Development Of A Solar-Powered Controller For Drainage System With Water Treatment.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DEVELOPMENT OF A SOLAR-POWERED CONTROLLER FOR

DRAINAGE SYSTEM WITH WATER TREATMENT

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Robotic and Automation) with Honours.

MOHD IBRAHIM BIN RAHAMAT B050810336

FACULTY OF MANUFACTURING ENGINEERING 2011

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Development of Solar-Powered Cont roller for Drainage Syst em Wit h Wat er Treat ment

SESI PENGAJIAN: 2010/ 11 Semest er 2

Saya MOHD IBRAHIM BIN RAHAMAT

mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut : 1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis. 2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan

unt uk t uj uan pengaj ian sahaj a dengan izin penulis.

3. Perpust akaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.

4. **Sila t andakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)

(TANDATANGAN PENULIS)

Alamat Tet ap:

No. 40, Jalan Cempaka, Desa Temu Jodoh Chaah, 85400 Segamat Johor.

Tarikh: _________________________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

Tarikh: _______________________

** Jika Laporan PSM ini SULIT at au TERHAD, sil a lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyat akan sekal i sebab dan t empoh l aporan PSM ini perl u dikelaskan sebagai SULIT at au TERHAD.

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DECLARATION

I hereby, declared this report entitled Development of Solar-Powered for Drainage System With Water Treatment is the results of my own research except as cited in

references.

Signature : ……….

Author’s Name : ………

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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotic and Automation) with Honours. The member of the supervisory committee is as follow:

……… Supervisor

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ABSTRAK

‘Development of a Solar Powered Controller’ adalah satu system yang digunakan untuk mengawal pengaliran air yang melalui ‘Drainage System with Water Treatment’. System ini menggunakan tenaga solar sebagai sumber kuasa untuk memacu motor arus terus. Tenaga suria yang di serap oleh panel solar akan distabilkan dengan menggunakan litar pengatur voltan agar ianya sentiasa berada dalam kadar 12 volt. Arus elektrik seterusnya di simpan didalam sel kering dan akan digunakan untuk mengoperasikan litar. Pengguna hanya perlu menekan butang mula bagi mengoperasikan litar seterusnya pengawalan akan berjalan secara automatik. Pengoperasian litar adalah berdasarkan kepada paras air yang berada di dalam bendang.

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ABSTRACT

Development of a Solar Powered Controller is a system that use to control the Drainage System with Water Treatment. This system uses solar energy as a power source to drive DC motors. Solar energy is absorbed by the solar panels and will be stabilized by using the voltage regulator circuit so that it will always in range of 12 volts. Electric current then stored in batteries and will be used to operate the circuit. Users only need to press the start button for operating the control circuit and will then run automatically. Operation of the circuit is based on the level of water in the paddy-field

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DEDICATION

I would like to dedicate this report for my lovely mother and family, all lecture in manufacturing engineering department, all staff, and also for all my friends. They keep me in track and encourage me to do my best.

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ACKNOWLEDGEMENTS

First of all, I would like to express my gratitude to Mr. Ahmad Yusairi Bin Bani Hashim

as a PSM supervisor. This is for her invaluable support, encouragement, supervision, ideas, opinions and suggestions throughout this PSM. Without her moral support and continuous guidance, this project will not complete successfully.

My deepest grace and thank goes to my beloved mother, Mrs. Zainon Binti Abd Manap for their love and who gave me an endless supports and patience toward the completion of the dissertation. Their supports and advices have boosted up my spirit to do the best in my final year project. I also wish to thank to my siblings for their support and understanding during my final year project.

Lastly, my greatest gratitude to Faculty of Manufacturing Engineering through the knowledge benefited and to all my friends who contributed in giving me toughness, spirit and support for me in completing my final year project whether it is directly or indirectly. The kindness, corporation and support from all of the above mentioned people would always be remembered.

