CONVEYOR AUTOMATION

Submitted in partial fulfillment of the requirement for the award of

DIPLOMA

IN

MECHANICAL ENGINEERING

BY

Under the guidance of-----------------------------

2005-2006
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
 Register number: _________________________

This is to certify that the project report titled “CONVEYOR

AUTOMATION” submitted by the following students for the award of diploma
engineering is record of bonafide work carried out by them.
Done by

Mr. /Ms._______________________________

In partial fulfillment of the requirement for the award of

Diploma in Mechanical Engineering

During the Year – (2005-2006)

_________________ _______________
Head of Department Guide

Coimbatore –641651.
Date:

Submitted for the university examination held on ___________

_________________ ________________
Internal Examiner External Examiner
---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
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ACKNOWLEDGEMENT
 At this pleasing moment of having successfully completed our
project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved chairman
…………………………………………………, who provided all the
facilities to us.
We would like to express our sincere thanks to our principal
………………………………………, for forwarding us to do our
project and offering adequate duration in completing our project.
We are also grateful to the Head of Department Prof.
…………………………………….., for her constructive suggestions &
encouragement during our project.
With deep sense of gratitude, we extend our earnest & sincere
thanks to our guide ……………………………………………………..,
Department of Mechanical for her kind guidance & encouragement
during this project.
We also express our indebt thanks to our TEACHING and NON
TEACHING staffs of MECHANICAL ENGINEERING
DEPARTMENT,……………………….(COLLEGE NAME).
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CONVEYOR AUTOMATION
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CONTENTS
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 CONTENTS

ACKNOWLEDGEMENT

1. SYNOPSIS

2. INTRODUCTION

3. LITERATURE SURVEY

4. DESCRIPTION OF COMPONENTS

5. DESIGN AND DRAWINGS

6. FABRICATION

7. WORKING OPERATION

8. ADVANTAGES AND LIMITATIONS

9. APPLICATIONS

10. LIST OF MATERIAL

11. COST ESTIMATION

12. CONCLUSION

BIBLIOGRAPHY

PHOTOGRAPHY
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Chapter-1
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SYNOPSIS
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 CHAPTER-1

SYNOPSIS

In our project “CONVEYOR AUTOMATION” beings with an introduction to

pneumatic, it’s various applications.

The conveyor Automation is very useful for material handling in modern

engineering industries. The motor is used to drive the conveyor. The materials are

transferred from one place to another place by using conveyor. In this conveyor itself,

some operation (Example: - Number Punching, Addressing, Tested OK mark) are doing

with the help of pneumatic power. This system gives smooth operation and smooth

movement of the belts to the jobs at required time.

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Chapter-2
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INTRODUCTION
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 CHAPTER-2

INTRODUCTION

This is an era of automation where it is broadly defined as replacement of manual

effort by mechanical power in all degrees of automation. The operation remains an

essential part of the system although with changing demands on physical input as the

degree of mechanization is increased.

Degrees of automation are of two types, viz.

Full automation.

Semi automation.

In semi automation a combination of manual effort and mechanical power is

required whereas in full automation human participation is very negligible.

Need For Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc., of these sources, pneumatics form an attractive medium for low cost automation.

The main advantages of all pneumatic systems are economy and simplicity. Automation

plays an important role in mass production.

 For mass production of the product, the machining operations decide the sequence

of machining. The machines designed for producing a particular product are called

transfer machines. The components must be moved automatically from the bins to

various machines sequentially and the final component can be placed separately for

packaging. Materials can also be repeatedly transferred from the moving conveyors to the

work place and vice versa.

Conveyor Automation concepts are the most important things in factory design.

Automation plays a vital role in mass production of a product, the machining operations

decides the sequence of machining. The machines designed for producing a particular

product are called transfer machines. Conveyor Automation is a specialized activity for a

modern manufacturing concern. It has been estimated that about 60-70% of the cost

production is spent in material transferring activities.

Need for Conveyor Automation:

 Reduction of labour and material cost

 Reduction of overall cost
 Increased production
 Increased safety
 To reduce the inspection time
 Reduction in fatigue
 Improved personnel comfort
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Chapter-3
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LITERATURE SURVEY
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 CHAPTER –3
LITERATURE SURVEY

PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The word

pneumatics is the study of air movement and its phenomena is derived from the word

pneuma. Today pneumatics is mainly understood to means the application of air as a

working medium in industry especially the driving and controlling of machines and

equipment.

Pneumatics has for some considerable time between used for carrying out the

simplest mechanical tasks in more recent times has played a more important role in the

development of pneumatic technology for automation.

Pneumatic systems operate on a supply of compressed air which must be made

available in sufficient quantity and at a pressure to suit the capacity of the system. When

the pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

 The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions namely at atmosphere pressure

and normal ambient temperature.

The compressibility of the air was first investigated by Robert Boyle in 1962 and

that found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7

Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high

in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly

used system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic is an attractive medium for low cost mechanization

particularly for sequential (or) repetitive operations. Many factories and plants already

have a compressed air system, which is capable of providing the power (or) energy

requirements and the control system (although equally pneumatic control systems may be

economic and can be advantageously applied to other forms of power).

The main advantage of an all pneumatic system are usually economic and

simplicity the latter reducing maintenance to a low level. It can also have out standing

advantages in terms of safety.

PNEUMATIC POWER

Pneumatic systems use pressurised gases to transmit and control power.

Pneumatic systems typically use air as the fluid medium because air is safe, low cost and

readily available.
The Advantages of Pneumatics:

1. Air used in pneumatic systems can be directly exhausted back in to the

surrounding environment and hence the need of special reservoirs and no-

leak system designs are eliminated.

2. Pneumatic systems are simple and economical.

3. Control of pneumatic systems is easier.

The Disadvantages of Pneumatics:

1. Pneumatic systems exhibit spongy characteristics due to compressibility of air.

2. Pneumatic pressures are quite low due to compressor design limitations (less that

250 psi).

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made

available in sufficient quantity and at a pressure to suit the capacity of the system. When
pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure. Compressor capacity is the actual

quantity of air compressed and delivered and the volume expressed is that of the air at

intake conditions namely at atmosphere pressure and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the life of a

compressor. Warm and moist suction air will result in increased precipitation of condense

from the compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for

compressed air plant and have proved highly successful and supply air for pneumatic

control application.

The types of positive compressor

 1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic control

application unless built in multistage designs and are seldom encountered in pneumatic

service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is by

far the most common type. Reciprocating compressors lap be had is sizes from the

smallest capacities to deliver more than 500 m³/min. In single stage compressor, the air

pressure may be of 6 bar machines discharge of pressure is up to 15 bars. Discharge

pressure in the range of 250 bars can be obtained with high pressure reciprocating

compressors that of three & four stages. Single stage and 1200 stage models are

particularly suitable for pneumatic applications , with preference going to the two stage

design as soon as the discharge pressure exceeds 6 bar , because it in capable of matching

the performance of single stage machine at lower costs per driving powers in the range .

ULTIMATE AIM
 The Conveyor Automation can be widely used in low cost automation. The

manpower requirement is negligible also reducing the manufacturing time of material.

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Chapter-4
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DESCRIPTION OF COMPONENTS
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CHAPTER-4

DESCRIPTION OF COMPONENTS

MAJOR PARTS

The major parts “CONVEYOR AUTOMATION” are described below:

 Pneumatic single Acting Cylinder

 3/2 Single Acting Solenoid Valve

 Flow Control Valve

 Hose Collar and PU Connector

 Permanent Magnet D.C. Motor

 IR Sensor unit

 Timer Unit

 Conveyor Belt and Roller

 1. PNEUMATIC CYLINDER:-

An air cylinder is an operative device in which the state input energy of

compressed air i.e. pneumatic power is converted in to mechanical output power, by

reducing the pressure of the air to that of the atmosphere.

a) Single acting cylinder

Single acting cylinder is only capable of performing an operating medium in only

one direction. Single acting cylinders equipped with one inlet for the operating air

pressure, can be production in several fundamentally different designs. Single cylinders

develop power in one direction only.

