Professional Documents
Culture Documents
1.1.1 Index
INTRODUCTION
INTRODUCTION TO AUTOMATION
DEFINITION OF PROJECT
BACKGROUND OF PROJECT
2.CONCEPT
6. DESIGN CALCULATIONS
7. CONCLUSIVE REMARKS
8. FURURE SCOPES
9. REFERENCES
AUTOMATIC T-SHIRT FOLDING MACHINE
ABSTRACT
Our project ”AUTOMATIC T-SHIRT FOLDING MACHINE ” , the idea came into our mind by
viewing the t.v. serial ‘BIG BANG THEORY’ in which one scientist name Sheldon Cooper used
such kind of t-shirt folding flaps to fold his t-shirts. We thought of making this machine by
operating it automatically.
Then we searched for existence of such kind of machines, and we found that there is a company
in Greece that makes automatic T-shirt folding machine and the name of the company is
‘THERMOTRON’.
Initially we thought of making the project related to automatic car parking but the problem
related to Image Processing was faced by us. So we thought of making the T-Shirt folding
machine.
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AUTOMATIC T-SHIRT FOLDING MACHINE
INTRODUCTION
Automation is the use of machines, control systems and information technologies to
optimize productivity in the production of goods and delivery of services. The correct
incentive for applying automation is to increase productivity, and/or quality beyond that
possible with current human labor levels so as to realize economies of scale, and/or
realize predictable quality levels. In the scope of industrialisation, automation is a step
beyond mechanization. Whereas mechanization provides human operators
with machinery to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental requirements while increasing
load capacity, speed, and repeatability. Automation plays an increasingly important role
in the world economy and in daily experience.
Automation has had a notable impact in a wide range of industries
beyond manufacturing (where it began). Once-ubiquitous telephone operators have been
replaced largely by automated telephone switchboards and answering machines. Medical
processes such as primary screening in electrocardiography or radiography and laboratory
analysis of human genes, sera, cells, and tissues are carried out at much greater speed and
accuracy by automated systems. Automated teller machines have reduced the need for
bank visits to obtain cash and carry out transactions. In general, automation has been
responsible for the shift in the world economy from industrial jobs to service jobs in the
20th and 21st centuries.
The main advantages of automation are:
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AUTOMATIC T-SHIRT FOLDING MACHINE
Besides designing the machine, it also aims at improving price per performance ratio.
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AUTOMATIC T-SHIRT FOLDING MACHINE
CONCEPT
Manual t-shirt folding flaps were already available in the market as shown in figure
below.
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AUTOMATIC T-SHIRT FOLDING MACHINE
Here also, we can completely eliminate the variations in the fold of a t-shirt, but since it
is manual, so time consumed was not reduced much. Also as many labours were required
as much required by the simple traditional t-shirt folding process.
That is why, we decided to automate the process of t-shirt folding by using concepts
mentioned below.
We used electronic circuit to signal the pneumatic valves, which controlled the actuation
of pneumatic cylinder.
Also, not any proper positioning of this manual folding flaps was possible, but in
automatic t-shirt folding machine we have made a dedicated table with base considering
the ergonomics of the average human height .
We have made the base detachable so, that only the base is needed to change for
changing the variation in the sizes and the variety of clothes (for example:- shirts, pants,
jackets, ladies suit etc.)
Only thing we need to change is to change the mode of machine i.e. to change the mode
from t-shirt folding to shirt folding or pant folding and so on.
After absorbing the critical experience of the first experiment by folding the t-shirt with the help
of bare hands, we come to a conclusion that the T-shirt which has lines made by folding will
leads to unrealistic and false appearance.
It also took too long to to get folded and all the t-shirts were having some variation in their sizes
as were observed when stack of ten t-shirts were made.
The designed experiments which introduce tools were conducted. During this phase we tried
folding the t-shirt using cardboard flaps.
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AUTOMATIC T-SHIRT FOLDING MACHINE
But then we decided to make flaps of machine with little modification using the concept of
cardboard flaps. The only difference in the new design was that every flap was hinged
individually and flap B can also be moved to place the folded t-shirts on to the stacker.
FINALLY, we decided to automate the whole process by using electronic circuit made using a
microcontroller (AT 89 C 51) and pneumatic cylinders.
We tried to make t-shirt folding flaps with the help of waste cardboard pieces and we were
succeded in folding the t-shirt.
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AUTOMATIC T-SHIRT FOLDING MACHINE
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AUTOMATIC T-SHIRT FOLDING MACHINE
CONSTRUCTION
Fabrication
1. We made one base as shown in figure.
2. Drilling of holes on this stand of base to attach it to the main table with the help of nuts
and bolts.