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TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Table ix

List of Figure x

List of Abbreviations xiii

1: INTRODUCTION 1

1.1 Overview 1

1.2 Introduction 1

1.3 Problem Statement 2

1.4 Objective 3

1.5 Project Scope 3

1.6 Expected Result 3

2: LITERATURE REVIEW 4

2.1 Overview 4

2.2 Solar Power 4

2.2.1 History of the Photoelectric Phenomenon 5

2.2.2 Solar Cell Physics 6

2.2.3 Solar Cell Electronics 7

2.3 Electric Power 8

2.3.1 Electric Power Generation 8

2.3.2 Direct Current Generation 8

2.3.3 Generation of Alternating Current (AC) 9

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2.3.5 Electricity Distribution 10

2.4 Battery Power 10

2.4.1 Introduction to Battery Power 10

2.4.2 History of Battery 11

2.4.3 How Batteries Work 12

2.4.4 Categories and Types of Batteries 13

2.5 Motor 13

2.5.1 DC Motor 13

2.5.1.a) DC Motor Principle 14

2.5.1 b) Basic of DC Motor Classified 15

2.5.1 c) Series DC Motor 15

2.5.1.d) Shunt DC Motor 16

2.5.1.e) Compound DC motor 17

2.5.1.f) Changing the Direction of Rotation of Motor Armature 17

2.5.1.g) Example of DC Motor 18

2.5.2 AC Motor 20

5.2.2.a) Introduction of Amplitude Current Motor 20

5.2.2.b) AC Motor Principle 21

2.5.2.c) Basic of AC Motor Cross Sectional 22

2.6. Motor Torque 22

2.7 Motor Rotational Control Circuit 24

2.8 Voltage Regulator Circuit 25

2.9 Controller Station Design 26

2.9.1 Solar Power Indicator Light 26

2.9.2 A Solar Powered Weather Station 27

2.9.3 Solar Power Telecommunication Station 27

2.10 Review 28

3: METHODOLOGY 30

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vii

3.2 Project Schedule 31

3.3 Development Phase 32

3.4 Stage Explanations 34

3.4.1 Title Selection and Approval Stage 34

3.4.2 Research and Data Collection Stage 34

3.4.3 Design and Development Stage 36

3.4.4 Testing, Analysis, Improvement and Modification Stage 37

4: DESIGN AND DEVELOPMENT 39

4.1 Introduction 39

4.2 Electronic Circuit Design 39

4.2.1 Motor Rotational Control Circuit 40

4.2.2 Automatic Recharge Battery Circuit 42

4.3 Station Design 45

4.3.1 Box for Store Electronic Circuit 46

4.3.2 Station Body 48

4.3.3 Based 48

4.3.4 Pillar 48

4.3.5 Box Holder 49

4.3.6 Whole Station Sketch 49

4.3.7 Solid Work Drawing 50

4.4 Electronics Circuit Development 51

4.4.1 Motor Rotational Control Circuit 52

4.4.2 Automatic Recharge Battery Circuit 53

4.5 Development of Station 55

4.5.1 Cutting 55

4.5.2 Laser cutting 56

4.5.3 Welding 57

4.5.4 Grinding 58

4.5.5 Painting 59

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viii

5 : _{RESULT AND DISCUSSION} 60

5.1 Introduction 60

5.2 Result 61

5.2.1 Motor Rotation 61

5.2.2 Motor Torque 62

5.2.3 Battery Charging Evaluation 64

5.2.4 Water Sensor 67

5.3 Discussion 67

5.3.1 Motor circuit 67

5.3.2 Automatic Recharge Battery Circuit 69

5.3.3 Water Sensor 69

5.3.4 Stop Cork 69

5.3.5 Concluding Remarks 69

6: CONCLUSION AND RECOMMENDATION 70

6.1 Conclusion 70

6.2 Recommendation 71

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LIST OF TABLES

Table 4.1 Components list on Automatic Recharge Battery Circuit 43

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LIST OF FIGURES

Figure 2.1: Solar Panel 5

Figure 2.2: The photoelectric effect experiment 6

Figure 2.3: Photovoltaic module operational diagrams 7

Figure 2.4: AC Generating System 9

Figure 2.5: Battery Form 10

Figure 2.6: Battery Circuit Diagram 11

Figure 2.7: Example of Battery Structure-Dry Cell 12

Figure 2.8: DC Motor Part 18

Figure 2.9: Illustration on how the DC motor working principle 15