Therefore no heavy control equipment should be attached to them, which requires

to be moved on the piston return stoke single action cylinder requires only about half the

air volume consumed by a double acting for one operating cycle.

B) Double acting cylinders:

A double acting cylinder is employed in control systems with the full

pneumatic cushioning and it is essential when the cylinder itself is required to retard

heavy messes. This can only be done at the end positions of the piston stock.
 In all intermediate position a separate externally mounted cushioning derive most be

provided with the damping feature. The normal escape of air is out off by a cushioning

piston before the end of the stock is required.

As a result the sit in the cushioning chamber is again compressed since it cannot

escape but slowly according to the setting made on reverses.

The air freely enters the cylinder and the piston stokes in the other direction at full

force and velocity.

GENERALLY USED MATERIALS

Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Plastic Hard drawn brass tube hard drawn brass tube.

2. Hard drawn Aluminium Hard drawn steel tube

Aluminium tube Castings tube.

4. Hard drawn Brass, Bronze, Iron or

 Brass tube Castings, welded steel tube

End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

(Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

Piston Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1.Aluminium Aluminium Castings Aluminium Forgings,

Castings Brass (Fabricated) Aluminium Castings.

2. Bronze (Fabricated) Bronze (Fabricated)

3. Iron and Steel Brass, Bronze, Iron or

Castings Steel Castings.

Mount Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium Aluminium, Brass High Tensile

Castings And Steel Castings Steel Castings

2. Light Alloy High Tensile

(Fabricated) Steel Fabrication

Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished hardened, Generally preferred chrome

ground and polished. plated

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

2. SINGLE ACTING 3/2 SOLENOID VALVE:-

 The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in the

pneumatic system. The directional valve does this by changing the position of its internal

movable parts.

This valve was selected for speedy operation and to reduce the manual effort and

also for the modification of the machine into automatic machine by means of using a

solenoid valve.

A solenoid is an electrical device that converts electrical energy into straight line

motion and force. These are also used to operate a mechanical operation which in turn

operates the valve mechanism. Solenoids may be push type or pull type. The push type

solenoid is one in which the plunger is pushed when the solenoid is energized

electrically. The pull type solenoid is one is which the plunger is pulled when the

solenoid is energized.

The name of the parts of the solenoid should be learned so that they can be

recognized when called upon to make repairs, to do service work or to install them.

Parts of a 3/2 Solenoid Valve

 1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated by

insulating layer. The entire solenoid coil is covered with a varnish that is not affected by

solvents, moisture, cutting oil or often fluids.

Coils are rated in various voltages such as 115 volts AC, 230 volts AC, 460 volts

AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts

DC. They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated sheets,

it is magnetized when the current passes through the coil. The magnetized coil attracts

the metal plunger to move. The frame has provisions for attaching the mounting. They

are usually bolted or welded to the frame. The frame has provisions for receivers, the

plunger. The wear strips are mounted to the solenoid frame, and are made of materials

such as metal or impregnated less fiber cloth.

3. Solenoid Plunger
 The Solenoid plunger is the mover mechanism of the solenoid. The plunger is

made of steel laminations which are riveted together under high pressure, so that there

will be no movement of the lamination with respect to one another. At the top of the

plunger a pin hole is placed for making a connection to some device.

The solenoid plunger is moved by a magnetic force in one direction and is usually

returned by spring action.

Solenoid operated valves are usually provided with cover over either the solenoid

or the entire valve. This protects the solenoid from dirt and other foreign matter, and

protects the actuator. In many applications it is necessary to use explosion proof

solenoids.

Working of Solenoid Valve:

The Solenoid control valve is used to control the flow direction is called cut off

valve or solenoid valve. This solenoid cut off valve is controlled by the electronic control

unit.
 In our project 3/2 Single acting solenoid valve is used. This solenoid valve is

used to punching, printing or marking operation in to the materials.

3. FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed of the

actuator. The floe control can be achieved by varying the area of flow through which the

air in passing.

When area is increased, more quantity of air will be sent to actuator as a result its

speed will increase. If the quantity of air entering into the actuator is reduced, the speed

of the actuator is reduced.

4. HOSE COLLAR AND PU CONNECTOR:-

In our pneumatic system there are two types of connectors used; one is the

hose connector and the other is the reducer. Hose connectors normally comprise an

adapter (connector) hose nipple and cap nut. These types of connectors are made up of

brass or Al or hardened steel.

Reducers are used to provide inter connection between two pipes or hoses of

different sizes. They may be fitted straight, tee, “V” or other configurations. These

reducers are made up of gunmetal or other materials like hardened steel etc.
 Hoses used in this pneumatic system are made up of polyurethane. These hoses

can with stand at a maximum pressure level of 10 kg/cm2.

5. D.C. MOTOR (PERMANENT MAGNET):

DESCRIPTION OF DC MOTOR

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor is

placed in a magnetic field, it experiences a magnetic force whose direction is given by

Fleming’s left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or

series wound or compound wound motors.

FLEMING’S LEFT HAND RULE:

Keep the force finger, middle finger and thumb of the left hand mutually

perpendicular to one another. If the fore finger indicates the direction of magnetic field

and middle finger indicates direction of current in the conductor, then the thumb indicates

the direction of the motion of conductor.

PRINCIPLE OF OPERATION OF DC MOTOR:

Figure show a uniform magnetic field in which a straight conductor carrying no

current is placed. The conductor is perpendicular to the direction of the magnetic field.

The conductor is as carrying a current away from the viewer, but the field due to

the N and S poles has been removed. There is no movement of the conductor during the

above two conditions. The current carrying conductor is placed in the magnetic field.

The field due to the current in the conductor supports the main field above the conductor,

but opposes the main field below the conductor.

Movement of

Conductor

N S

Magnetic flux current carrying

Conductor
 The result is to increase the flux density in to the region directly above the

conductor and to reduce the flux density in the region directly below the conductor. It is

found that a force acts on the conductor, trying to push the conductor downwards as

shown by the arrow. If the current in the conductor is reversed, the strengthening of flux

lines occurs below the conductor, and the conductor will be pushed upwards.

Now consider a single turn coil carrying a current as shown in the above figure. in

view of the reasons given above, the coil side A will be forced to move downwards,

whereas the coil side B will be forced to move upwards. The forces acting on the coil

sides A and B will be of same magnitude. But their direction is opposite to one another.

As the coil is wound on the armature core which is supported by the bearings, the

armature will now rotate. The commutator periodically reverses the direction of current

flow through the armature. Therefore the armature will have a continuous rotation.

The conductors are wound over a soft iron core. DC supply is given to the field

poles for producing flux. The conductors are connected to the DC supply through

brushes. Let’s start by looking at the overall plan of a simple 2-pole DC electric motor. A

simple motor has 6 parts, as shown in the diagram below.

  An armature or rotor

 A commutator

 Brushes

 An axle

 A field magnet

 A DC power supply of some sort

An electric motor is all about magnets and magnetism: a motor uses magnets to

create motion. If you have ever played with magnets you know about the fundamental

law of all magnets: Opposites attract and likes repel.

 So if you have 2 bar magnets with their ends marked north and south, then the

North end of one magnet will attract the South end of the other. On the other hand, the

North end of one magnet will repel the North end of the other (and similarly south will

repel south). Inside an electric motor these attracting and repelling forces create rotational

motion.

In the diagram above and below you can see two magnets in the motor, the

armature (or rotor) is an electromagnet, while the field magnet is a permanent magnet

(the field magnet could be an electromagnet as well, but in most small motors it is not to

save power).

Electromagnets and Motors:

To understand how an electric motor works, the key is to understand how the

electromagnet works. An electromagnet is the basis of an electric motor. You can

understand how things work in the motor by imagining the following scenario. Say that

you created a simple electromagnet by wrapping 100 loops of wire around a nail and

connecting it to a battery. The nail would become a magnet and have a North and South

Pole while the battery is connected.

 Now say that you take your nail electromagnet, run an axle through the middle of

it, and you suspended it in the middle of a horseshoe magnet as shown in the figure

below.

If you were to attach a battery to the electromagnet so that the North end of the

nail appeared as shown, the basic law of magnetism tells you what would happen: The

North end of the electromagnet would be repelled from the north end of the horseshoe

magnet and attracted to the south end of the horseshoe magnet.

The South end of the electromagnet would be repelled in a similar way. The nail

would move about half a turn and then stop in the position shown.

You can see that this half-turn of

motion is simple and obvious because of

the way magnets naturally attract and

repel one another. The key to an electric

motor is to then go one step further so

that, at the moment that this half-turn of

motion completes, the field of the

electromagnet flips. The flip causes the

electromagnet to complete another half-turn of motion.

 You flip the magnetic field simply by changing the direction of the electrons

flowing in the wire (you do that by flipping the battery over). If the field of the

electromagnet flipped at just the right moment at the end of each half-turn of motion, the

electric motor would spin freely.

The Armature:

The armature takes the place of the nail in an electric motor. The

armature is an electromagnet made by coiling thin wire around

two or more poles of a metal core. The armature has an axle, and

the commutator is attached to the axle. In the diagram above you

can see three different views of the same armature: front, side and

end-on. In the end-on view the winding is eliminated to make the

commutator more obvious. You can see that the commutator is simply a pair of plates

attached to the axle. These plates provide the two connections for the coil of the

electromagnet.
The Commutator and brushes:

The "flipping the electric field" part of an electric motor is

accomplished by two parts: the commutator and the brushes. The

diagram at the right shows how the commutator and brushes work

together to let current flow to the electromagnet, and also to flip

the direction that the electrons are flowing at just the right

moment. The contacts of the commutator are attached to the axle

of the electromagnet, so they spin with the magnet. The brushes are just two pieces of

springy metal or carbon that make contact with the contacts of the commutator.

Putting It All Together:

When you put all of these parts together, what you have is a complete electric

motor:
 In this figure, the armature winding has been left out so that it is easier to see the

commutator in action. The key thing to notice is that as the armature passes through the

horizontal position, the poles of the electromagnet flip. Because of the flip, the North

Pole of the electromagnet is always above the axle so it can repel the field magnet's North

Pole and attract the field magnet's South Pole. If you ever take apart an electric motor you

will find that it contains the same pieces described above: two small permanent magnets,

a commutator, two brushes and an electromagnet made by winding wire around a piece

of metal. Almost always, however, the rotor will have three poles rather than the two

poles as shown in this article. There are two good reasons for a motor to have three poles:

It causes the motor to have better dynamics. In a two-pole motor, if the

electromagnet is at the balance point, perfectly horizontal between the two poles of

the field magnet when the motor starts; you can imagine the armature getting

"stuck" there. That never happens in a three-pole motor.

Each time the commutator hits the point where it flips the field in a two-pole

motor, the commutator shorts out the battery (directly connects the positive and

negative terminals) for a moment. This shorting wastes energy and drains the

battery needlessly. A three-pole motor solves this problem as well.

It is possible to have any number of poles, depending on the size of the motor and

the specific application it is being used in.

 6. IR SENSOR UNIT:-

The IR TRANSMITTER circuit is to transmite the Infra-Red rays. This Infra-

Red rays are received by the receiver circuit is called “IR RECEIVER”. If any obstacle

is there in a path, the Infra-Red rays are cutted.

The IR receiver circuir receives the IR rays and giving the control signal to the

control circuit. The control circuit is used to off the solenoid valve at normal condition.

There is any abstacle in their path meand, the control signal is activate the solenoid valve

so that the punching, printing or marking operation occurs. The operating principle of

solenoid valve is already explained in the above chapter.

The IR transmitting circuit is used in many projects. The IR transmitter sends 40

kHz (frequency can be adjusted) carrier under computer control (computer can turn the

IR transmission on and off). IR carriers at around 40 kHz carrier frequencies are widely

used in TV remote controlling and ICs for receiving these signals are quite easily

available.

7. TIMER UNIT:-

The timer unit is used to proper printing operation to the work piece. The timer

having one variable resister is there, you have to vary the off time of the timer unit.
 The IR sensor output signal gives the input power supply of the timer unit. The

OP-AMP 324 IC is used as a comparator. The comparator is giving the output voltages

depends upon the two input voltage values.

In our project one input voltage (Reference Voltages) is given to the PIN

number 2 (- ive pin) of 324 IC from the variable resistor (10 K Ohm). The Variable

resistance output is given to the OP-AMP pin number 3 (+ ive pin).

CIRCUIT DIAGRAM:-

1K

9V (ZENER) 10K

10K 2 - 4
IC3
IR SENSOR 1000µF 3 + 24 1
OUTPUT
10K 10K

2.2K

LDR 1N4007 5 + 7
IC3
10K 6 - 24 11

SOLENOID N/C BC547 1K

VALVE RELAY

N/O LED 1K
AT NORMEL CONDITION:-

In normal condition the Sensor output signal is zero.. The voltages applied to the

non-inverting terminal (+ ive) is low when compared to the inverting terminal voltages (-

ive). In that time, the OP-AMP output is –Vsat. (I.e -12 Volt). The transistor and relay are

in “OFF” condition. In that condition, the solenoid valve is off condition.

AT ABNORMAL CONDITION:-

In Abnormal condition the IR sensor output signal is ON. The voltages applied to

the non-inverting terminal (+ ive) is high when compared to the inverting terminal

voltages (- ive). In that time, the OP-AMP output is +Vsat. (I.e +12 Volt). The transistor

and relay are in “ON” condition. In that time, the solenoid valve is in ON condition, the

printing operation is done.

8. CONVEYOR BELT AND ROLLER:-

Conveyor belt and roller mechanism is used to transfer the work piece from one place

to the other place. The roller havine two end bearings with bearing cap. It is made upof

mild steel.
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Chapter-5
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DESIGN AND DRAWINGS

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 CHAPTER-5

DESIGN AND DRAWINGS

PNEUMATIC CYLINDER:

Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) = 35 mm

Pressure acting (p) = 6 kgf/cm²

Material used for rod = C 45

Yield stress (σy) = 36 kgf/mm²

Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (Πd² / 4)

= 6 x {( Π x 3.5² ) / 4 }

P = 57.73 Kgf
 Design Stress(σy) = σy / F0 S

= 36 / 2 = 8 Kgf/mm²

= P / (Π d² / 4 )

∴d = √ 4 p / Π [ σy ]

= √ 4 x 57.73 / {Π x 18}

= √ 4.02 = 2.02 mm

∴ Minimum diameter of rod required for the load = 2.02 mm

We assume diameter of the rod = 12.5 mm

Design of cylinder thickness:

Material used = Cast iron

Assuming internal diameter of the cylinder = 35 mm

Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²

Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

Working stress ( ft ) = 2500 / 4 = 625 Kgf/cm²

According to ‘LAMES EQUATION’

Minimum thickness of cylinder ( t ) = ri {√ (ft + p) / (ft – p ) -1 }

Where,

ri = inner radius of cylinder in cm.

ft = Working stress (Kgf/cm²)

p = Working pressure in Kgf/cm²

∴ Substituting values we get,

t = 1.75 { √ (625 + 6) / ( 625 – 6) -1}

t = 0.0168 cm = 0.17 mm

We assume thickness of cylinder = 2.5 mm

Inner diameter of barrel = 35 mm

Outer diameter of barrel = 35 + 2t

= 35 + ( 2 x 2.5 ) = 40 mm
Design of Piston rod:

Diameter of Piston Rod:

Force of piston Rod (P) = Pressure x area = p x Π/4 (d²)

= 6 x (Π / 4) x (3.5)²

= 57.73 Kgf

Also, force on piston rod (P) = (Π/4) (dp)² x ft

P = (Π/4) x (dp)² x 625

57.73 = (Π/4) x (dp)² x 625

∴ dp² = 57.73 x (4/Π) x (1/625)

= 0.12

dp = 0.34 cm = 3.4 mm

By standardizing dp = 12.5 mm

Length of piston rod:

Approach stroke = 50 mm

Length of threads = 2 x 20 = 40mm

Extra length due to front cover = 12 mm

 Extra length of accommodate head = 20 mm

Total length of the piston rod = 50 + 40 + 12 + 20

= 122 mm

By standardizing, length of the piston rod = 130 mm

SPECIFICATION

1. Single acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 50 mm

Quantity : 1

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN – 8

Media : Air

Temperature : 0-80 º C

Pressure Range : 8 N/m²

2. Solenoid Valve

Technical data
 Max pressure range : 0-10 x 10 ⁵ N/m²

Quantity : 3

3. Flow control Valve

Technical Data

Port size : 0.635 x 10 ֿ² m

Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1

4. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

5. Hoses

Technical date

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³m
Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m
--------------------------------------------------------------------------------------

Chapter-6
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

FABRICATION
--------------------------------------------------------------------------------------
 CHAPTER-6

FABRICATION

Method of Fabrication:

The stand (or) base is to carry the whole machine. The two conveyor roller is fixed

to the two ends of the frame stand with the help of end bearing (6202) with bearing cap.

The conveyor roller shaft is coupled to the D.C. permanent magnet motor with the help of

spur gear mechanism. This total arrangement is used to transfer the material from one

place to another place with the help of conveyor.

The IR transmitter and IR receiver circuit is used to sense the work piece material.

It is fixed to the frame stand with a suitable arrangement. The pneumatic cylinder is fixed

to the frame stand by right angles to the sensor. This cylinder arrangement is used to

punch, print or mark the materials transferred from the conveyor. The pneumatic cylinder

is controlled by the flow control valve, single acting solenoid valve and control unit.
--------------------------------------------------------------------------------------

Chapter-7
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

WORKING OPERATION
--------------------------------------------------------------------------------------
 CHAPTER-7

WORKING OPERATION

The 12 volt power supply is used to drive the permanent magnet D.C motor. The

two conveyor roller is fixed to the two ends of the frame stand with the help of end

bearing (6202) with bearing cap. The conveyor roller shaft is coupled to the D.C.

permanent magnet motor with the help of spur gear mechanism. This total arrangement is

used to transfer the material from one place to another place with the help of conveyor.

The IR sensor is used to detect the material and giving control signal to the control

unit. The IR transmitter and IR receiver circuit is used to sense the material. It is fixed to

the frame stand with a suitable arrangement. This mechanism is also adjustable with the

help of bolt and nut. The pneumatic cylinder is fixed to the frame stand by right angles to

the frame stand. This cylinder arrangement is used to punching, marking or printing into

the material from the conveyor. The pneumatic cylinder is controlled by the flow control

valve, single acting solenoid valve and control unit.

 IR TRANSMITTER CIRCUIT:

+Vcc

R4 (47Ω) T1 (BD140) 150K

3 1
2 1 8
C3 (100µ/25V) R1
2 7
R2 (47Ω) IC 555 1.5K
3 6
R5 4.7Ω
4 5

L1 IR LED C2 C1
0.01pF 0.1pF
 IR RECEIVER CIRCUIT:

1K

+12V

RELAY
R12 (680Ω) R1 (4.7K)
RL1 L1 (IR SENSOR)
D2 R10 C3 (100µ) C2 (100µ) L2 (IR SENSOR)
L3 (LED) 1N4007 4.7K R3 R2
R7 (100K) 4.7K 4.7K

D1 (1N 4007) T3 C4 (0.1pF) C1 (0.01 pF)

T5 (BC547B) R9 (4.7K) R8 BC 557
T4 (BC 547B) T2 (BC549C) R13
120Ω C8 (47 pF) 120Ω
R5
T1 (BC 549C)
R11 C7
22µF (50V) R6
22K 2.2K C5 (0.1pF)
AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC

timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor

T1, T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF

condition. At that time sensor output signal is OFF.

AT MATERIAL CONDITION:

At material conditions the IR transmitter and IR receiver, the resistance across the

Transmitter and receiver is high due to the non-conductivity of the IR waves. So the

output of transistor T5 goes from OFF condition to ON stage. The timer unit relay is ON

to the 3/2 solenoid valve, so that the air from the compressor is goes to the pneumatic

cylinder. The punching or marking or printing operations are done with the help of die

fixed in the piston rod of the pneumatic cylinder.

COUNTER CIRCUIT

The circuit diagram of the digital counter as shown in bellow. There are two

pulse signal is given to the microprocessor 89C51 (control unit). This pulse signal

received from IR sensor circuit when the one packing cover is finished.
 Pulse to Pin 12 - For Each correct material

Pulse to reset pin - For reset the microcontroller

The signal from the IR receiver is given to the pin number 12 of

Microcontroller IC through high pass filter. This high pass filter is used to eliminate the

high frequency signal due to external unwanted signal. In our circuit simple R-C high

pass filter circuit is used. The zener diode (5.6 Volt) also used to cut off the high voltage

signal from the input signal.

 Vcc 10µ/63V Vcc 0.1µ
9 40
Vcc
10K Vcc 10K 150Ω
P0.0
10K 150Ω
P0.1
8 150Ω COMMON ANODE LED
P0.2
9 150Ω
P0.3
C 150Ω
PULSE FROM SENSOR P0.4
5 150Ω
1.5K P0.5
100K 12 2 150Ω
P0.6
0.1µ 150K Vcc
5.6V 10K 2.2K
PULSE FROM RESET
P2.2
BC557
100K 1.5K 2.2K
13 P2.1 BC 557
33pF 18
5.6V 0.1µ 150K CRYSTAL
12MHZ Vcc
33pF 10k
19 1K 12V Vcc
P2.0
20 1N4007 RELAY
MOTOR

BC 547
 The pin number 12 of microcontroller is multifunctional pin. It is used as a

port (P3.2-high signal) or external interrupt (INT0-Low signal). In our project the pin

number 12 as used as an external interrupt. The signal received from the sensor is low

pulse, so that the microcontroller acts as an interrupt signal.

The microcontroller (by using microcontroller program) activates the port

P0.0-P0.6 and P2.1 –P2.3 when the interrupt signal receiving on Pin number 12. The port

P0.0-P0.6 and P2.1-P2.3 are connected to the 3 digit 7-Segment Common Anode LED.

The 7-segment LED count the number of person entered into the particular entrance place

start 1. At the same time microcontroller is activates the pin number P2.0 from low to

high. The pin number P2.0 is connected to packing conveyor through relay. Then this

process is continuous one.

BATTERIES

INTRODUCTION:

In isolated systems away from the grid, batteries are used for storage of excess

solar energy converted into electrical energy. The only exceptions are isolated sunshine

load such as irrigation pumps or drinking water supplies for storage. In fact for small

units with output less than one kilowatt.

 Batteries seem to be the only technically and economically available storage

means. Since both the photo-voltaic system and batteries are high in capital costs. It is

necessary that the overall system be optimized with respect to available energy and local

demand pattern. To be economically attractive the storage of solar electricity requires a

battery with a particular combination of properties:

(1) Low cost

(2) Long life

(3) High reliability

(4) High overall efficiency

(5) Low discharge

(6) Minimum maintenance

(A) Ampere hour efficiency

(B) Watt hour efficiency

We use lead acid battery for storing the electrical energy from the solar panel for

lighting the street and so about the lead acid cells are explained below.
2.1 LEAD-ACID WET CELL:

Where high values of load current are necessary, the lead-acid cell is the type most

commonly used. The electrolyte is a dilute solution of sulfuric acid (H₂SO₄). In the

application of battery power to start the engine in an auto mobile, for example, the load

current to the starter motor is typically 200 to 400A. One cell has a nominal output of

2.1V, but lead-acid cells are often used in a series combination of three for a 6-V battery

and six for a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be recharged.

The charge and discharge cycle can be repeated many times to restore the output voltage,

as long as the cell is in good physical condition. However, heat with excessive charge

and discharge currents shortends the useful life to about 3 to 5 years for an automobile

battery. Of the different types of secondary cells, the lead-acid type has the highest

output voltage, which allows fewer cells for a specified battery voltage.
2.2 CONSTRUCTION:

Inside a lead-acid battery, the positive and negative electrodes consist of a group

of plates welded to a connecting strap. The plates are immersed in the electrolyte,

consisting of 8 parts of water to 3 parts of concentrated sulfuric acid. Each plate is a grid

or framework, made of a lead-antimony alloy. This construction enables the active

material, which is lead oxide, to be pasted into the grid. In manufacture of the cell, a

forming charge produces the positive and negative electrodes. In the forming process,

the active material in the positive plate is changed to lead peroxide (pbo₂). The negative

electrode is spongy lead (pb).

Automobile batteries are usually shipped dry from the manufacturer. The

electrolyte is put in at the time of installation, and then the battery is charged to from the

plates. With maintenance-free batteries, little or no water need be added in normal

service. Some types are sealed, except for a pressure vent, without provision for adding

water.

The construction parts of battery are shown in figure.

2.3 CHEMICAL ACTION:

Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell

discharges, lead peroxide from the positive electrode combines with hydrogen ions to

form water and with sulfate ions to form lead sulfate. Combining lead on the negative

plate with sulfate ions also produces he sulfate. There fore, the net result of discharge is

to produce more water, which dilutes the electrolyte, and to form lead sulfate on the

plates.

As the discharge continues, the sulfate fills the pores of the grids, retarding

circulation of acid in the active material. Lead sulfate is the powder often seen on the

outside terminals of old batteries. When the combination of weak electrolyte and

sulfating on the plate lowers the output of the battery, charging is necessary.

On charge, the external D.C. source reverses the current in the battery. The

reversed direction of ions flows in the electrolyte result in a reversal of the chemical

reactions. Now the lead sulfates on the positive plate reactive with the water and sulfate

ions to produce lead peroxide and sulfuric acid. This action re-forms the positive plates

and makes the electrolyte stronger by adding sulfuric acid.

 At the same time, charging enables the lead sulfate on the negative plate to react

with hydrogen ions; this also forms sulfuric acid while reforming lead on the negative

plate to react with hydrogen ions; this also forms currents can restore the cell to full

output, with lead peroxide on the positive plates, spongy lead on the negative plate, and

the required concentration of sulfuric acid in the electrolyte.

The chemical equation for the lead-acid cell is

Charge

Pb + pbO₂ + 2H₂SO₄ 2pbSO₄ + 2H₂O

Discharge

On discharge, the pb and pbo₂ combine with the SO₄ ions at the left side of the

equation to form lead sulfate (pbSO₄) and water (H₂O) at the right side of the equation.

One battery consists of 6 cell, each have an output voltage of 2.1V, which are

connected in series to get an voltage of 12V and the same 12V battery is connected in

series, to get an 24 V battery. They are placed in the water proof iron casing box.
2.4 CARING FOR LEAD-ACID BATTERIES:

Always use extreme caution when handling batteries and electrolyte. Wear

gloves, goggles and old clothes. “Battery acid” will burn skin and eyes and destroy

cotton and wool clothing.

The quickest way of ruin lead-acid batteries is to discharge them deeply and leave

them stand “dead” for an extended period of time. When they discharge, there is a

chemical change in the positive plates of the battery. They change from lead oxide when

charge out lead sulfate when discharged. If they remain in the lead Sulfate State for a

few days, some part of the plate dose not returns to lead oxide when the battery is

recharged. If the battery remains discharge longer, a greater amount of the positive plate

will remain lead sulfate. The parts of the plates that become “sulfate” no longer store

energy. Batteries that are deeply discharged, and then charged partially on a regular basis

can fail in less then one year.

Check your batteries on a regular basis to be sure they are getting charged. Use a

hydrometer to check the specific gravity of your lead acid batteries. If batteries are

cycled very deeply and then recharged quickly, the specific gravity reading will be lower

than it should because the electrolyte at the top of the battery may not have mixed with

the “charged” electrolyte.

 Check the electrolyte level in the wet-cell batteries at the least four times a year

and top each cell of with distilled water. Do not add water to discharged batteries.

Electrolyte is absorbed when batteries are very discharged. If you add water at this time,

and then recharge the battery, electrolyte will overflow and make a mess.

Keep the top of your batteries clean and check that cables are tight. Do not tighten

or remove cables while charging or discharging. Any spark around batteries can cause a

hydrogen explosion inside, and ruin one of the cells, and you.

On charge, with reverse current through the electrolyte, the chemical action is

reversed. Then the pb ions from the lead sulfate on the right side of the equation re-form

the lead and lead peroxide electrodes. Also the SO₄ ions combine with H₂ ions from the

water to produce more sulfuric acid at the left side of the equation.

2.5 CURRENT RATINGS:

Lead-acid batteries are generally rated in terms of how much discharge currents

they can supply for a specified period of time; the output voltage must be maintained

above a minimum level, which is 1.5 to 1.8V per cell. A common rating is ampere-hours

(A.h.) based on a specific discharge time, which is often 8h. Typical values for

automobile batteries are 100 to 300 A.h.

 As an example, a 200 A.h battery can supply a load current of 200/8 or 25A, used

on 8h discharge. The battery can supply less current for a longer time or more current for

a shorter time. Automobile batteries may be rated for “cold cranking power”, which is

related to the job of starting the engine. A typical rating is 450A for 30s at a temperature

of 0 degree F.

Note that the ampere-hour unit specifies coulombs of charge. For instance, 200

A.h. corresponds to 200A*3600s (1h=3600s). the equals 720,000 A.S, or coulombs.

One ampere-second is equal to one coulomb. Then the charge equals 720,000 or

7.2*10^5ºC. To put this much charge back into the battery would require 20 hours with a

charging current of 10A.

The ratings for lead-acid batteries are given for a temperature range of 77 to 80ºF.

Higher temperature increase the chemical reaction, but operation above 110ºF shortens

the battery life.

Low temperatures reduce the current capacity and voltage output. The ampere-

hour capacity is reduced approximately 0.75% for each decreases of 1º F below normal

temperature rating. At 0ºF the available output is only 60 % of the ampere-hour battery

rating.
 In cold weather, therefore, it is very important to have an automobile battery unto

full charge. In addition, the electrolyte freezes more easily when diluted by water in the

discharged condition.

2.6 SPECIFIC GRAVITY:

Measuring the specific gravity of the electrolyte generally checks the state of

discharge for a lead-acid cell. Specific gravity is a ratio comparing the weight of a

substance with the weight of a substance with the weight of water. For instance,

concentrated sulfuric acid is 1.835 times as heavy as water for the same volume.

Therefore, its specific gravity equals 1.835. The specific gravity of water is 1, since it is

the reference.

In a fully charged automotive cell, mixture of sulfuric acid and water results in a

specific gravity of 1.280 at room temperatures of 70 to 80ºF. as the cell discharges, more

water is formed, lowering the specific gravity. When it is down to about 1.150, the cell is

completely discharged.

Specific-gravity readings are taken with a battery hydrometer, such as one in

figure (7). Note that the calibrated float with the specific gravity marks will rest higher in

an electrolyte of higher specific gravity.

 The decimal point is often omitted for convenience. For example, the value of

1.220 in figure (7) is simply read “twelve twenty”. A hydrometer reading of 1260 to

1280 indicates full charge, approximately 12.50 are half charge, and 1150 to 1200

indicates complete discharge.

The importance of the specific gravity can be seen from the fact that the open-

circuit voltage of the lead-acid cell is approximately equal to

V = Specific gravity + 0.84

For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an

example. These values are for a fully charged battery.

2.7 CHARGING THE LEAD-ACID BATERY:

The requirements are illustrated in figure. An external D.C. voltage source is

necessary to produce current in one direction. Also, the charging voltage must be more

than the battery e.m.f. Approximately 2.5 per cell are enough to over the cell e.m.f. so

that the charging voltage can produce current opposite to the direction of discharge

current.
 Note that the reversal of current is obtained just by connecting the battery VB and

charging source VG with + to + and –to-, as shown in figure. The charging current is

reversed because the battery effectively becomes a load resistance for VG when it higher

than VB. In this example, the net voltage available to produce charging currents is 15-

12=3V.

A commercial charger for automobile batteries is essentially a D.C. power supply,

rectifying input from the AC power line to provide D.C. output for charging batteries.

Float charging refers to a method in which the charger and the battery are always

connected to each other for supplying current to the load. In figure the charger provides

current for the load and the current necessary to keep the battery fully charged. The

battery here is an auxiliary source for D.C. power.

It may be of interest to note that an automobile battery is in a floating-charge

circuit. The battery charger is an AC generator or alternator with rectifier diodes, driver

by a belt from the engine. When you start the car, the battery supplies the cranking

power. Once the engine is running, the alternator charges he battery. It is not necessary

for the car to be moving. A voltage regulator is used in this system to maintain the output

at approximately 13 to 15 V.
 The constant voltage of 24V comes from the solar panel controlled by the charge

controller so for storing this energy we need a 24V battery so two 12V battery are

connected in series.

It is a good idea to do an equalizing charge when some cells show a variation of

0.05 specific gravity from each other. This is a long steady overcharge, bringing the

battery to a gassing or bubbling state. Do not equalize sealed or gel type batteries.

With proper care, lead-acid batteries will have a long service life and work very

well in almost any power system. Unfortunately, with poor treatment lead-acid battery

life will be very short.

CONTROL UNIT -89C52

In our project 89C52 Microcontroller is used as a control unit.

INTRODUCTION ABOUT MICRO CONTROLLER:

A microcontroller consists of a powerful CPU tightly coupled with memory

(RAM, ROM or EPROM), various I/O features such as serial port(s), parallel port(s),

Timer/Counter(s), Interrupt controller, Data Acquisition interfaces-Analog to Digital

Converter (ADC), Digital to Analog Converter (DAC), everything integrated onto a

single silicon chip.

 It does not mean that any micro controller should have above said features on-

chip. Depending on the need and area of application for which it is designed, the on-chip

features present in it may or may not include all the individual sections said above. Any

micro computer system requires memory to store a sequence of instructions making up a

program, parallel port or serial port for communicating with an external system,

timer/counter for control purposes like generating time delays, baud rate for the serial

port, apart from the controlling unit called the Central Processing Unit.

MEMORY ASSOCIATED WITH AT-89C52:

PROGRAM MEMORY:

A program memory is a block of memory, which can be used to store a sequence

of program codes (by using special EPROM / PROM programmers). It can only be read

from and not written into, under normal operating conditions.

There can be up to 64 k bytes of program memory in AT-89C52. in ROM and

EPROM versions of the MCS-351 family of devices, the lower 4K are provided on-chip

whereas in ROM fewer versions, all program memory is external.

 In ROM and EPROM versions of this device, if the special control signals EA

(External Access enable) is strapped off Vcc, and then program fetches to addresses 0000

to 0FFF are directed to the internal ROM. The program fetch will be from external

memory, where EA* is grounded.

After reset, the CPU begins execution from address location 0000 of the program

memory.

Figure shows a map of the AT-89C52-program memory

FFFF
60K Bytes
Internal FFFF

1000 OR 64 K Bytes
External
0FFF
4 K Bytes
Internal 0000

0000
DATA MEMORY:

Data memory is the Read/Write memory. Hence, it can be both read from and

written into. AT-89C52 has got 128 bytes of internal data memory and 64K of external

data memory.

FF SFRS
DIRECT
ADDRESS
80 SING FFFF
ONLY 64 K Bytes
7F AND External
DIRECT
AND 0000
INDIRECT
ADDRESS
00 ING

INTERNAL DATA MEMORY:

Internal data memory addresses are one byte wide, which includes 128 bytes of

on-chip RAM plus a number of special Function Registers. The 128 bytes of RAM can

be accessed either by direct addressing (MOV data address) or by indirect addressing

(MOV @Ri).
 The lowest 32bytes (00-1F) of on-chip RAM are grouped into 4 banks of 8

registers each. Program instructions call out these registers as R0 through R7 > Bits 3

and 4 (PSW.3 and PSW.4) in register program status word (PSW) select which register

bank is n use. This allows more efficient use of code space, since register instructions are

shorter than instructions that use direct addressing.

Reset initializes the stack pointer register to 7 and its incremented once to start

from locating 08, which is register R0 of second register bank. Hence, in order to use

more than one register bank, the stack pointer should be initialized to a different location

of RAM if it is not used for data storage.

The next 16 bytes (20-2F) from a block of bit addressable memory space, which

can also byte addressed.

Bytes 30 through 7F are available to the user as data RAM. However, is the stack

pointer has been initialized to this area, enough number of bytes should be left a side to

prevent stack overflow.

I/O STRUCTURE OF AT-89C52:

AT-89C52 has four 8-bit parallel ports (hence 8*4=32 I/O lines are available). All

four parallel ports are bi-directional. Each line consists of a latch, an output driver and an

input buffer.

The four ports are named as port 0 (po), port 1 (p1), port 2 (p2) and port 3(p3).

They are bit addressable and has to be represented in the form PX.Y is i.e. bit Y of port X

while using bit addressing mode. PX.0 is the LSB (least significant Bit) of port x and

px.7 is the MSB (Most Significant Bit) of that port.

Out of the four ports, port 0 and port 2 are used in accesses to external memory.

All the port 3 pins are multifunctional. Port 3 is an 8-bit bidirectional with internal pull-

ups.
Port pin Alternate Functions

P3.0 RXD (Serial input port)

P3.1 TXD (Serial output port)

P3.2 INTO (External Interrupt 0)

P3.3 INT1 (External Interrupt 1)

P3.4 T0 (Timer 0 External input)

P3.5 T1 (Timer 1 External Input)

P3.6 WR (External Data memory write

strobe)

P3.7 RD (External Data memory Read

Strobe)

PORT 0:

Port 0 is an 8-bit open drain bi-directional I/O port. It is also the multiplexed low

order address and data bus during access to external memory.

 It also receives the instruction bytes during EPROM programming and outputs

instruction bytes during program verification. (External pull-ups are required during

verification). Port 0 can sink (and operation and source) eight LS TTL input.

PORT 1:

Port 1 is an 8-bit bi-directional with internal pull-ups. It receives the low order

address byte during EPROM program verification. The port-1 output buffers can

sink/source four LS TTL inputs.

PORT 2:

Port 2 is an 8-bit bi-directional with external pull-ups. It emits the high order

address byte during accesses to external memory. It also receives, these high-order

address bits during EPROM programming Verification. Port 2 can sink/source four LS

TTL inputs.

RST:

While the oscillator is running a high on this pin for two machine cycles resets the

device. A small external pull down resistor (8.2k) from RST to Vss permits power on

reset when a capacitor (10 micro frequencies) also connected from this pin to Vcc.
ALE/PROG:

Address latch enable is the output for latching low byte of the address, during

access 10 external memory. ALE is activated at a constant rate of 1/6 the oscillator

frequency except during an external data memory access at which time one ALE pulse is

skipped. ALE can sink/source eight LS TTL inputs. This pin is also the program pulse

input (PROG) during EPROM programming.

PSEN:

Program Store Enable is the read strobe to external program memory. PSEN is

activated twice each machine cycle, during fetches form external program memory.

PSEN is not activated during fetches from internal program memory. PSEN can

sink/source 8 LS TTL inputs.

EA/Vpp:

When external access enable (EA) is held high, the AT-89C52 execute out of

internal program memory (Unless the program counter exceeds OFF (H)). When EA is

held low, the AT-89C52 H executes only out of external program memory. This pin also

receives the 21 Volts programming. Supply Voltage (Vpp) during EPROM programming.

This pin should not be floated during normal.

XTAL1:

It is inputs to the inverting amplifier that forms the oscillator. XTAL1 should be

grounded when an external oscillator is used.

XTAL 2:

It is Outputs to the inverting amplifier that forms the oscillator, and input to the

internal clock generator, receives the external oscillator signal when an external oscillator

is used.

Vss - Circuit ground potential

Vcc - Supply Voltage during Programming Verification and normal

Operation.

TIMERS/COUNTERS:

AT-89C52 has two 16-bit timer/counter 0, and timer/counter 1. They can be

configured in any of the four operating modes, which are selected by bit-pars (m1, 0) in

register TMOD (Timer/counter Mode control). Modes 0, 1 and 2 are the same for the

timer/counters. Mode 3 is different.

FEATURES OF AT-89C52:

Now a days an 8-bit AT-89C52/8031/8751 and 16 bit 8097 micro controllers

available in the form of kits. Its special features are summarized as:-

4k Bytes of Flash

128 Bytes of RAM

32 I/O lines

A five vector two level interrupt architecture.

A full duplex serial port

On chip Oscillator and clock circuitry.

ADDRESSING MODES:

The AT-89C52 instructions operate on data stored in internal CPU registers,

external memory or on the I/O ports. There are a number of methods (modes) in which

these registers, memory (internal or external) and I/O Ports (Internal / External) can be

addressed, called addressing modes. This section gives a brief summary of the various

types of addressing modes available in AT-89C52.

These Modes are:

Immediate

Direct

Indirect

Register

Register Specific

Indexed

IMMEDIATE ADDRESSING:

In this mode, the data to be operated upon is in the location immediately following

the opcodes. For example, the instruction,

MOV A, # 41

-Loads the accumulator with the hex value 41.

‘//’ Signifies IMMEDIATE ADDRESSING.

DIRECT ADDRESSING:

In direct addressing, the operand is specified by an 8-bit address field in the

instruction. For example, the instruction,

INC 20

Increments the contents of the On-Chip data address 20 by one.

INDIRECT ADDRESSING:

In indirect addressing, the instruction specifies a register, which contains the

address of the operand. Both internal and external RAM can be indirectly addressed.

The address register for 8-bit address can be R0 or R1 of the selected register bank

or the stack pointer. The address register for 16-bit address can only be the 16-bit “data

pointer” register, DPTR. For example, the instruction,

MOVX @DPTR, A

-Writes the contents of the accumulator to the address held by the DPTR register.
RESISTOR ADDRESSING:

The register banks, containing resistors R0 through R7, can be accessed by certain

instructions, which carry a 3-bit register specification within the opcode of the

instruction. Instructions that access the registers this way are code efficient, since this

mode eliminates an address byte.

When the instruction is executed, one of the eight resistors in the selected bank at

the execution time by two bank select bits is selected at the execution time by the two

bank select bits in the PSW. For example, the instruction,

MOV A, R0

-Copies the contents of the resistor R0 (of the selected bank) to the accumulator.

INDEXED ADDRESSING:

Only program memory can be accessed with indexed intended for reading look-up

tables in program memory. A 16-bit base resistor (Either DPTR or the Program counter)

points to the base of the table and accumulator is set up with the table entry number. The

address of the table entry in program memory is formed by adding the accumulator data

to the base pointer. The instruction,

 MOVC A,@A+DPTR

This function reads the contents of program memory, whose address is obtained

by adding the content of DPTR and accumulator copies it to the accumulator.

PIN DIAGRAM OF AT89C52:

PDIP

1 40
P1.0 Vcc

P1.1 2 39 P 0.0(AD 0)

P1.2 3 38 P 0.1 (AD 1)

P1.3 4 37 P 0.2 (AD 2)

P1.4 5 36 P 0.3 (AD 3)

P1.5 6 35 P 0.4 (AD 4)

P1.6 7 34 P 0.5 (AD 5)

P1.7 8 33 P 0.6 (AD 6)

RST P 0.7 (AD 7)

9 32
(R X D) P3.0 EA / VPP
10 31
(T X D) P3.1 ALE/PROG
11 30
(INT 0) P3.2 PSEN
12 29
(INT 1) P3.3 P2.7 (A 15)
13 28
(T 0) P3.4 P2.6 (A 14)
14 27
(T1) P3.5 P2.5 (A 13)
15 26
(WR) P3.6 P2.4
(A 12) 16 25
(RD) P3.7 P2.3 (A 11)
17 24
XTAL 2 P2.2 (A 10)
18 23
XTAL 1 P2.1 (A 9)
19 22
GND P2.0 (A 8)
20 21
 P 0. 0 – P 0 . 7 P2.0 – P2.7

Vcc

PORT 0 DRIVERS PORT 2 DRIVERS

GND

RAM ADDR RAM PORT 0 PORT 2 FLASH

RESISTOR LATCH LATCH

B STACK PROGRAM
REGISTER ACC POINTER ADDRESS
REGISTER

TMP 2 TMP 1 BUFFER

PC
INCREME
ALU N-TER

INTERRUPT SERIAL PORT

AND TIMER BLOCKS
PSW PROGRAM
COUNTER

PSEN DPTR
TIMING INSTRUCT
ALE/
AND -ION
PROG
CONTROL REGISTER
EA/Vpp

RST PORT 1 PORT 3

LATCH LATCH

OSC PORT 1 DRIVERS PORT 3 DRIVERS

 P1.0 – P1.7 P3.0 – P3.7

ACCUMULATOR:

Accumulator is the Accumulator register mnemonics for Accumulator. Specific

instruction however, refer to the Accumulator simply A.

B REGISTER:

The B register is used during multiply and divide operations. For other

instructions can be treated as another scratch pad register.

PROGRAM STATUS WORD:

The PSW resistor contains program status information. The program status word

(PSW) contains several status bits that reflect the current state of the CPU. The PSW

resides in SFR space. It contains the carry bit, the auxiliary carry 9for BCD operations),

the two register bank select bits, the overflow flag a parity bit and two user definable

status flags. The carry bit other than serving the functions of a carry bit in arithmetic

operations, also serves as the ‘Accumulator’ for a number of Boolean operations. The bits

and RSI are used to select one of the register bans. A number instruction refers of their
 RAM location R0 through R7. The selection of which the four banks is being referred to

is made on the bass of the bits RS0 and RS1 execution time.

The lower 32B are grouped into 4 banks of 8 resistors. Program instructions call

out there resistors as R0 through R7 bits in the PSW select which register is n use. The

parity bit reflects the number is in the accumulator. P=1 if the accumulator contains an

old number of 1 s and p=0 if the accumulator contains an even number of 1 s. Thus the

number of 1 s in the accumulator plus P is always even. Two bits in the PSW are

uncommitted and may be used as general-purpose status flags.

PROGRAM STATUS WORD OF AT89C52 DEVICES:

C AC FO RS1 RS0 OV P

Carry flag receives carry Parity of accumulator by hard

out from bit-1 of ALU ware to 1 bit if it contains an old
operation number of 1 s otherwise set to 0

Auxiliary carry flag User Definable Flag

receives carry out from bit-
1 of addition operands

Overflow Flag set by

Arithmetic Operation
General Purpose Status Flag

Resistor Bank Select bit- 0

Register Bank Select bit-1

 THE LOWER 128 BYTES OF INTERNAL RAM

7F (H)

2F (H) Bit addressable Space

20 (H) Bit address 0-7F (H)
Bank Select Bit 11 Bank-3 1F (H)
18 (H)
In PSW
Bank-2 17 (H)
10 (H)
10 4 Banks of 8 resistors
Bank-1 0F (H)
08 (H) R0 - R7
01 Bank-0 07 (H)
00 00 (H)

STACK POINTER:

The stack pointer resistor is 8-bit wide. It is incremented before data is stored

during PUSH and CALL execution while the stack may where in on-chip RAM. The

stack pointer is initialized to 07(H) after a reset. This causes the stack to begin at location

08(H).
DATA POINTER:

The data pointer (DPTR) consists of a high byte (DPH) and a low byte (DPL).

Its intended function is to hold a 16-bit address. It may be manipulated as a 16-bit resistor

or 08 two independent bit registers. Ports 0 to 3 – p0, p1, p2 and p3 are the SFR latches

for ports 0, 1, 2, and 3 respectively.

SERIAL DATA BUFFER:

The serial data buffer is actually two separate resistors transmit buffer and a

receive buffer resistor. When data is moved to SBUF, it goes to the transmit buffer where

it is held for serial transmission. (Moving a byte to SBUF is what initiates the

transmission) When data is moved from SBUF, it comes from the receive buffer.

TIME RESISTORS:

Resistors pairs (TH0, TL), (TH1, TL1) and (TH2, TL2) are the 16-bits counting

resistors for the interrupt system, the timer counters and the serial port.
--------------------------------------------------------------------------------------

Chapter-8
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
 ADVANTAGES AND LIMITATIONS
--------------------------------------------------------------------------------------

CHAPTER-8

ADVANTAGES AND LIMITATIONS

ADVANTAGES

 The Conveyor Automation is more efficient in the technical field

 Quick response is achieved

 Simple in construction

 Easy to maintain and repair

 Cost of the unit is less when compared to other robotics

 No fire hazard problem due to over loading

 Comparatively the operation cost is less

 Continuous operation is possible without stopping

LIMITATIONS

 While working, the compressed air (For Punching Operation) produces noise

therefore a silencer may be used.

--------------------------------------------------------------------------------------

Chapter-9
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
 APPLICATIONS
--------------------------------------------------------------------------------------

CHAPTER-9

APPLICATIONS

 Discharge of work piece:-

The Conveyor Feed has a wide application in low cost automation industries. It

can be used in automated assembly lines to carry up the finished product from

workstation and place them in bins. It can also be used to pick raw material and place

them on the conveyor belts.

 Punching operation:-

This unit can also be used in Punching Operation in the material at high

speeds. The application of these units is limited to operations which involved moderate

clamping forces.
--------------------------------------------------------------------------------------

Chapter-10
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------

LIST OF MATERIALS
--------------------------------------------------------------------------------------

CHAPTER-10

LIST OF MATERIALS

S. No. Description Qty Material

1 Single Acting pneumatic cylinder 1 Mild Steel

2 Single Acting 3/2 Solenoid Valve 1 Aluminium

3 Flow control Valve 1 Aluminium

4 PU Tubes 5 meter Polyurethene

5 Hose Collar 8 Brass

6 Reducer 2 Brass

7 Frame stand 1 M.S

8 Sensor with control Unit 1 -

9 Conveyor Roller 2 M.S

10 Conveyor Belt 1 Rekchin

11 Bearing (6202) 4 Steel

12 Bearing Cap 4 M.S

13 Shaft 2 M.S
--------------------------------------------------------------------------------------

Chapter-11
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------

COST ESTIMATION
--------------------------------------------------------------------------------------

CHAPTER-11

COST ESTIMATION

1. MATERIAL COST:-

S. No. Description Qty Material Amount (Rs)

1 Single Acting pneumatic cylinder 1 Mild Steel

2 Single Acting 3/2 Solenoid Valve 1 Aluminium

3 Flow control Valve 1 Aluminium

4 PU Tubes 5 meter Polyurethene

5 Hose Collar 8 Brass

6 Reducer 2 Brass

7 Frame stand 1 M.S

8 Sensor with control Unit 1 -

9 Conveyor Roller 2 M.S

10 Conveyor Belt 1 Rekchin

11 Bearing (6202) 4 Steel

12 Bearing Cap 4 M.S

13 Shaft 2 M.S
 TOTAL =

2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =

3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

=
=

Overhead Charges = 20% of the manufacturing cost

=

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

=
=

Total cost for this project =

--------------------------------------------------------------------------------------

Chapter-12
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------

CONCLUSION
--------------------------------------------------------------------------------------

CHAPTER-12

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

purchasing, assembling and machining while doing this project work. We feel that the

project work is a good solution to bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time successfully.

The “CONVEYOR AUTOMATION” is working with satisfactory conditions. We are

able to understand the difficulties in maintaining the tolerances and also quality. We

have done to our ability and skill making maximum use of available facilities. In

conclusion remarks of our project work, let us add a few more lines about our impression

project work.

Thus we have developed an “CONVEYOR AUTOMATION” which helps to

know how to achieve low cost automation with sensor arrangement. The operating

procedure of this system is very simple, so any person can operate. By using more

techniques, they can be modified and developed according to the applications.

---------------------------------------------------------------------------------

BIBLIOGRAPHY
---------------------------------------------------------------------------------
 BIBLIOGRAPHY

Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore.

Design data book –compiled by faculty of mechanical engineering

P.S.G. college of technology,Coimbatore

Festo Didactic KG – Fundamentals of control technology, Esslingen-1998.

Festo Pneumatic Catlogue - Festo Pvt Ltd. – Bangalore.

Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag

Wurzburg, 1998.
--------------------------------------------------------------------------------

PHOTOGRAPHY
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