE
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 PIC16F877A
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 12V relay
The connection id a 5V voltage regulator
The image of the voltage regulator and 9V battery connector
LIST OF ABBREVIATIONS
ADC
Analog to Digital Converter
BJT
Bipolar Junction Transistor
CPU
Central processing unit
HEX
Hexadecimal
L
LED
M
MIMO
Large
Light-Emitting diode
Medium
Multi inputs multi outputs
NC
Normally CIose
NO
Normally Open
PCB
Printed Circuit Board
PIC
Programmable Intelligent Computer
RAM
Random Access Memory
ROM
Read Only Memory
S
Small
SLS
Single Lane Sorters
XL
Extra Large
LIST OF APPENDICES
APPENDIX TITLE
PAGE
A
GANTT CHART
49
B
PIC16F877A DATASHEET
51
C
7805 DATASHEET
59
D
PIC16F877AUSB 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.
1
7,03011 5,914120,734 9,990118,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, kiwifit. 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, S h a p e 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.