Bahir Dar University

Institute of Technology

Faculty Of Electrical Engineering

Automatic Injera Making

Machine

Authors:
Alganesh ygzaw[196/03]
Birke Tsadik [465/03] Supervisor:
Bizunesh Negash [483/03] Edmialem G.
Sofanet
Kesetebrihan[1745/03]

A project submitted in partial fulfilment of the requirements

for the degree of Bachelor of Science
in the

Faculty Of Electrical Engineering (Power & Control Engineering)

June 2015
 ii

Declariation

We here by certify that the work titled by automatic injera making machine which
submitted to Bahir Dar institute of technology is an authentic record of original
work done by Alganesh Ygzaw, Birke Tsadik, Bizunesh Negash and Sofanit Ke-
setebrhan under the supervision of Mr. Edmialem Gedefay. The matter presented
in this project is not been submitted elsewhere. Submitted by:

1. Alganesh Ygzaw,

2. Birke Tsadik,

3. Bizunesh Negash

4. Sofanit Kesetebrhan

Advisor: Mr Edmialem Gedefay

 iii

Authors:
Supervisor:
Alganesh ygzawu
Mr. Edmialem Gedefay

Birke Tsadik
P. Manager:
Bizunesh Negash Mr. Edimealem Gegefay

Sofanet Kestebrihan
Date:
Date:

It is approved that this thesis has been written in compliance with the formatting
rules laid down by the school of the university.
Examining Committe Members Signature Date

1. Chairman {− − − − − − − − − − − − − − − − − − − − − − − − − − − −
− − − − − − − − − − − − − − − − − − − − − − −}

2. Examiner 1 {− − − − − − − − − − − − − − − − − − − − − − − − − −
− − − − − − − − − − − − − − − − − − − − − − − − −}

3. Examiner 2 {− − − − − − − − − − − − − − − − − − − − − − − − − − − −
− − − − − − − − − − − − − − − − − − − − − − −}

}
 iv

Abstract

For this Final project we design and implemented a machine that will make Injera
baking process less difficult, easy labor intensive and less time consuming process.
Injera is a specific type of bread that is part and parcel to the Ethiopian culture
which is the mean food for long time even though that injera making process
is difficult, labor intensive and time consuming process. Therefore for our final
project we design and implemented an automatic Injera making machine which
intends to give a great solution for a those problems. This machine is designed to
automate the mixing, brushing, pouring and baking processes. The whole process
starts from the mixing teff flour with water and ferment it in closed mixing tanker
which is an open system and controlled by its own motor. This mixing tanker is
connected mechanically to the pleat valve through a pipe valve, which is used to
pour out the mixture and glaze it on the mitad to be baked.
The baking process starts by give power supply to electric mitad, the temperature
of the mitad will start to rice when the mitad heats up until the nominal temper-
ature (200c). When the mitad riches its nominal temperature the oven conveyor
motor will start and move out to open the mitad so that brushing system will start
as soon as the forward conveyor motor stopped and cleans the mitad to avoid any
stick particles. After this process finish it is flowed by pouring processes which is
glazing mixture (dough) on mitad slowly when the pouring motor starts as soon
as the brushing motor stops.
After the mixture (dough) is glazed in the mitad the oven return back and close
the mitad to start baking process. The injera baking process will continue until the
baking timer stops and after that the oven opens again to take the injera out and
repeat the whole system all over again. This operation will stop either the tem-
perature becomes higher or lower than the nominal value because this operation
is temperature sensitive and the system also stop when empty sensor of the tanker
detects the tanker is empty. The control system operation of this automatic injera
baking machine is verified using programming logic controller logo software.
 Acknowledgements
We are very humbled and field with a great gratitude to acknowledge the people
and institutions that had a great help in this project. First and for most we
would like to give our dippiest honor to our advisor Mr Edemialm .G who helps
us in every way and guides us in right direction. We are also very grateful to
our university Bahir Dar Institute of Technology for providing us a work space,
materials and finical support for our project.
Last but not least we would like to sincerely thank and acknowledge to Bahir Dar
poly technic, Bahir Dar Textile Company, teachers and individuals who had a
great role in achieving this project this much far.

v
Contents

Abstract iv

Acknowledgements v

List of Figures ix

List of Tables xi

Abbreviations xiii

1 Introduction 1
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Statement of the Problem . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Motivation of the Work . . . . . . . . . . . . . . . . . . . . . 3
1.2.2 Significant of the Project . . . . . . . . . . . . . . . . . . . . 4
1.3 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 General Objective . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1.1 Specific Objective . . . . . . . . . . . . . . . . . . 4
1.4 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Scope of the Project and Limitation of the Project . . . . . . . . . 7
1.5.1 Scope of the Project . . . . . . . . . . . . . . . . . . . . . . 7
1.5.2 Limitations of the Project . . . . . . . . . . . . . . . . . . . 8
1.5.3 Challenges We Faced During the Project . . . . . . . . . . . 8
1.6 Organizations of the Project . . . . . . . . . . . . . . . . . . . . . . 9

2 Literature Review 11
2.1 Traditional Injera Making System in Ethiopia . . . . . . . . . . . . 11
2.2 Literature Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Overall System Design And Components 15

3.1 Overall System Design . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 Components of the Design . . . . . . . . . . . . . . . . . . . 15
3.2 Overall System Operation . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

vii
Contents viii

3.2.1.1 Power circuit and control circuit of mixer . . . . . 19

3.2.2 Brushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.2.1 Conveying System . . . . . . . . . . . . . . . . . . 20
3.2.3 Pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.3.1 Design and Working Principle pouring . . . . . . . 21
3.2.4 Baking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Power and Control Circuit of the System . . . . . . . . . . . . . . . 23

4 System Component and Description 25

4.1 Squirrel Cage Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Mixing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.1 Speed Control of the Motor Using Potentiometer . . . . . . 26
4.2.2 Decreasing the Speed of Motor . . . . . . . . . . . . . . . . 28
4.3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.1 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2 Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.3 Liquid Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.3.1 Liquid Level Sensors & Switches . . . . . . . . . . 31
4.4 Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5 Results And Discussions 37

5.1 Software Simulation of the System . . . . . . . . . . . . . . . . . . . 37
5.1.1 Programmable Logic Controller (PLC) . . . . . . . . . . . . 37
5.1.2 LOGO Software . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 LOGO Simulation of the System . . . . . . . . . . . . . . . . . . . . 39
5.3 Hardware Simulation of the System . . . . . . . . . . . . . . . . . . 43
5.3.1 Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.2 Brushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.3 Pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.4 Baking and convening . . . . . . . . . . . . . . . . . . . . . 45
5.4 Cost Estimation of the Product . . . . . . . . . . . . . . . . . . . . 46

6 Conclusion And Recommendation 49

6.1 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
List of Figures

1.1 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Tradational Injera Making Method . . . . . . . . . . . . . . . . . . 12

3.1 Overall System Design . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 power circuit of mixer . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 control circuit of mixer . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Mitad and brush with conveyor . . . . . . . . . . . . . . . . . . . . 20
3.6 Plate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Infrared Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.8 Power circuit of the system . . . . . . . . . . . . . . . . . . . . . . . 24

4.1 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Structure of thermocouple temperature sensor . . . . . . . . . . . . 30
4.3 Liquid Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.1 Flow chart of the the system . . . . . . . . . . . . . . . . . . . . . 41

5.2 LOGO Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 LOGO Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 Plate Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5 Final overall system . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

ix
List of Tables

3.1 Delays in the system . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.1 Components of the system . . . . . . . . . . . . . . . . . . . . . . . 40

5.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3 outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 raw materials of a single product . . . . . . . . . . . . . . . . . . . 47
5.5 Cost of components . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

xi
Abbreviations

PLC Programming Logic Control

TO sensor temperature sensor
LS limit switch
ES empty sensor
H heater
M1, M2, M3, M4 motor 1, 2, 3, and 4 respectively
T1, T2 timer 1 and 2
AC motor alternating current motor

xiii
Chapter 1

Introduction

1.1 Background

We Ethiopians uses Injera as our mean food for long time now even though that
Injera making process is difficult, labor intensive and time consuming process.
Injera is a specific type of bread that is part and parcel to the Ethiopian culture.
Its is a necessity food item for almost all Ethiopians and is utilize in almost all
traditional cuisine.
Teff is the main ingredient of injera and it is cultivated by farmers in the high
land of Ethiopia. The grains of teff are very small, almost one-tenth of the size of
wheat and are very time consuming and labor intensive to separate them from their
stalks. Because of Ethiopias geography the teff farmers did not trade their grain
with the rest of Africa. It was one of the reasons why Teff was almost exclusively
grown only in Ethiopia for many years now. But, in the recent years individuals
in Idaho and Minnesota have introduced teff and cultivate and distributes to the
United States.
This most valued grain used to make injera is known to be iron-rich. It is also
packed with protein, and calcium, it is also one of the gluten-free grains, along
with other grains such as, amaranth, buckwheat, millet, and quinoa. In fact one
cup of cooked teff contains as much iron as the USDA recommends for adults

1
Chapter 1. Introduction 2

in one day. Its nutritionally rich because most of the grain is made up of bran
and germ where the nutrients live and the whole grain is made into flour to meek
injera. The process of making injera requires the teff flour to be mixed with water
and allowed to ferment for few days. This fermentation, as mentioned above is
a delicate process and is temperature and humidity sensitive. Traditionally the
batter prepared is cooked either on a specialized electric stove or a pan made of
clay using fire.
As the world advanced to modern technology and high level automation solutions
in various fields Injera making machines in our country are not yet have been
advanced. Even though lots of highly technical advanced electronic devices are
introduced there is still major drawback in Injera making machine and this due to
Ethiopia is the only country that use Injera. So improving this technology have
been challenging so far and our project main aim is to solve this problem for our
country [1].

1.2 Statement of the Problem

Injera baking process is difficult and highly time consuming process in day to
day life of we Ethiopians. In rural areas and some part of the urban cities of
Ethiopia injera is backed on pan made out of clay using wood fire usage which
causes massive deforestation. Even though the traditional way of baking injera
is replaced by electrical usage mitad but it doesnt reduces the man labor, highly
consuming electrical power, time and baking process. Although there are many
drawbacks of the traditional and electrical usage injera baking methods here are
the most common problems.

• It required maximum working time

• Massive deforestation.

• It needs man labor.

Chapter 1. Introduction 3

• Difficult to manage in high level of production like in universities cafeterias,

restaurants and etc.

• It is not easily operating system.

• In Ethiopia most of injera making process is held by girls, men were not
perfect in injera making

• The process is a long process, need much time and need also more energy

• Due to the long process and a lot of equipment used there was some difficulty
in health care

• Women was suffered doing all the process alone in their rest time

• Men who live alone suffered from have not injera due to the difficulty of the
process.

• Ethiopians live in abroad lacks accesses of injera due to less exportation and
distribution of injera.

1.2.1 Motivation of the Work

Injera is one of the significant identities which make Ethiopia different and unique
from the rest of the world. Now a days injera starts to distribute in some coun-
tries of the world like USA, England and other countries even if the technology
for backing injera is still not improved yet. Even though injera is the favorite food
of Ethiopians the process of making injera is difficult and not improved by new
technology. This project is motivated to decrease the tedious process, time con-
summation of injera making process and also making the process more productive
and easily applicable for house hold serves. In high institutions like universities,
prisons, hotels and restaurants we saw the operators suffering to supply for all the
user ,this motivate us to automate to save their time and energy. Considering the
increase of power generation in Ethiopia and industrialization of the country also
motivate us to develop this machine because this machine can be used ever where
and also to export injera as trade mark to the rest of the world.
Chapter 1. Introduction 4

1.2.2 Significant of the Project

The significant of this project is wider than we are trying to explain when this
project is finished the machine will solve so many problems regarding to injera
baking operation. This machine solves deforestation, time consumption, efficiency,
man labor and others. As a new invention this project has a great role and advan-
tages to our country, for everyone using this machine and also to our University
Bahir Dar Institute Technology. For high institutions like universities, prisons,
hotels and restaurants it will help to supply the users in a short period of tie
when industrialized. The automatic injera making machine can be modified in to
a food complex industry machine to produce injera in industrial level to export
and distribute. This will open up job opportunity and improving the economy of
our country.

1.3 Objectives

The project main objective is to come up with a complete solution to overcome

the limitations of the traditional process, by converting the manual injera mitad
in to automatic. Our project has its own general and specific objectives:

1.3.1 General Objective

To design and an implementable Automatic injera making machine for house hold
level.

1.3.1.1 Specific Objective

• To analyze and select the conveyor system, sensors, contactor, circuit breaker
and motor operation.

• To design the mixing, pouring ,brushing and baking systems.

Chapter 1. Introduction 5

• Adjust the thickness of the injera in the same size throughout the system.

• To review the design of the electrical mitad and improve it in to automatic

mechanism.

• Develop the model using logo software

• Make the process easy for anyone who can have this machine.
Chapter 1. Introduction 6

1.4 Methodology

Our project flows the methodology the table below; to implement this project
successfully the process should pass the following stages.

Figure 1.1: Methodology

Chapter 1. Introduction 7

1. Literature review: reading journals, books, websites, and also reviewing some
related electrical projects.

2. Literature review: reading journals, books, websites, and also reviewing some
related electrical projects.

3. Collection of data: collecting rating of motor, type of temperature sensor we

use, contractors, circuit breaker, and questioner answers on the effects of the
traditional and electrical usage mitad.

4. Analyzing data: using the data that have been collected we chose and de-
termine the most effective and workable mechanism to design the model.
In the stage we also select the most preferable materials that are need in
the modeling the system. Analyzing the data collection will help in the cost
estimation, standards and availability of material that are used in the system

5. Implementation: when the whole model of the system is tested and if its
performance is accurate, than designed model are implemented practically.

6. Testing the model: after the implementation our project is testing by giving
supply(voltage source) to check the system is feasible or not.

1.5 Scope of the Project and Limitation of the

Project

1.5.1 Scope of the Project

Ethiopia is the only country that harvest teff and uses Injera as the main food
supplement, and improving this injera making machine will solve a lot of prob-
lem for our country .The scope of this project is that to develop and implement
automatic injera making machine.
Chapter 1. Introduction 8

1.5.2 Limitations of the Project

Since this project is a new innovation it had some mechanical and material lim-
itations which reduce the efficiency of the machine. Injera making process is a
tedious processes and continuous cycle which held in short period of time due to
this reason motors working capacity and efficiency will decrease through time. To
avoid this problem we tried to use brushless DC motors which avoid power loss
by operating without brushes, but these motors are not available in market. The
other main factor is the mechanical perfection of the hardware this is due to the
materials that used for the hardware implementation lucks specification and qual-
ity. Even though the design of the hardware is perfect the implementation lucks
efficiency because it is handmade work and this has some effect in the efficiency
of the work.

1.5.3 Challenges We Faced During the Project

Even though the challenges we faced during this final project are too many this
are the main once we have faced,

• Because of the technology have not been done further before this time, we
have suffered lack of sources and references to improve our knowledge and
data regarding the project

• Since the mechanical parts are done by man hand the perfection of our design
in some parts of the equipment is not satisfactory. Due to this reason some
part of the machine will have less perfection.

• Shortage of time and overloaded course

• Lack of materials
Chapter 1. Introduction 9

1.6 Organizations of the Project

This project has six chapters expelling operation and proving who the automatic
injera making machine works. The back ground history of injera, problem state-
ment, objective, methodology and motivation of the project are held in chapter
one. The literature review and traditional injera baking process part of the project
are explained in chapter two which is flowed by chapter three counting the sys-
tem design, overall operation. Chapter four explain the components need for the
automatic injera making machine and their operation, and the result of the soft
ware and hard ware simulation is explained in chapter five. This project finishes
up with conclusion and recommendation of the project in chapter six.
Chapter 2

Literature Review

2.1 Traditional Injera Making System in Ethiopia

Ethiopia is the only country that about 60Injera making process includes several
steps, the whole process start from mixing the teff flour with water and letting it
to ferment in closed tanker for days. The fermentation depends on whether con-
dition and type of teff. It is possible to over ferment the mixture if it is beyond its
limit which will create alcoholic dough or highly sour dough which is not pleasant
to eat. But if it ferments at right time it will give a slight classic sour flavor to the
mixture. After the mixture fermented for some days, the mixture will again mix
with boiled water or cold water depending on the type teff and even it deends on
the softness of the water because sometimes the same teff will mix by cold water
on some area but on another place it needs boiled water. For example, in Mekelle
every teff uses cold water only, if it mixes with boiled water the quality of the
injera decreases[2].
After the second mixing system, the next process is baking the mixtre. In tradi-
tional way injera is backed on a flat circular ceramic griddle with shiny smooth
black surface known as mitad. As soon as mitad is heated whether by wood fire or
electricity for electric mitad, then a specially prepared herb is sprinkled over the
hot surface to help polish the cooking surface further and to make sure the injera

11
Chapter 2. Literature Review 12

will not stick to the surface and the herb is polished from the surface. After this
stage the pouring process will start from the outer ridges of the griddle and work
your way in filling up the whole in the middle then you cover the griddle with its
top known as akembalo.
Once this step is accomplished let the injera to bake for minutes [the duration of
the minutes depend on the temperature of the mitad]. After we feel that the injera
poured baked enough to become a perfect injera, we will open the akembalo and
take the injera from mitad with a sefed. The injera should cool off on the sefed
until the pouring of dough on the hot griddle. Then transfer the cooled injera
to an enkeb, a special basket used to keep injera and Ethiopian bread and keep
repeating this process until you have finished all the dough and keep piling one
injera on top of the other on the moseb.

Figure 2.1: Tradational Injera Making Method

Chapter 2. Literature Review 13

The above pictures describe the processes, which at last produce the amazing
precise injera. The picture on the left side shows the traditional way of baking
which consume wood fire as source of heating to the mitad which cover at least
90For traditional injera baking process the following are the main equipment used
in the whole process:

• Circular mitad made of clay

• Two tankers one big in size used to store the mixture for fermentation and
during process and the one the small one used to pour the mixture

• Masesha used to clean the mitad

• sefed to take injera

• enkebo temporary store of injera to cool and mesob as permanent store of

injera

2.2 Literature Review

So far we have look at some literature views which are related with the devel-
opment of injera making machine. The development of this machine starts
simply by change or improve the power consumption ability of the clay pad
mitad like mirit mitad which have the same process and the same wood fire
usage but it just decrease the amount of wood fire usage. Also like MIghty
mitad and others develop the physical appearance of the clay mitad to wait
for a long period. But still with same tedious process and the same power
consumption.
Dr. Wudneh Admassu a professor at University of Idaho and Chairman of
Department of Chemical Engineering built the first automatic Injera mitad
in industrial level; he was friend of the Zelalem injera owner of Ato Kasshun
Maru [3]. Zelalem injera making machine is industrial level production ma-
chine that trade injera in all USA state. This creation replaces the clay
mitad with steel pan belt and changed the traditional methods of baking
Chapter 2. Literature Review 14

injera; it is a belt wise system which plates the injera on the steel pan and
circulates by leaving the injera for operators to take it. However, the quality
of the product mean the injera is less efficient than the traditional injera of
Ethiopians due to the steel pan mitad that create eye back of the injera and
other necessary qualities [1].
Wassie digital mitad is another recent creation, Wassie Mulugeta mitad is
mechanically and electrical improved machine that operate with minimum
power usage. Even though Wasssie digital mitad is energy conserving mitad
it didnt change any of the baking process of the injera[4]. In 2001, at Bahir
Dar institute of technology students have also tried to solve this problem
by converting the system in to automatic system. They avoid the pouring
system by using mechanical valve system. But the system doesnt include
mixing and baking system and they did not implement the system[3]. If this
project is completed it will solve the difficult handmade and highly time con-
suming process of injera according to both traditional and electrical usage
mitad by avoiding human participation on the mixing, pouring, baking and
cooking process of the system .

//
Chapter 3

Overall System Design And

Components

3.1 Overall System Design

Figure 3.1: Overall System Design

3.1.1 Components of the Design

1. Tanker: is a container which is used for the mixing of water and teff flour
and also as used as storage of the mix. The two stage of mixing processes
are held in this stage.
15
Chapter 3. Overall System Design And Components 16

2. Mitad: is the electrical mitad used to bake the injera and this mitad used in
this project is the same as electric mitad used in house hold now days except
it is designed mechanically movable. The thickness of the clay pan will also
adjusted to decrease the power consumption

3. Oven: it is used as the coverage of the mitad until the injera baked, it is only
designed as mechanical cover of the mitad there is no electrical connection
process.

4. Brush: used to clean the mitad before pouring the mixture in to the mitad
and after the injera taking out part is completed. The brush main purpose is
to make sure the baking system is safe and to continue with smooth process.

5. Plate valve: the plate valve is used to outlet the mixture to the mitad for
the pouring process. It operates by rotating the circular plate 360 with the
shaft mechanically screwed at the end of motor rotor.

6. Conveyor: is the system which used to transport the mitad to the oven back
and forth after pouring system. It has one approximate sensors at the end
of the conveyor to detect the mitad is outside the oven and also two limit
switch one at the end and start of conveyor to stop the motion of the mitad

3.2 Overall System Operation

This project main aim is to design an automatic injera making machine with
less labor, with less contamination of human hand and less time consumption.
The whole process includes electrical equipment operated in parallel to each other
which starts by mixing teff flour with water in the mixing tanker; this system is
an open system and it is controlled by its own motor. This mixing tanker is also
attached with pipe and plate valve which is used to transport the mixed fluid and
to pour the fluid to mitad to be baked.
After the teff flour is mixed with water in the tanker by adjusting the water level
manually, the mixture will be leaved for a days depend on the weather condition
Chapter 3. Overall System Design And Components 17

of the surrounding to be fermented. The mixture to be fermented is sensitive to

temperature and the type of teff used, in cold season the fermentation may take
three or four days but in hot season it may be enough in two days. The fermen-
tation system has a great role in the taste of the food; therefore depending on the
temperature of the surrounding the time should be adjusted to have perfect taste
and quality.
This mixing tanker system is independent of the control circuit of the system be-
cause it is used for two purposes, one is for mixing and the second is to store for
fermentation and after fermentation. Due to this mixing system is controlled by
its own motor; it is connected to the rest of system when the injera backing process
starts through mechanical pipe valve. The baking system starts by giving supply
source to the electric mitad, which let to increase the temperature of the mitad
up until the nominal temperature. For injera to be perfectly baked, the nominal
temperature is about 200c, this temperature is the preferable for baking injera
without sticking and burning due to high temperature and decrease its quality
due to low temperature [gathered from the data we collect].
When the temperature of the mitad reaches its nominal temperature, the thermo-
couple temperature sensor connected with the mitad will detect the temperature.
For the heating period the mitad must be inside the oven to decrease the time
consumed to heat the mitad as well as the power consumption, the oven in this
case is used as cover for the mitad to preserve the heat. After the temperature
sensor detects nominal temperature the conveyor motor forward biased starts to
move the oven in forward direction away from the mitad for further processes.
The conveyor system is controlled by limit switch at both ends of the conveyor.
When the limit switch detects the oven opened completely, the motor will stop
forwarding to start start the brushing conveyor motor in forward biased to clean
the mitad in forward direction. The brushing conveyor also has limit switch which
can control the movement of the brush in both direction. As soon as the brush
brushed in forward direction, pouring motor will start to slowly pour or cover the
mitad the mixture from the small tanker used as temporary storage and as pour-
ing which controlled by its own timer and motor. The pouring timer is adjusted
Chapter 3. Overall System Design And Components 18

with the speed of the motor to rotate 360 which can cover the whole mitad with
mixture.
As long as the mitad is covered with mixture orlit, the conveyor motor will move
the oven to the first position to cover the mitad for baking process. After the oven
is completely cover the mitad and motor will stop and the baking delay timer (T1)
starts counting the delay to bake injera. To bake one injera in 200 c temperature,
it takes one and half minute. This timer will recycle the whole system for every
individual injera except the injera taking sub process which is held manually by
the operator. The system will continue the operation as mentioned above at nom-
inal temperature until the empty sensor of the tanker detects the tanker is empty.
If the temperature is above the nominal the breaker will immediately break until
the temperature returns back to its nominal value. The whole operation will con-
tinue the cycle until the mixture in the tanker is below the empty sensor if so the
whole system stops. Thus the system contains four processes, mixing, brushing,
pouring and baking as defined below.

Figure 3.2: Process

3.2.1 Mixing

Mixing the teff flour with water is the first process in injera making. The mixing
processes for injera have two stages the first is before fermentation when the teff
flour is mixed with water, and the second is mixing the fermented mixture with
additional boiled or cold water depending on the type of teff. Because the mixing
system doesnt have any effect on the rest processes, it is open system separately
Chapter 3. Overall System Design And Components 19

controlled by its own motor and breaker. However, the mixing tanker which con-
tains the mixture is connected mechanically with the pleat valve through the pipe
valve.

3.2.1.1 Power circuit and control circuit of mixer

The power circuit and control circuit of the mixer electrical circuit diagram are
connected as following.

Figure 3.3: power circuit of mixer

Figure 3.4: control circuit of mixer

Chapter 3. Overall System Design And Components 20

3.2.2 Brushing

Brush is used to clean up the stick unwanted things from mitad after the injera
taking process is held and before pouring the mixture in to the mitad. The brush
main purpose is to make sure the baking system is safe and to continue with
smooth process. It has limit switch to control the conveyor motor, the conveyor
operates by single phase AC motor. The brush has 46cm long which is equal to
the diameter of mitad and it cleans the mitad back and forth respectively with
the rotation of the motor.

3.2.2.1 Conveying System

Conveyor system is a common devise of mechanical handling equipment that moves

materials from one location to another location, which allows quick and efficient
transportation. Many kinds of conveying systems are available according to the
mechanical operation we use however in this project we use the conveyor system
we use to move both oven and brush back and forth is simple nut and bolt system.
The conveyor operating principle is when the shaft that connected to the motor
with belt rotate the nut will move back and forth depending on the direction of the
motor, this nut is wiled to bearing that are attached to the oven to move it back
and forth direction The conveying system operates using squirrel cage induction
motor and controlled my limit switch.

Figure 3.5: Mitad and brush with conveyor

Chapter 3. Overall System Design And Components 21

3.2.3 Pouring

Pouring is one of the stages of injera baking process, it is held by rotating the
circular plate valve 360 to slowly pour the mixture to mitad. The circular plate
valve have 41cm diameter which the same size of the injera to be baked, the pleat
valve have also pouring gap with 2cm width and a half of the diameter length. As
the shaft mounted to the pouring motor rotates the circular plate start to move,
the mixture start pouring and/or glazed on the mitad. The plate valve have a
cylindrical shape that can temporarily store the mix until its poured, it also have
a shaft mounted to the motor to rotate the circular pleat. This process is controlled
by squirrel cage motor, starts after the revers brushing conveyor motor stops.

3.2.3.1 Design and Working Principle pouring

In pouring system adjusting the thickness of the injera is the main factor which
affects the whole design of the components found in this subsystem. The thickness
of the injera is affected by the amount of mixture poured in to mitad, the distance
between the mitad and the plate valve, speed of the rotating shaft and also gap
used for pouring. The diameter of mitad pan differs from one to others depending
on the type and purpose of usage, but for this specific project we are using 46cm
diameter mitad. However the diameter used for the poured mixture to be glazed

Figure 3.6: Plate valve

is 40cm, leaving 3cm by each side of the mitad because it will be difficult to take
out the baked injera if it covers the whole mitad pan. Therefore in this case the
diameter of plate valve will be 40cm with radius of twenty centimeter, the circular
pleat valve also have gap of 2cm used to outlet the mixture. The thickness of the
Chapter 3. Overall System Design And Components 22

mitad then can be adjusted by controlling the factors that affect the thickness of
injera

3.2.4 Baking

Baking is the duration take to cook the pouring mixture and change to injera.
It starts immediately after pouring system until taking injera is held. It is a
temperature sensitive process. After the pouring system is closed the oven is
cover the mitad through a conveyor system controlled by forward and reverse
motor. There is a timer which counts the baking time and after baking process
is finished the oven is return back to the place where pouring system is occurred.
Before pouring process there are delays for taking injera manually and for brushing
system. To identify the nominal temperature and baking delay, we have taken data
from the electric mitad baking on different temperature and baked by different
person.

Figure 3.7: Infrared Thermostat

Chapter 3. Overall System Design And Components 23

Table 3.1: Delays in the system

Data Temperature[0c] Brushing delay[sec: micro-sec] Pouring delay [sec: micro-sec] Bak
1 23.8 5:88 5:38
2 253.6 2:59 1:14:71
3 219.5 3:67 10:67
4 212.5 3:94 2:72
5 208.3 9:31 8:51
6 234.9 5:58 1:39:32
7 248.2 2:59 7:34
8 201.2 3:35 3:72
9 248.2 6:44 7:17
10 231.6 4:75 8:03

N.B: the above collected data is held manually and by different person due to
this reason the data we collected is average assumption. However this collected
data will helps to take the average assumption value for input data, Average
nominal temperature. The Average delay between pouring and covering the oven
to transport are important data, the time delay need for the oven to open is the
same time interval takes for the injera to pop eyes before it is covered by the
oven. This time delay is calculated from the average data collected above and the
average time delay is about 12sec move the mitad to the oven.

3.3 Power and Control Circuit of the System

Combining the four processes will compute the system operateshttp//www.wasselectronics.com/in

electronics-blog/latest automatically and simultaneously, which can be showed by
identifying the power circuit and control circuit of the system. Power circuit shows
the overall power flow of the system starting from starting push button and control
circuit show how the input device affects any output on the system, which shows
the interconnection of the electrical devise in the system.
Chapter 3. Overall System Design And Components 24

Figure 3.8: Power circuit of the system

Chapter 4

System Component and

Description

4.1 Squirrel Cage Motor

An electric motor with a squirrel-cage rotor is termed a squirrel-cage motor. The

motor rotor shape is a cylinder mounted on a shaft. A squirrel-cage rotor is the
rotating part used in the most common form of AC induction motor which consists
of a cylinder of steel with aluminum or copper conductors embedded in its surface.
Internally it contains longitudinal conductive bars set into grooves and connected
at both ends by shorting rings forming a cage-like shape. The name is derived
from the similarity between this rings-and-bars winding and a squirrel cage. The
rotor has a smaller number of slots than the stator and must be a non-integer
multiple of stator slots so as to prevent magnetic interlocking of rotor and stator
teeth at the starting instant[4].
Since the voltage developed in the squirrel cage winding is very low, no intentional
insulation layer is present between the bars and the rotor steel. The field windings
in the stator of an induction motor set up a rotating magnetic field through the
rotor. The relative motion between this field and the rotor induces electric current
in the conductive bars. In turn these currents lengthwise in the conductors react

25
Chapter 4. System Component and Description 26

with the magnetic field of the motor to produce force acting at a tangent orthogonal
to the rotor, resulting intorque to turn the shaft.

4.2 Mixing Motor

The mixer is operated by Squirrel cage motor and the speed is controlled by
variable resistance. As the level of water increase in the mixing and high speed of
motor the mixing process will be difficult due to the high speed of the shaft the
liquid mixture will splash out of the tanker. To avoid this, the speed of the motor
is controlled by variable resistance potentiometer.
Power rating of the system is calculated by:
P= torque [Kg*m]* rpm
= 2Kg* .26m * 1400rpm
=728watt

4.2.1 Speed Control of the Motor Using Potentiometer

Squirrel cage motor is a motor that is feed from ac voltage source. The speed can be
controlled by varying the applied voltage, this can be achieved by having a variable
voltage source or by using a variable resistor connected in series with the armature.
A potentiometer is used as the variable resistor, which is a manually adjustable
electrical resistor that uses three terminals. It is a device which establishes the
levels of the output, like in loudspeaker to adjust the volume, in television set and
computer monitor or light dimmer to control the brightness of the screen and in
motor to regulate the voltage and speed of the motor.
Chapter 4. System Component and Description 27

Figure 4.1: Potentiometer

As shown in the figure it has three terminals. One terminal is connected to a power
source, and another is hooked up to a ground a point with no voltage or resistance
and which serves as a neutral reference point. The third terminal slides across a
strip of resistive material. This resistive strip generally has a low resistance at one
end, and its resistance gradually increases to a maximum resistance at the other
end. The third terminal serves as the connection between the power source and
ground, and it usually is operated by the user through the use of a knob or lever.
The user can adjust the position of the third terminal along the resistive strip
to manually increase or decrease resistance. The amount of resistance determines
how much current flow through a circuit. When used to regulate current, the
potentiometer is limited by the maximum resistivity of the strip.
The potentiometer can be used as a voltage divider to obtain a manually adjustable
output voltage at the slider from a fixed input voltage applied across the two ends
of the potentiometer. This is their most common use. The voltage across RL can
be calculated by:
R2 RL
VL = .Vs (4.1)
R1 RL + R2 RL + R1 R2
If RL is large compared to the other resistances, the output voltage can be ap-
proximated by the simpler equation:

R2
VL = .Vs (4.2)
R1 + R2
Chapter 4. System Component and Description 28

The main purpose of the potentiometer in this mixer motor is to control the speed
of motor in the two stage of mixing processes to avoid the splash of the mixture out
from the tanker and also the high speed mixing in the second stage may decrease
the quality of the mixture because it let the mixture create bubble. The initial
speed of the motor was 1400r/min. According to the above potentiometer voltage
regulation steps the speed of the motor is converted to the wanted speed as can
see on the following.
The initial speed of the motor was 1400r/min. According to the above potentiome-
ter voltage regulation steps the speed of the motor is converted to the wanted speed
as can see on the following. From the above power rating of the motor, we can find
the current I= 3.33A. Thus with RPM of the motor 1400rpm, the speed control
of the potentiometer will be as:

4.2.2 Decreasing the Speed of Motor

P
RP M = (4.3)
kgm
P =VI (4.4)

Therefore,
VI
rpm = (4.5)
kgm
220V I
= (4.6)
0.522
220 ∗ 3.33
= = 1400rpm (4.7)
0.522

At voltage V= 20v
20 ∗ 3.333
RP M = = 128rpm (4.8)
0.522
At voltage= 10v ,
10 ∗ 3.33
= = 64rpm (4.9)
0.522
Chapter 4. System Component and Description 29

At voltage v=5v , Rpm =32rpm

4.3 Sensors

Sensor is an electrical device held to detect the presence or absence, the change or
the appearance of things as whole. It differ depend of the function of the usage.
The sensitivity of a sensor s defined in terms of the relationship between input
physical signal and output electrical signal. The sensitivity is generally the ratio
between a small change in electrical signal to a small change in physical signal. As
such, it may be expressed as the derivative of the transfer function with respect
to physical signal. In this project we use temperature sensor and liquid sensor.

4.3.1 Temperature Sensors

Temperature sensors are devices that gather data concerning the temperature from
source and convert it to a form that can be understood either by an observer or
another device. In this project we use thermocouple temperature sensor.

4.3.2 Thermocouple

Thermocouple is a temperature-measuring device consisting of two dissimilar con-

ductors that contact each other at one or more spots, where a temperature differ-
ential is experienced by the different conductors; it produces a voltage when the
temperature of one of the spots differs from the reference temperature at other
parts of the circuit. In contrast to most other methods of temperature measure-
ment, thermocouples are self-powered and require no external form of excitation
and can also convert a temperature gradient into electricity. The standard con-
figuration for thermocouple usage is shown in the figure. Briefly, the desired
temperature Tsense is obtained using three inputsthe characteristic function E(T)
Chapter 4. System Component and Description 30

Figure 4.2: Structure of thermocouple temperature sensor

of the thermocouple, the measured voltage V, and the reference junctions’ temper-
ature Tref. The solution to the equation E(Tsense) = V + E(Tref) yields Tsense.
Under open-circuit conditions where there is no internal current flow, the gradient
of change voltage is directly proportional to the gradient in change temperature:
change V = -change T*S(T) S(T) is a temperature-dependent material property
known as the coefficient. The measured voltage can be found by adding up (inte-
grating) the electromotive forces along the entire path from the negative terminal
of the voltmeter to the positive terminal. The standard measurement configura-
tion, exemplified in the figure, has four temperature gradient regions and thus four
voltage contributions:

1. Change from Tmeter to Tref, in the lower copper wire.

2. Change from Tref to Tsense, in the alumel wire.

3. Change from Tsense to Tref, in the chromel wire.

Chapter 4. System Component and Description 31

4. Change from Tref to Tmeter, in the upper copper wire.

The first and fourth contributions cancel out exactly, because these regions involve
the same temperature change and an identical material. As a result, Tmeter does
not influence the measured voltage. The second and third contributions do not
cancel, as they involve different materials. The measured voltage turns out to be.
R
V= Tr ef Ts enseS(T ) − (S − (T ))dt
S+ and S- are the Seebeck coefficients of the conductors attached to the positive
and negative terminals of the voltmeter. An integral does not need to be per-
formed for every temperature measurement. Rather, the thermocouple’s behavior
is captured by a characteristic function, which needs only to be consulted at two
arguments:
V = E(Tsense) - E(Tref)

4.3.3 Liquid Sensors

Liquid sensors are sensors which can detect the presence or absence of a liquid.
They can be classified depend on what type of liquid they sense or depend on the
construction material. In this project we use liquid sensor in the main tanker to
detect the presence of mixture and the absence of mixture during baking system.

4.3.3.1 Liquid Level Sensors & Switches

Liquid level sensors can be single stage liquid level switches or double stage liquid
level switches. Single Stage Liquid Level Switches are designed to shut down
machinery or turn on warning devices when the liquid supply fails or recedes
to a predetermined level. They can be wired to flash a warning light, sound a
howler, shut down a machine, or signal a computer. This is especially helpful in
unattended automated plants. When the liquid in the reservoir recedes to the
low level, a magnet carried inside of the stainless steel float actuates a red switch
Chapter 4. System Component and Description 32

within the central pipe. The normally closed design means the contacts open with
the descending liquid level. Liquid Sensors installation can be on the top, bottom,
or side mnted in plastic or metal vessels, depending on application. To ensure
proper contact is maintained between the sensor and a metal vessel, care should
be taken not to over-insulate the sensor threads with sealant

Figure 4.3: Liquid Level Sensors

4.4 Limit Switch

Limit switch is a switch operated by the motion of a machine part or presence of

an object. They are used for controlling machinery as part of a control system,
as a safety interlocks, or to count objects passing a point. A limit switch is an
electromechanical device that consists of an actuator mechanically linked to a set
of contacts. When an object comes into contact with the actuator, the device
operates the contacts to make or break an electrical connection. Limit switches
are used in a variety of applications and environments because of their ruggedness,
ease of installation, and reliability of operation. They can determine the presence
or absence, passing, positioning, and end of travel of an object. They were first
used to define the limit of travel of an object; hence the name ”Limit Switch”.
Chapter 4. System Component and Description 33

Figure 4.4: Limit switch

4.5 Timers

Timer is a specialized type of clock for measuring time intervals while counting in
fixed intervals of time. It is also used for counting precise time delay which can
be used to repeat or initiate an action after or at a known period of time. Timer
also used to count an action or event, the value of counter increases by one every
time its corresponding action or event occurs.
A timer which counts upwards from zero for measuring elapsed time is often called
a stopwatch; a device which counts down from a specified time interval is more
usually called a countdown timer. A simple example for this type is an hourglass.
It can be On Delay and Off Delay timers.
The main difference between On Delay and Off Delay time delay functions, the
differences between all the functions available in time delay relays can sometimes be
a daunting task. When designing circuits using time delay relays, questions such
as what initiates a time delay relay, does the timing start with the application
or release of voltage, when is the output relay energized, etc... must be asked.
Application of input voltage
Chapter 4. System Component and Description 34

• Opening or closing of a trigger signal

• These trigger signals can be one of two designs:

• A control switch (dry contact), i.e., limit switch, push button, float switch,
etc.

• Voltage (commonly known as a power trigger)

Input Voltage: it control voltage applied to the input terminals. Depending on

the function, input voltage will either initiate the unit or make it ready to initiate
when a trigger is applied. Trigger Signal: it on certain timing functions, a trigger
is used to initiate the unit after input voltage has been applied. This trigger
can either be a control switch (dry contact switch) or a power trigger (voltage).
Output (Load): every time delay relay has an output (either mechanical relay or
solid state) that will open and close to control the load. Note that the user must
provide the voltage to power the load being switched by the output contacts of
the time delay relay. This timing Chart shows the relationship between Input
Voltage, Trigger (if present) and Output. If you cannot find a product to fit your
requirements or have any questions.

4.6 Contactors

A switching device more than 15 amperes or in circuits rated more than a few
kilowatts are usually called contactors. Contactors are designed to be directly
connected to high-current load devices, which used for switching a power supply
purpose. Contactor is electrically controlled switch similar to a relay except it
works at higher current ratings but controlled by a much lower power level than
the switched circuit. Contactor comes in many forms with varying capacities and
a feature unlike a circuit breaker, there are many ranges of contactor from those
having a breaking current of several amperes to thousands of amperes and 24 V
DC to many kilovolts with different physical size. A contactor has three compo-
nents, the current carrying part of the contactor which includes power contacts,
Chapter 4. System Component and Description 35

auxiliary contacts, and contact springs[5].

The second part is electromagnet (or ”coil”) provides the driving force to close
the contacts. Last the enclosure which the frame housing the contact and the
electromagnet. Enclosures are made of insulating materials like Bakelite, Nylon
6, and thermosetting plastics to protect and insulate the contacts and to provide
some measure of protection against personnel touching the contacts.
Sometimes an economizer circuit is also installed to reduce the power required to
keep a contactor closed; an auxiliary contact reduces coil current after the contac-
tor closes. A greater amount of power is required to initially close a contactor than
it requires for keeping it closed. Such a circuit can save a substantial amount of
power and allow the energized coil to stay cooler. Economizer circuits are nearly
always applied on direct-current contactor coils and on large alternating current
contactor coils. Contactors are rated by designed load current per contact (pole),
maximum fault withstand current, duty cycle, voltage, and coil voltage. The
contactors we use in this project are rated depending the above characteristics.

4.7 Circuit Breakers

A circuit breaker is an automatically operated electrical switch designed to pro-

tect an electrical circuit from damage caused by overload or short circuit. Its basic
function is to detect a fault condition and interrupt current flow. Unlike a fuse,
which operates once and then must be replaced, a circuit breaker can be reset
(either manually or automatically) to resume normal operation. Circuit breakers
are made in varying sizes, from small devices that protect an individual household
appliance up to large switchgear designed to protect high voltage circuits feeding
an entire city. All circuit breaker systems have common features in their operation,
although details vary substantially depending on the voltage class, current rating
and type of the circuit breaker. The circuit breaker must detect a fault condition;
in low voltage circuit breakers this is usually done within the breaker enclosure.
Circuit breakers for large currents or high voltages are usually arranged with pro-
tective relay pilot devices to sense a fault condition and to operate the trip opening
Chapter 4. System Component and Description 36

mechanism. The trip solenoid that releases the latch is usually energized by a sep-
arate battery, although some high-voltage circuit breakers are self-contained with
current transformers, protective relays and an internal control power source.
Once a fault is detected, contacts within the circuit breaker must open to interrupt
the circuit; some mechanically-stored energy (using something such as springs or
compressed air) contained within the breaker is used to separate the contacts, al-
though some of the energy required may be obtained from the fault current itself.
Small circuit breakers may be manually operated, larger units have solenoids to
trip the mechanism, and electric motors to restore energy to the springs[5].
The circuit breaker contacts must carry the load current without excessive heat-
ing, and must also withstand the heat of the arc produced when interrupting
(opening) the circuit. Contacts are made of copper or copper alloys, silver al-
loys and other highly conductive materials. Service life of the contacts is limited
by the erosion of contact material due to arcing while interrupting the current.
Miniature and molded-case circuit breakers are usually discarded when the con-
tacts have worn, but power circuit breakers and high-voltage circuit breakers have
replaceable contacts.When a current is interrupted, an arc is generated. This arc
must be contained, cooled and extinguished in a controlled way, so that the gap
between the contacts can again withstand the voltage in the circuit. Different
circuit breakers use vacuum, air, insulating gas or oil as the medium the arc forms
in. Different techniques are used to extinguish the arc including:

• Lengthening / deflection of the arc

• Intensive cooling (in jet chambers)

• Division into partial arcs

• Zero point quenching (Contacts open at the zero current time crossing of the
AC waveform, effectively breaking no load current at the time of opening.
The zero crossing occurs at twice the line frequency, i.e. 100 times per second
for 50 Hz and 120 times per second for 60 Hz AC) Connecting capacitors in
parallel with contacts in DC circuit
Chapter 5

Results And Discussions

5.1 Software Simulation of the System

Our system is simulated by programming logic controller logo software. LOGO

software is one type of PLC which is more advantageous to simulate the system
in offline state without connecting the hardware of the PLC or the system.

5.1.1 Programmable Logic Controller (PLC)

A programmable logic cont [6] is computer control system that continuously mon-
itors the state of input devices and makes decisions based upon a custom program
to control the state of output devices. It consists of input modules, a central pro-
cessing unit (CPU), output module, programming device and operating interface.
An input accepts a variety of digital or analog signals from various field devices
(sensors) and converts them into a logic signal that can be used by the CPU. The
CPU makes decisions and executes control instructions based on program instruc-
tions in memory. Output module converts control instructions from the CPU into
a digital or analog signal that can be used to control various field of devices (ac-
tuators). A programming device is used to input the desired instructions. These

37
Chapter 5. Results And Discussions 38

instructions determine What the PLC will do for a specific input. An operator in-
terface device allows process information to be displayed and new control program
parameters to be entered. The advantages PLC offer includes:

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.

• Computational abilities allow more sophisticated control.

• Trouble shooting aids make programming easier and reduce downtime.

• Reliable components make these likely to operate for years before failure

5.1.2 LOGO Software

LOGO is type of PLC which allows the implementation of a system using ladder
logic diagram and function block diagrams. It is differ from other types because it
can simulate and test the program offline on the pc and online during operation,
and also it provides professional documentation with all of the necessary project
information. Ladder Logic: is one programming language used with PLCs. It uses
components that resemble elements used in a line diagram format to describe hard
wired control. By selecting ladder logic as the main programming method, the
amount of retraining needed for engineers and trades people was greatly reduced.
In drawing a ladder diagram, certain conventions are adopted:

• The vertical lines of the diagram represent the power rails between which
circuits are connected. The power flow is taken to be from the left-hand
vertical across a rung.

• Each rung on the ladder defines one operation in the control process.

• A ladder diagram is read from left to right and from top to bottom,
Chapter 5. Results And Discussions 39

• Process control system is made up of a group of electronic devices and equip-

ment that provide stability, accuracy and eliminate harmful transition sta-
tuses in production processes.

• Operating system can have different form and implementation, from energy
supply units to machines.

• Beside connections with instruments like operating panels, motors, sensors,

switches, valves and such, possibilities for communication among instruments
are so great that they allow high level of exploitation and process coordina-
tion, as well as greater flexibility in realizing a process control system.

• Each component of a process control system plays an important role, regard-

less of its size.

With execution of a program stored in program memory, PLC continuously mon-

itors status of the system through signals from input device.

5.2 LOGO Simulation of the System

In LOGO software select and drag any device comment on it, set its function
on the system and connect it with the power line is easy and impressive process,
however to do this first and for most we should identify the system components
and then decide whether it is input or output of the system and their function on
the work. The following are input and output of our system and their function on
the work.
Chapter 5. Results And Discussions 40

Table 5.1: Components of the system

Component Symbol Description

motor-1 M1 Mixing motor
Motor-2 M2 Brushing motor
Motor-3 M3 Pouring motor
Motor-4 M4 Conveyor motor
Empty sensor ES Mixture empty sensor
Temperature sensor TS Mitad Temperature detector sensor
Limit switch-1 LS-1 Outside oven position detector of mitad
Limit switch-2 LS-2 Inside oven position detector of mitad
Limit swith-3 LS-3 Forward position of brush detector
Limit switch-4 LS-4 Reverse position of brush detector
Liquid senor LIS Full pouring detector
Timer-1 T1 Baking delay counter
Timer-2 T2 Injera taking delay

Table 5.2: Inputs

Input Device name Function LOGO CODE

Stop push button Stop the system 0000
Start push button Start the system 0001
Liquid (Empty) sensor Detects presence of mixture in the tanker 0002
Inside oven limit switch Detect mitad is inside the oven 0003
Temperature sensor Reads the preferable temperature for baking 0004
Outside oven limit switch Detects mitad is outside the oven 0005
Brush motor forward limit switch Detects brush is on the forward position 0006
Brush motor reverse limit switch Detect brush is on the reverse position 0007
Pouring limit switch Detects the plate pours the whole mitad 0008

Table 5.3: outputs

Output Device name Function LOGO Code

Mitad (heater ) Bake injera 0010
Baking timer Count the baking delay of individual injera 0011
Injera taking timer Count the delay to take injera manually 0012
Brushing motor Move the brush to clean the mitad after taking injera 0013
Pouring motor Pour the mixture in the mitad 0014
Conveyor motor Move in to or move out the mitad from the oven 0015
Chapter 5. Results And Discussions 41

Figure 5.1: Flow chart of the the system

Chapter 5. Results And Discussions 42

Figure 5.2: LOGO Simulation

Chapter 5. Results And Discussions 43

5.3 Hardware Simulation of the System

With the combination of all the sub processes and connecting the hard ware and
control circuit of the system automatic injera making machine automate the mix-
ing, brushing, pouring convening oven and baking processes. Depending in our
objective we have tried to accomplish all the processes as much as possible.

5.3.1 Mixer

This sub system is controlled by its own control circuit independent of the other sub
processes. Its main purpose is to mix the two stages and as storing at fermentation
and injera baking period. To make sure the speed of the motor doesnt affect the
second mixing stage its speed is controlled by potentiometer rheostat. The speed
will decrease with the potentiometer wiper position as mentioned above. The
mixing tanker used for the hardware simulation is PV-plastic due to the absence
and expensive of stain steel.

5.3.2 Brushing

It is the process of cleaning mitad to make sure it is safe for further baking system.
This brush operates using mechanical conveyor system to clean the mitad for every
individual injera and it is manufactured from steel as it shown in the picture.
Chapter 5. Results And Discussions 44

Figure 5.3: LOGO Simulation

Chapter 5. Results And Discussions 45

5.3.3 Pouring

Pouring is the process of glazing the mixture (dough) from the tanker to the
mitad. The pouring pleat valve is handmade aluminum sheet due to absence and
expensive of stain steel this decreases the pouring process quality.

Figure 5.4: Plate Value

5.3.4 Baking and convening

Baking is the delay between end of pouring and injera taking processes that is
haled in electric mitad covered by the oven. The mitad is opened and closed using
conveyor system which operates mechanical depending on the control circuit of
the system.
Chapter 5. Results And Discussions 46

This is the final assemble of the hardware automatic injera making machine which
avoids the tedious manual processes of injera baking

Figure 5.5: Final overall system

5.4 Cost Estimation of the Product

Cost Estimation is used to analyze the benefit of our product.

Chapter 5. Results And Discussions 47

Table 5.4: raw materials of a single product

Raw materials Per product requirement

Pure aluminum 3
Aluminum sheet 3[100m2]
Mitad 3
Bearing 4
Anglianer 216cm2
Motor 4
Limit switch 3
Timer 3
Contactor 5
Temperature sensor 1
Level sensor 1
Connector 1[ by 24 set]
Wire [2mm2] 12m
Breaker 2
Potentiometer 2

Table 5.5: Cost of components

Name of equipment Qty. Cost (birr)

Motor 4 8100
contactor 5 5000
Timer 3 500
Limit switch 3 800
Breaker 3 600
Wire uncountable 312
Connector 1 120
Temperature sensor 1 1300
Level sensor 1 500
Sheet metal aluminum 400
Pure aluminum 3 600
Mitad 1 1700
Angilianer - 350
Holder box 1 175
Mold 1 300
Potentiometer/rheostat 1 430
Handler 1 50
Total 21237 birr
Chapter 5. Results And Discussions 48

The above table indicates the total Component cost is almost 21,457. with out
other expenditures.To estimate ones Product Price Fixed costs like land cost,Machines,Office
furniture and variable costs like component cost,electric cost,water cost and other
extra expenditures and profits.Generally the total cost of our product will be
29,999.9 birr.
Chapter 6

Conclusion And Recommendation

6.1 Conclusion

Injera is special bread which is the only mean food of Ethiopian people and due to
this it was suffer to develop its technology. Until now its technology was mostly fo-
cused on the conversion of wood fire and decrease of its consumption. This project
deals with problems of manually processed injera making machine and overcom-
ing the challenges by making the system automatic including mixing, brushing,
pouring and baking operation systems. The operation of the system is simulated
using the LOGO software simulation, the work was successfully simulated simul-
taneously starting from the mixing the teff flour with water, conveying both mitad
and pouring and baking. The operation will continue until empty liquid sensor
found in the tanker detects the mixture is low; the power supply feed to the heater
will be automatically break the system. The whole system is temperature sensi-
tive system it only works when mitad is at nominal temperature, the breaker will
break the power supply when the temperature is higher and the mitad will wait
until it reach its nominal. In this whole processes the fermentation period and
type of teff fermented will not affect the system due to the mixing process is open
system from the other processes. For anyone who can have this automatic injera

49
Bibliography 50

making machine no matter he have the ability to bake injera or not will be so easy
to bake injera.

6.2 Recommendation

Even though this project has overcome most of the problem of the traditional injera
making process, for further works and improvement we recommend the following
ideas:

• Make the system completely automatic by change the manual handled injera
taking process to automatic.

• Decrease the power consumption of the system.

• Connecting this system with Biogas, solar and other power sources so as to
make it useable in rural areas of the country.

• Advancing the system to make it suitable for industrial production level

Bibliography

[1] et al Ali. Food and forage legumes of ethiopia progress and prospects, pro-
ceeding of the workshop on the food and forage legumes addis ababa, ethiopia.
2003.

[2] John Wiley and Sons. P.c.sen. principles of electric machines and power elec-
troncs. 1997.

[3] Study and test of a bldc motor drive systems function and operation fr a pump
application. . URL http//www.info@zelaleminjera.com.

[4] . URL http//www.wasselectronics.com.index.php/

wass-electronics-blog/latest.

[5] Danel and Hansson.

[6] Stefan Baldusson. Stefan baldursson. may 2005.

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