Figure 2.10: DC motor circuit 16

Figure 2.11: Shunt DC motor circuit 16

Figure 2.12: a. Connection diagram of a dc compound motor. 17 b. Schematic diagram of the motor 17 Figure 2.13: Circuit(a,b,c) for changing the DC motor rotating direction 18

Figure 2.14: Power Window Motor 18

Figure 2.15: Stepper Motor 19

Figure 2.16: Servo Motor 20

Figure 2.17: AC Motor Cross Sectional 22

Figure 2.18: Motor circuit control 24

Figure 2.19: Sensor detect water ON and Detect water OFF 25

Figure 2.20: Voltage Regulator Circuit 25

Figure 2.21: Solar Power Indicator Light 26

Figure 2.22: Solar Power Weather Station 27

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Figure 3.1: PSM 1 Gantt Chart 31

Figure 3.2: PSM 2 Gantt Chart 32

Figure 3.3: Flow chart of the overall project process 33 Figure 3.4: Flow chart of the title selection and approved stage 34 Figure 3.5: Flow chart of the research and data collection stage 35 Figure 3.6: Flow chart of the design and development phase 37 Figure 3.7: Flow chart of the testing and analysis stage 38

Figure 4.1: H- circuit concept 40

Figure 4.2: H-circuit modify 41

Figure 4.3: H-circuit illustration 42

Figure 4.4: Solar charger schematic circuit 44

Figure 4.5: Circuit design by using Livewire Professional Edition 45

Figure 4.6: Box sketching 47

Figure 4.7: Box re-draws by using Solid Work 47

Figure 4.8: L-Bracket 48

Figure 4.9: Hollow metal bar 49

Figure 4.10: Sketch of based, pillar and box holder after joining 49

Figure 4.11: Whole sketch of station 50

Figure 4.12: Solid Work full drawing 50

Figure 4.13: Soldering iron 51

Figure 4.14: Soldering lead 51

Figure 4.15 : Soldering process 52

Figure 4.16 : Motor rotational circuit 52

Figure 4.17 : Component testing and measuring 53

Figure 4.18 : Finish circuit 54

Figure 4.19 : Circuit assembly inside the box 54

Figure 4.20 : Full assemble for electronic circuit 54

Figure 4.21 : Picture blade cutting 55

Figure 4.22 : Drawing for cutting the acrylic and zink plate 56

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xii

Figure 4.24: Clamping process 57

Figure 4.25: Welding Process 58

Figure 4.26: Hand grinder 58

Figure 4.27: Final station 59

Figure 5.1 : Motor with limit switch picture 61

Figure 5.2 : Evaluating process 64

Figure 5.3 : Voltage form in battery after charging 65

Figure 5.4 : Current form in battery after charging 66

Figure 5.5 : Water sensor 67

Figure 5.6 : Old circuit 68

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LIST OF ABBREVIATIONS, SYMBOL, SPECIALIZED

NOMENCLATURE

DC - Direct Current

AC - Alternating Current

PV - Photovoltaic

N - Negative

P - Positive

V - Voltage

T - Torque

F - Force

D - Distance

Nm - Newton Meter

HP - Horse Power

Rpm - Revolution Per Minute

A - Ampere

S - Switch

IEEE - Electrical and Electronics Engineers PCB - Printed Circuit Board

VSM - Virtual System Modeling

Ah - Ampere-hour

LM - Limit Switch

LED - Light Emitting Diode

CAD - Computer-aided Design

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CHAPTER 1 INTRODUCTION

1.1 Overview

An introduction is a beginning section which states the purpose and goals of the following writing. This section is usually interesting and it intrigues the reader and causes reader to read on. This chapter is about introducing the research of this project. The project is research and development about drainage system for paddy-field. The drainage system typically refers to the method for control the water level on that paddy-field. Also, it is will state the problems occur during the development, the objectives of this project and expected result at the end of the semester.