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AUTOMATIC T-SHIRT FOLDING MACHINE
The size of flaps were chosen as per the average size of t-shirt, folded t-shirt and size of
the packaging bag available in the market.
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AUTOMATIC T-SHIRT FOLDING MACHINE
4. These flaps were mounted over the plate which will be attached over the base so as to
make a perfect top.
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AUTOMATIC T-SHIRT FOLDING MACHINE
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AUTOMATIC T-SHIRT FOLDING MACHINE
6. After that , some extra fabrication work was done like welding angle rods horizontally
along with two vertical adjacent angle rods to make the table more stiff and balanced.
Also, the wooden base is attached 55 c.m. below the main base for mounting pneumatic
cylinders.
7. SolidWorks Design of mechanism used to connect the actuators with flaps are as shown.
Cylinders are mounted vertically over the wooden base below the main base. They are
mounted with the help of pivot joints so that cylinder can also oscillate about the axis
perpendicular to the stroke of cylinder as shown.
Total actuation angle is the sum of the angle of oscillation of cylinder and the angle
which the joint make with the flap.
The above mentioned joint connects the flap to the cylinder. It is fixed to the plate and
again, it is connected to the cylinder in pivoted manner.
This total actuation angle is nothing but the angle by which flap revolves or sweeps
around its axis from its home position. ( home position i.e. lying horizontally on the base
plate at 180 when ,cylinder is completely at its home position. )
We approximately get the angle of actuation of around 150 which is sufficient to get a
perfect fold of the t-shirt.
But from them we had used MICROCONTROLLER. Because it reduce cost of project.
For interfacing, number of electronic devices are required which are listed below:-
Capacitors
Switches
Hook-up wires
ULN2003A
IC 7805
Relays
DC Solenoid Valve
Microcontroller
A microcontroller (abbreviated µC, uC or MCU) is a small computer on a single integrated
circuit containing a processor core, memory, and programmable input/output peripherals. This
programmes memory in the form of NOR flash or OTP ROM is also often included on chip, as
well as a typically small amount of RAM.
Advantages of Microcontroller
Microcontrollers are widely used in today’s control systems for the following reasons:
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AUTOMATIC T-SHIRT FOLDING MACHINE
• Design and Simulation – Because you are programming with software, detailed
simulations may be performed in advance to assure correctness of code and system
performance.
• High Integration – Most microcontrollers are essentially single chip computers with
on-chip processing, memory, and I/O. Some contain peripherals for serial
communication and reading analog signals (with an analog-to-digital converter or ADC).
This differentiates a microcontroller from a microprocessor. Microprocessors require
that this functionality be provided by added components.
• Cost – Cost savings come from several locations. Development costs are greatly
decreased because of the design/flexibility advantages mentioned previously. Because
so many components are included on one IC, board area and component savings are
often evident as well.
• Easy to Use – Just program and go! While in the past, programming has often involved
tedious assembly code, today C compilers are available for most microcontrollers.
Microcontrollers often only require a single 5V supply as well which makes them easier
to power and use.
The low-power Atmel 8-bit AVR RISC-based microcontroller combines 8KB of programmable
flash memory, 1KB of SRAM, 512K EEPROM, and a 6 or 8 channel 10-bit A/D converter.
The device supports throughput of 16 MIPS at 16 MHz and operates between 2.7-5.5
volts.
Key Parameters
Parameter Value
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AUTOMATIC T-SHIRT FOLDING MACHINE
USB Interface: No
Pin diagram:
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AUTOMATIC T-SHIRT FOLDING MACHINE
Capacitors:-
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AUTOMATIC T-SHIRT FOLDING MACHINE
The vast majority are fixed capacitance value (their value is not user variable)
For our application we had used 33pf, 1000µ f & 47µ f capacitors.
ULN2003A
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AUTOMATIC T-SHIRT FOLDING MACHINE
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AUTOMATIC T-SHIRT FOLDING MACHINE
The ULN2003A is high-voltage high-current Darlington transistor arrays. Each consists of seven
NPN Darlington pairs that feature high-voltage outputs with common-cathode clamp diodes for
switching inductive loads. The collector-current rating of a single Darlington pair is 500 mA.
The Darlington pairs can be paralleled for higher current capability. Applications include relay
drivers, hammer drivers, lamp drivers, display drivers (LED and gas discharge), line drivers, and
logic buffers. The ULN2003A and ULQ2003A have a 2.7-kΩ series base resistor for each
Darlington pair for operation directly with TTL or 5-V CMOS devices.
There are 16 pins in ULN2003A out of which 7-inputs, 7-outputs, 1-COM & 1-Ground.12V
supply is needed to operate this IC so 12V is supplied on pin-9 & pin-8 is ground. In our
application we had used pins-3, 4, 5, 6 as input & pin-11, 12, 13, 14 as output. The main purpose
of this IC is to operate Relay .Microcontroller pins can provide a maximum of 1-2 mA current
and relay’s coil needs around 10mA to be energized for this reason this chip is used.
Features
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AUTOMATIC T-SHIRT FOLDING MACHINE
IC 7805(voltage regulator)
7805 is a 5V fixed three terminal positive voltage regulator IC. The IC has
features such as safe operating, area protection, thermal shut down, internal
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AUTOMATIC T-SHIRT FOLDING MACHINE
current limiting which makes the IC very rugged. Output currents up to 1A can be
drawn from the IC provided that there is a proper heat sink. The voltage source in
a circuit may have fluctuations and would not give the fixed voltage output. The
voltage regulator IC maintains the output voltage at a constant value. The IC 7805
indicates the fixed output volt.
Relay
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AUTOMATIC T-SHIRT FOLDING MACHINE
Relays are electrical switches that open or close another circuit under certain
conditions.
4. Logic Function
Advantages/Disadvantages
Much higher precision and more reliable and durable.
Improve the reliability and power quality of electrical power systems before, during and
after faults occur.
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AUTOMATIC T-SHIRT FOLDING MACHINE
Higher cost
DC Solenoid Valve
A solenoid valve is an electromagnetic valve for use with liquid or gas controlled by
running or stopping an electrical current through a solenoid, which is a coil of wire, thus
changing the state of the valve.
A solenoid valve has two main parts: the solenoid and the valve. The solenoid converts
electrical energy into mechanical energy which, in turn, opens or closes the valve
mechanically.
Solenoid valves may use metal seals or rubber seals, and may also have electrical
interfaces to allow for easy control.
A spring may be used to hold the valve opened or closed while the valve is not activated.
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AUTOMATIC T-SHIRT FOLDING MACHINE
When current flows in the coil, magnetic field is generated and it reduces the air gap.
Generally spring is used to create gap when coil is not energized.
Small signal can operate solenoids. Large back emf is generated when coil is switched
off.
Diode is used to suppress the back emf and it prevents the control electronics from
damage.
In switched on mode diode is reverse biased. During back emf diode is forward biased
and conducts and creates the alternative path for the current.
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AUTOMATIC T-SHIRT FOLDING MACHINE
Circuit diagram
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AUTOMATIC T-SHIRT FOLDING MACHINE
Hardware description
The components are connect on a Printed Circuit Board as per the given connection details in the
circuit diagram. The functioning of the circuit can be explained with respect to the action format
that occurs in the circuit. As the supply is switched ON and both the switches are open the
switching supplies ideally 5V is given to the microcontroller. Suppose if the any of the switch is
closed the supply gets directly shorted with the ground. This indicates the microcontroller about
the switch positions and thus generates the signal as per the given program for the respective
switches position. The transistor used allows current to conduct through it when ever a positive
pulse is given at its base that is given by the microcontroller in accordance with the program. As
the transistor is forward biased the supply that is used to actuate the Solenoid Valve gets
connected with the Valve terminal and valve start actuating. As soon as the 0 voltage is
encountered the NPN transistor used goes into reverse bias and stops its conduction so the valve
terminal supply gets disconnected till the base current is 0 volts. By this we can deduce that the
actuation of the valve is directly dependent on the supply given by microcontroller to the base
which indeed depends on the program written. So the speed of working of the circuit depends on
the number of switches used, for instance in the above circuit two switches are used so the
3 X
number of speed levels are 2 = 8. So the number of speed levels for X switches will be 2 .
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AUTOMATIC T-SHIRT FOLDING MACHINE
Working of Circuit
Fig 1-4 shows the working of circuit. Here in real circuit instead of LED’S Solenoid Valve are
connected.
Fig-1
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AUTOMATIC T-SHIRT FOLDING MACHINE
Fig-2
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AUTOMATIC T-SHIRT FOLDING MACHINE
Fig-3
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AUTOMATIC T-SHIRT FOLDING MACHINE
Fig-4
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AUTOMATIC T-SHIRT FOLDING MACHINE
When the switch1 is closed and switch 2 is open in this position the supply from the
switch1 is shorted into the ground terminal so microcontroller get voltage so the switch
is considered as 1.
When switch1 is closed then it produce signal to pins p2.0 to p2.3 and between each
signal delay is provided.
When the switch2 is closed and switch 1 is open in this position the supply from the
switch1 is shorted into the ground terminal so microcontroller get voltage so the switch
is considered as 1.
When switch2 is closed then it produce signal to pins p2.0 to p2.3 and between each
signal delay is provided and this procedure will repeat upto 10 times.
For stoping the program the reset circuitry is incorporated which is explained below:
Reset circuit:
Reset pin is an input and is active high. Upon applying a high pulse to this pin the
microcontroller will reset and terminates all activities.
Component list
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AUTOMATIC T-SHIRT FOLDING MACHINE
AT89C51 ATMEL 1
Microcontroller
Resistor R1 10KΩ 1
Capacitor C1,C2,C3 33pF,33pF,10µ F 1
Switch S1,S2 3
Crystal oscillator X1 11.0592MHZ 1
ULN2003A ATMEL 1
Relay HC 6V 4
Solenoid Valve Jelpc 12V 4
IC 7895 LM 9-12V 1
We have used 5/2 solenoid operated spring return valves. These valves are configured with
electronic circuit to operate cylinders in a proper sequence.
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AUTOMATIC T-SHIRT FOLDING MACHINE
When button 1 is pressed , the single t.shirt placed over the flaps gets folded.
With pneumatic cylinders, we had to do a lot of work related to the issues like what kind
of linkage to use for converting translator motion of the pneumatic cylinder to rotary
motion.
With motors, we had to use stepper motor but operation of that was quite slow. To fold t-
shirt we need fast swapping motion of the flaps (otherwise the t-shirt may get slipped
down over the flap), therefore we didn’t choose stepper motor.
Then we decided to use permanent magnet d.c. motor (p.m.d.c.m), but again, its
movement was not accurate plus one another circuit was needed to control the motion of
the motor and also motors were bit costly.
The motors were not getting fitted properly onto the base plate and they were creating
hinderance to the home position of the flaps. Also, if we would have used the motors, the
channel joint (the joint used to connect flaps with the base plate ) would have been
designed accordingly to accommodate the shaft of the motor. This again would have
added a lot to the cost.
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AUTOMATIC T-SHIRT FOLDING MACHINE
THAT IS WHY, we diverted our minds towards using pneumatic cylinders and atlast, we
got an idea of the mechanism as mentioned in the construction above.
During fabrication
During fabrication, there wasn’t any such problem except the mounting of cylinders. We
had to cut the cylinder mounting base of the table and reweld it as cylinders were not
getting adjusted. Cutting those welded joints was big task. Due to unavailability of
resources , we had to cut it with manual saw. Then we rewelded it to a proper position as
per new calculations.
When supply is given to Microcontroller then output pins of controller sets to higher state
,so to overcome this problem we had done certain changes in program.
CALCULATIONS
Ideal condition
Flap weight=300grams
Force
=m*g
=0.3*9.81
=2.943N
Area of Cylinder
= /4*d²
=π/4*(20)²
=314.16mm²
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AUTOMATIC T-SHIRT FOLDING MACHINE
=314.16*10^-6m²
Pressure
=F/A
=2.943/(314.16*10^-6)
=9367.84N/m²
0.1bar
But for quick operation we will take value of pressure to be p = 0.5bar ……… (1)
Moment of hinge
M(h)=F*(20/100)
=2.943*(20/100)
=0.59
0.6N-m
=400grams
=3.924N
Pressure
=F/A
=3.924/(314.16/1000000)
=12490.45N/m²
From 1 & 2, we get, P=0.5bar so in ideal or in loading condition pressure will remain almost
constant.
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AUTOMATIC T-SHIRT FOLDING MACHINE
M(h)=3.924*(20/100)
=0.7848N-m
As we need to take the constant pressure for every flap, so we will take the maximum pressure
i.e. the pressure required by flap A i.e. P = 0.5 bar.
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AUTOMATIC T-SHIRT FOLDING MACHINE
CONCLUSIVE REMARKS
During this wonderful project I have came across many difficulties but I have tackled them
successfully. During this, I have gained knowledge about various machines used in industries,
the ideas and tricks that are used in industry.
The project facilitate much more improved functions related with weight loss , simplifying
operation, and other aspects. And more over it will not add cost but we tried to minimize the cost
also. Even then we want to say that there is much space to improvement in the machine. The
experience will be very useful for our future.
During completing this project, we came to know the various problems that occur in any
process. And if you want to success you have to manage each and every part of any task or
project. Now we are more confident that we can also do something new and are interested to start
a new career in mechatronics engineering.
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AUTOMATIC T-SHIRT FOLDING MACHINE
FUTURE SCOPES
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AUTOMATIC T-SHIRT FOLDING MACHINE
REFERENCES
• Books on Microcontroller: The 8051 microcontroller and embedded systems by
JANICE GILLISPIE MAZIDI & Kenneth J Ayala
• www.pearsoned.co.in/muhammadalimazidi
• www.MicroDigitalEd.com
• www.8051.com
• MagicPrints, Ahmedabad
• Thermotron, Bangaluru
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