1.2 Introduction

In Malaysia, some drainage system for paddy-field was prepared by government to full their paddy-partition with water. This make paddy farmer not worried to get water from natural river and pump the water by water pump to their paddy-field. This system only have small pipe from the drainage to the paddy-field. This small pipe doesn’t have any device to control the water flow. Manual methods are use for control that water to past that’s pipe and flow to the personel paddy-field from main drainage.

This method needs farmer to used additional pipe or modify the government main drainage to make the water flow fast. Usually farmer use pipe with ‘L’ shape as interface between government drainage and their paddy-field. Farmer will full the

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pipe with water and use the vacuum concept for maintain the water flow. This method also causes farmer need to open and closed the pipe by bung it using un-used cloth, wood or plastic to control the water flow. Farmer also needs to wait in long time to ensure the water was enough and take out the ‘L’ pipe. This situation cause farmer difficult to do other activities because need to wait.

It is important to develop a system that makes farmer no need to wait at in long time to full their paddy-partition by water. This system is using solar panel to collect the power for drive a direct current motor. Direct current motor will assemble to the inlet outlet valve to operate it. Battery will use to save the solar power for system operate in cloudy weather and night. This system also will stabilize the level of water in the paddy-field.

1.3 Problem Statement

Because of the using of motor as the drive for valve (stop cork), it is important for prepare the electric source. Here the solar power is use for supply the electric source. Direct Current (DC) motor where use in this project should be modify for combine with pipe of Drainage System with Water Treatment. It is needed to design new shaft between DC motor and that pipe. After motor rotate, some cut off circuit should be design to prevent DC motor from burn. Solar board angle and position should be consider for collecting the full sun energy. Conditions in the paddy-field sometimes do not allow the position of the control station to be placed under the path of sunlight. Therefore, the flexible station design is important to ensure maximum absorption of solar energy can be collected.

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3 1.4 Objective

The objective of this project are:

1. To develop a controller for Drainage System with Water Treatment. 2. To design a limit switch that use for maintain the level of water. 3. To design circuit for re-charge the battery voltage by using solar panel.

1.5 Project Scope

1. This project only focus on developing a controller for control the rotation of DC motor where assemble for Drainage System With Water Treatment. 2. Solar panel will be use for supply a power to operate this project.

1.6 Expected Result

In the end of this project, one station for control the Drainage System should design and implemented. This system will able to change the rotary of motor from clockwise to counter-clock wise and otherwise. Battery can be rechargeable by solar energy and automatic cut-off.

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CHAPTER 2 LITERATURE REVIEW

2.1 Overview

A literature review is a body of text that aims to review the critical points of current knowledge including substantive findings as well as theoretical and methodological contributions to a particular topic. Most often associated with academic-oriented literature, such as theses, a literature review usually precedes a research proposal and results section. This section will review a logical flow of ideas current and relevant references with consistent, appropriate referencing style proper use of terminology and an unbiased and comprehensive view of the previous research on the topic. For this reports, literature review will explain about the related equipment, theory, formula, electronic circuit and mechanical part that’s use for this project.

2.2 Solar Power

Solar or photovoltaic (PV), cell are electronic device that essentially convert the solar energy of sunlight into electric or electricity. The physic of solar cell is based on the same semiconductor principle as diodes and transistor, which form the building blocks of the entire of electronics. Solar cell convert energy as long as there is sunlight. Figure 2.1 show example of solar panel. In the evenings and during cloudy conditions, the conversations process diminished. It stop completely at dusk and resumes at dawn.

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Solar cell do not store electricity, but the batteries can be used to store the energy. One of the most fascinating aspects of solar cell is their ability to convert the most abundant and free form of energy into electricity, without moving parts or components and without producing any adverse form of pollution that affect the ecology, as is associated with most known forms of nonrenewable energy production methods, such as fossil fuel, hydroelectric, or nuclear energy plants.

Figure 2.1: Solar Panel (Personel Capture August 2010).

2.2.1 History of the Photoelectric Phenomenon

In late of the century, physicist discover a phenomenon, when light is incident on liquids or metal cell surfaces, electrons are released. However, no one had an explanation for this bizarre occurrence. At the turn of the century, Albert Einstein provided a theory for this which won him the Nobel Prize in physics and laid the groundwork for the theory of the photoelectric effect. Figure 1.0 shows the photoelectric effect experiment. When light is shone on metal, electrons are released. These electrons are attracted toward a positively charged plate, thereby giving rise to a photoelectric current.

Einstein explained the observed phenomenon by a contemporary theory of quantized energy levels, which was previously developed by Max Planck. The theory describe light as being made up of miniscule bundles of energy called photons. Photons impinging on metals or semiconductors knock electrons off atoms. In the 1930s, these theorems led to a new discipline in physics called quantum mechanics, which

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consequently led to the discovery of transistor in the 1950s and to the development of semiconductor electronics.

Figure 2.2: The photoelectric effect experiment (Solar Power in Building Design 2008).

2.2.2 Solar Cell Physics

Most solar cell are constructed from semiconductor material, such as silicon(the fourteen element in the Mendeleyev table of elements). Silicon is a semiconductor that has the combined properties of a conductor and an insulator. Metals such as gold, copper, and iron are conductor. They have loosely bound electrons in the outer shell or orbit of their configuration. These electrons can be detached when subjected to an electric voltage or current. On the contrary, atoms of insulators, such as glass, have very strongly bonded electrons in the atomic configuration and do not allow the flow of electrons even under the severest application of voltage or current. Semiconductor materials, on the other hand, bind electrons midway between that of metals and insulators.

Semiconductor elements used in electronics are constructed by fusing two adjacently doped silicon wafer elements. Doping implies impregnation of silicon by positive and negative agents, such as phosphor and boron. Phosphor creates a free electron that produces so-called N-type (negative type) material. Boron creates a ‘hole’ or a shortage of an electron, which produces so-called P-type material. Impregnation is accomplished by depositing the previously referenced dopants on the surface of silicon using a certain heating or chemical process.

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The N-type material has a propensity to lose electrons and gain holes, so it acquires a positive charge. The P-type (positive type) material has a propensity to lose and gain electrons, so it acquires a negative charge.

When N-type and P-type doped silicon wafers are fused together, they form a PN junction. The negative charge on P-type material prevents electrons from crossing the junction, and the positive charge on the N-type material prevents hole from crossing the junction. A space created by the P and N, or PN, wafers create a potential barrier across the junction.

2.2.3 Solar Cell Electronics

An electrostatic field is produced at a PN junction of solar cell by impinging photons that create 0.5V of potential energy, which is characteristic of most PN junction and all solar cell. This miniscule potential resembles in function a small battery with positive and negative leads. These are then connect front to back in series to achieve higher voltages.

Figure 2.3: Photovoltaic module operational diagrams (Solar Power in Building Design 2008).

Glass

Ampere Meter Solar Cell

Glass

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1.3 Problem Statement

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3 1.4 Objective

The objective of this project are:

1.5 Project Scope

1.6 Expected Result

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CHAPTER 2

LITERATURE REVIEW

2.1 Overview

2.2 Solar Power

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Figure 2.1: Solar Panel (Personel Capture August 2010).

2.2.1 History of the Photoelectric Phenomenon

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consequently led to the discovery of transistor in the 1950s and to the development of semiconductor electronics.

Figure 2.2: The photoelectric effect experiment (Solar Power in Building Design 2008).

2.2.2 Solar Cell Physics

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2.2.3 Solar Cell Electronics

Figure 2.3: Photovoltaic module operational diagrams (Solar Power in Building Design 2008).

Glass

Ampere Meter Solar Cell

Glass

Development Of A Solar-Powered Controller For Drainage System With Water Treatment.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA