American University of Science and Technology

Faculty of Engineering
Department of Mechatronics Engineering

INDUSTRIAL CONTROL
MTE 428

The electric box panel for Faulty Product Detection Machine

Prepared

By

Yehya Rashid EL Akoum

42190055

Submitted to: Dr. Bassam Moslem

Beirut, Lebanon
May 8, 2023

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 ABSTRACT

A faulty product detection machine would necessitate the use of both hardware and software components. To
detect defects in the product, sensors would be required, and the type of sensor required would depend on the
product being inspected. A processing unit, which could be a microcontroller, a single-board computer, or a
dedicated ASIC, would need to analyze the data collected by the sensors. The data analysis would have to be
done by software, such as machine learning algorithms or rule-based systems. A power supply would be
required to power the sensors, processing unit, and other components, as well as an enclosure to house and
protect the components from environmental factors. A communication channel would also need to be
established in order to transfer the data and analysis results to a display unit or larger system. It should be
noted that developing a faulty product detection machine necessitates knowledge of electronics, programming,
and data analysis. It is recommended that experts in these fields be consulted, or that a team of professionals
be assembled, to ensure the machine's accuracy and reliability.

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Table of contents:
Introduction: ..................................................................................................................................................... 5
Background Information: ................................................................................................................................ 5
Functionality: ................................................................................................................................................... 6
The electric box panel: .................................................................................................................................. 1
Raspberry PI 4 (Model B): ........................................................................................................................... 4
Specification: ................................................................................................................................................. 5
DC Motor: ...................................................................................................................................................... 6
Four-channel relay Module: ............................................................................................................................ 6
SIEMENS IEC Miniature Circuit Breaker : .............................................................................................. 8
Webcam: ........................................................................................................................................................ 9
Panel mount Signal led indicator light: ..................................................................................................... 10
Emergency stop button: .............................................................................................................................. 11
ON/OFF main switch: ................................................................................................................................. 12
Driver board interface Description: .......................................................................................................... 14
Conclusion: ................................................................................................................................................... 16
References ..................................................................................................................................................... 17

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 List of figures:
Figure 1. CAD drawing for the electric box .................................................................................................... 2
Figure 2. The electric box panel for Faulty Product Detection Machine ......................................................... 3
Figure 3. screen to control ............................................................................................................................... 3
Figure 4. Raspberry Pi 4 .................................................................................................................................. 4
Figure 5. RPI 4 Pinout Diagram ...................................................................................................................... 5
Figure 6. DC motor .......................................................................................................................................... 6
Figure 7: 5V Four-relay module ( Source: https://components101.com/sites/default/files/components/Four-
Channel-Relay-Module.jpg) ............................................................................................................................. 7
Figure 8: Four-relay channel module detailed (Source: https://components101.com/sites/default/files/inline-
images/5V-Four-Channel-Relay-Module.jpg) .................................................................................................. 8
Figure 9: siemens IEC Circuit breaker (Source: https://www.grainger.com/product/SIEMENS-IEC-
Miniature-Circuit-Breaker-30XZ48) ................................................................................................................ 8
Figure 10: Webcam (Source:
https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.logitech.com) ............................................ 9
Figure 11: Led light (Source: https://rukminim1.flixcart.com) ..................................................................... 10
Figure 12: Emergency Stop button (Source: https://shop.schneider-
electric.co.in/media/shoptimize/blog/post/e/m/emergency_stop_button_-_copy.jpg) ................................... 11
Figure 13: ON / off switch .............................................................................................................................. 13
Figure 14: RASPBERRY Pi DISPLAY MODULE 9" HDMI (Source:
https://www.katranji.com/tocimages/410918-296365.jpg) ............................................................................ 14
Figure 15: driver board interface (Source: https://www.katranji.com/tocimages/files/410918-546508.pdf) 15

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 Introduction:
The electric box panel for Faulty Product Detection Machine is an essential component of a
manufacturing system that is designed to detect and reject faulty products from the production line.
The electric box panel is responsible for controlling and managing the electrical systems and
components of the detection machine, ensuring that it operates efficiently and effectively.

The faulty product detection machine typically consists of several components, including sensors,
actuators, and a control system. The sensors are responsible for detecting defects or anomalies in
the products as they move along the production line. The actuators are responsible for manipulating
the products, such as ejecting them from the line in the case of a defect. The control system is
responsible for coordinating the actions of the sensors and actuators to ensure that only good
products are allowed to continue along the production line.

Background Information:
Industrial control system (ICS) is a collective term used to describe different types of control
systems and associated instrumentation, which include the devices, systems, networks, and controls
used to operate and/or automate industrial processes. Depending on the industry, each ICS
functions differently and is built to electronically manage tasks efficiently. Today the devices and
protocols used in an ICS are used in nearly every industrial sector and critical infrastructure such as
the manufacturing, transportation, energy, and water treatment industries.

There are several types of ICSs, the most common of which are Supervisory Control and Data
Acquisition (SCADA) systems, and Distributed Control Systems (DCS). Local operations are
often controlled by so-called Field Devices that receive supervisory commands from remote
stations.

Circuit breakers trip (that is, shut off) when the circuit is overloaded. They’re safety devices, meant
to prevent damage to electrical devices or to the home itself. If the breaker didn’t trip and shut off
the power, overloaded circuits could start fires or electrocute someone.

Each breaker controls one circuit; each circuit usually corresponds to a room or an area of the
house. Power-hungry devices like electric ranges or air conditioners might have their own breaker.

A breaker is designed to carry a certain electrical load; if the electrical load grows too large for the
breaker, it shuts off. This happens if you have too many devices plugged into one circuit, for
example.

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There are assorted sizes of breakers depending on how much electricity they need to handle. Like
the home’s electrical service, individual breakers are divided by what amperage they can handle.
Breakers range from 15 to 200 amps; most are either 15, 20, or 30 amps, though.

Functionality:
1. Power input - Same as before to provide AC power and overcurrent protection.

2. Transformer - To convert the AC to lower DC voltages like 5V, 12V for powering the Raspberry
Pi and other components.

3. Raspberry Pi - Acts as the central controller of the system instead of a PLC. It needs to be
programmed appropriately for the product inspection logic using Python or other languages.

4. Relay boards - Raspberry Pi cannot directly drive high power loads like actuators, safety
mechanisms, etc. So relay boards are interfaced to the Pi which can switch such loads.

5. Sensors - Sensors are directly interfaced to the GPIO pins of the Raspberry Pi to provide input
signals. Some signal conditioning may be needed in some cases.

6. Actuators - Actuators and rejection mechanisms are interfaced to the relay boards which are
controlled by the Raspberry Pi.

7. Emergency stop - Again interfaced to relay boards to switch off all power in case of emergency.

8. HMI - Can be a touchscreen display interfaced to the Raspberry Pi via HDMI to provide an
interface to the operator. The Pi can detect touch inputs to control the system.

So in this system, the Raspberry Pi reads inputs from the various sensors to check for faulty
products. Upon detection, it activates the appropriate relays to control actuators, rejects
mechanisms or emergency stops. The HMI allows the operator to monitor and control the Pi. The
DC power supply provides necessary voltages to power the system.

Some additional benefits of using a Raspberry Pi based system are lower cost, flexibility to change
logic, integrated WiFi and Bluetooth, options for remote monitoring, etc. However, it may not be
suitable for very high speed or complex systems where a PLC would be better suited.

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 The electric box panel:
The panel has the following components:

Outside the box

- Screen 9 inch
- On/ off switch
- Emergency switch
- 3 Led indictors (Red led for error in the machine, green led indicate that the machine is
working good, yellow light indicate that the machine ready for to work)

Inside the box:

- Raspberry pi the computer for the machine
- 4 relay switches channel
- Circuit breaker
- Motor driver to be able to control the motor from the raspberry pi
- Power supply for to supply the DC motor with 24V and 5A
- Junction for terminal managements
- Wire to connect everything together

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Figure 1. CAD drawing for the electric box

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Figure 2. The electric box panel for Faulty Product Detection Machine

Figure 3. screen to control

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 Raspberry PI 4 (Model B):

Figure 4. Raspberry Pi 4

(Source: https://www.raspberrypi.com/products/raspberry-pi-4-model-b/)

Raspberry Pi 4 Model B is the latest product in the popular Raspberry Pi range of computers. It offers ground-
breaking increases in processor speed, multimedia performance, memory, and connectivity compared to the
prior-generation Raspberry Pi 3 Model B+, while retaining backwards compatibility and similar power
consumption. For the end user, Raspberry Pi 4 Model B provides desktop performance comparable to entry-
level x86 PC systems.

This product’s key features include a high-performance 64-bit quad-core processor, dual-display support at
resolutions up to 4K via a pair of micro-HDMI ports, hardware video decode at up to 4Kp60, up to 8GB of
RAM, dual-band 2.4/5.0 GHz wireless LAN, Bluetooth 5.0, Gigabit Ethernet, USB 3.0, and PoE capability
(via a separate PoE HAT add-on).

The dual-band wireless LAN and Bluetooth have modular compliance certification, allowing the board to be
designed into end products with significantly reduced compliance testing, improving both cost and time to
market.

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Specification:
 Processor: Broadcom BCM2711, quad-core Cortex-A72 (ARM v8) 64-bit SoC @ 1.5GHz.
 Memory: 1GB, 2GB, 4GB or 8GB LPDDR4 (depending on model) with on-die ECC.
 Connectivity: 2.4 GHz and 5.0 GHz IEEE 802.11b/g/n/ac wireless LAN, Bluetooth 5.0, BLE Gigabit
Ethernet 2 × USB 3.0 ports 2 × USB 2.0 ports.
 GPIO: Standard 40-pin GPIO header (fully backwards-compatible with previous boards)
 Video & sound: 2 × micro-HDMI ports (up to 4Kp60 supported) 2-lane MIPI DSI display port 2-lane
MIPI CSI camera port 4-pole stereo audio and composite video port.
 Multimedia: H.265 (4Kp60 decode); H.264 (1080p60 decode, 1080p30 encode); OpenGL ES, 3.0
graphics.
 SD card support: Micro SD card slot for loading operating system and data storage.
 Input power: 5V DC via USB-C connector (minimum 3A) 5V DC via GPIO header (minimum 3A )
Power over Ethernet (PoE)–enabled (requires separate PoE HAT) Environment: Operating
temperature 0–50ºC.

Figure 5. RPI 4 Pinout Diagram

(Source: https://docs.microsoft.com/en-us/dotnet/iot/tutorials/blink-led)

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 DC Motor:
A DC motor is an electric motor that runs on direct current (DC) electricity. In any electric motor, operation
is based on simple electromagnetism. A current-carrying conductor generates a magnetic field; when this is
then placed in an external magnetic field, it will experience a force proportional to the current in the conductor,
and to the strength of the external magnetic field. As you are well aware of from playing with magnets as a
kid, opposite (North and South) polarities attract, while like polarities (North and North, South and South)
repel. The internal configuration of a DC motor is designed to harness the magnetic interaction between a
current-carrying conductor and an external magnetic field to generate rotational motion.
Let's start by looking at a simple 2-pole DC electric motor (here red represents a magnet or winding
with a "North" polarization, while green represents a magnet or winding with a "South" polarization).

Figure 6. DC motor

(Source: https://www.etechnog.com/2021/07/dc-motor-diagram-parts.html)

Four-channel relay Module:

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Figure 7: 5V Four-relay module ( Source: https://components101.com/sites/default/files/components/Four-
Channel-Relay-Module.jpg)

The four-channel relay module contains four 5V relays and the associated switching and isolating components,
which makes interfacing with a microcontroller or sensor easy with minimum components and
connections. The contacts on each relay are specified for 250VAC and 30VDC and 10A in each case, as
marked on the body of the relays.

Table 2. Four-Channel Relay Module Pinout

Pin Number Pin Name
1 GND
2 IN1
3 IN2
4 IN3
5 IN4
6 VCC
7 VCC
8 JD-VCC
Description
Ground reference for the module
Input to activate relay 1
Input to activate relay 2
Input to activate relay 3
Input to activate relay 4
Power supply for the relay module
Power supply selection jumper
Alternate power pin for the relay module

Four-Channel Relay Module Specifications

- Supply voltage – 3.75V to 6V
- Trigger current – 5mA
- Current when the relay is active - ~70mA (single), ~300mA (all four)
- Relay maximum contact voltage – 250VAC, 30VDC
- Relay maximum current – 10A

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Figure 8: Four-relay channel module detailed (Source: https://components101.com/sites/default/files/inline-
images/5V-Four-Channel-Relay-Module.jpg)

SIEMENS IEC Miniature Circuit Breaker :

Figure 9: siemens IEC Circuit breaker (Source: https://www.grainger.com/product/SIEMENS-IEC-

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 Miniature-Circuit-Breaker-30XZ48)

C-curve one-pole miniature circuit breakers trip instantaneously when the current load exceeds five
to ten times the rating of the device. These breakers mount on standard 35mm DIN rail and are
UL489 listed for use as branch circuit protection or as supplementary protection from damage caused
by overcurrent’s. They're used when protection against medium-level short circuit faults is desired,
such as in control panels, lighting, and coils.
Table 3. Circuit breaker details
Amps 5A
Number of Poles 1
Curve Type C
AC Voltage Rating 240V AC
DC Voltage Rating 60V DC
Max. AIR Rating 14kA at 240V AC
Phase 1
Meets UL Type UL 489
Terminal Connection Screw Clamp
Trip Type Thermal Magnetic
Circuit Breaker Mounting Style DIN Rail
Application Branch Circuit Protection; Industrial;
Reverse Feed
Min. Wire Size 14 AWG

Webcam:

Figure 10: Webcam (Source:

https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.logitech.com)

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A webcam is a camera that records video footage of its surroundings and may be a useful tool for machine
learning applications. By analysing and interpreting video data acquired by the camera, the use of webcams
in machine learning helps computer systems to perceive and comprehend the visual world around them.
Machine learnings advancement in recent years has been substantially fuelled by webcam’s
integration into computer vision applications. Computer visions focus is on enabling computers to
comprehend the visual world by interpreting image data fed from video footage captured through
webcams. For instance, a software system trained with webcam captured data can differentiate
between individuals based on their distinctive facial attributes with remarkable accuracy and speed.
Webcams may also be utilized in object identification tasks, which include training machine learning
algorithms to recognize certain items or patterns in an image or video stream. This has the potential
to be beneficial in a variety of applications, including surveillance systems, robots, and self-driving
automobiles.
Webcams are proving themselves useful in optimizing the performance of machine learning models
with their ability to gather real time data. This affords these systems with constant opportunities for
growth and adaptation. An installation of a webcam within a factory can record production processes
that may later be analysed using machine learning algorithms in order to increase efficiency or detect
anomalies.

Panel mount Signal led indicator light:

Figure 11: Led light (Source: https://rukminim1.flixcart.com)

LED lights are a popular choice for low-maintenance lighting solutions that save energy. They consume less
energy than standard incandescent bulbs, resulting in cheaper power costs and a lesser carbon imprint. LED

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lights also have a far longer lifespan than incandescent bulbs, lasting up to 20,000 hours or more, making
them a cost-effective and long-lasting lighting alternative.
Furthermore, LED lights are extremely adaptable and may be utilized in a wide range of applications, such as
a visual status cue for indexing signals, anticipating signals, emergency signals, and other indexing signals.
They produce bright, clear, and long-lasting illumination, making them an excellent choice for situations
requiring high visibility.
Overall, LED lights are an ideal choice for both home and commercial lighting applications due to their energy
savings, minimal maintenance costs, and durability. Furthermore, because of their adaptability and capacity
to give clear and strong light in a variety of conditions, they are an ideal choice for indexing and emergency
signals.

Emergency stop button:

Figure 12: Emergency Stop button (Source: https://shop.schneider-

electric.co.in/media/shoptimize/blog/post/e/m/emergency_stop_button_-_copy.jpg)

Schneider Electric emergency stop push buttons are available as mushroom switches. With a 22mm
diameter, these push button starters are easy to find and much easier to use. The Harmony XB5 and
Prevent XPS are well-known emergency stop push button models featuring trigger action and
mechanical latching mechanisms. These emergency push buttons are available in both plastic and
metallic finishes and are resistant to most physical damages, heat, and corrosion. Schneider Electric's
emergency stop push buttons considerably increase industrial area safety.

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While emergency stop buttons are primarily employed to reduce the danger of industrial injuries to
workers, they also act as failsafe control switches for expensive and heavy-duty machinery. The
primary reasons for using emergency stop push buttons are as follows:

- Injury prevention: The industrial sector, particularly with bigger, heavy-duty machinery, can
represent a major physical hazard to operators and workers. The emergency stop push button can
assist prevent fatal injuries if a person comes in the line of an operational equipment and is unable to
escape in time. The emergency stops switch shuts power to the gadget, preventing it from causing
bodily injury.

- Preventing machine malfunction: Another critical purpose of emergency stop push buttons is to avoid
machine malfunction. If a machine behaves unusually or exhibits indications of trouble, it must be stopped
and evaluated quickly to avoid further harm. During such instances, the emergency stop push button functions
as a control switch to turn off electricity. The prompt avoidance of device malfunction may save the
organization money on needless costs such as replacements or repairs, as well as aid to minimize workplace
accidents.
Emergency stop push buttons are specifically designed for easy handling and can be operated either
by a footswitch on the ground level or by hand using a pole handle. When performed by hand,
emergency stop push buttons can be of three different types:
- Push-Pull: The push-pull is the most commonly available hand-operated emergency stop
push button, known for its direct activation. The push-pull emergency button is pushed in for
cutting off power to the machinery and pulled back for release.
- Twist Release: The twist release button can be activated by pushing in to cut off electrical
power to the connected industrial machinery and then twisted to release it.

ON/OFF main switch:

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 Figure 13: ON / off switch

An on/off switch in an industrial panel can give a number of advantages, including:

Controlling a machine or piece of equipment is easy and uncomplicated with an on/off switch. This is
especially beneficial when the operator wants to swiftly and conveniently shut down the unit in the event of
an emergency or for repair.
In industrial situations, an on/off switch can also help to increase safety. The switch can assist minimize
accidents and injuries caused by unexpected machine activation by offering a clear and visible means to turn
a machine on and off.
Maintenance and repair work may be made easier and more effective with an on/off switch. Technicians may
operate safely and without risking equipment damage by shutting off the machine or equipment before
performing repair.
Finally, the inclusion of an on/off switch can assist to boost production by allowing workers to start and stop
the machine quickly and conveniently. In industrial contexts, this can assist to decrease downtime and enhance
overall efficiency.

Overall, the advantages of including an on/off switch into an industrial panel make it a desirable addition to
any machine or piece of equipment. It provides a simple and effective method for controlling equipment,
improving safety, conserving energy, simplifying maintenance, and increasing output.

RASPBERRY Pi DISPLAY MODULE 9" HDMI

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 Figure 14: RASPBERRY Pi DISPLAY MODULE 9" HDMI (Source:
https://www.katranji.com/tocimages/410918-296365.jpg)

Driver board interface Description:

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Figure 15: driver board interface (Source: https://www.katranji.com/tocimages/files/410918-546508.pdf)

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 Conclusion:
In conclusion, the electric box panel for Faulty Product Detection Machine is a crucial component
in modern manufacturing systems that plays a critical role in ensuring the quality and consistency
of products produced on the production line. A well-designed electric box panel is essential for
reducing downtime and increasing the productivity of the manufacturing system. Additionally, it is
important to ensure that the electric box panel is designed and installed in compliance with relevant
safety standards and regulations to ensure the safety of operators and personnel working around the
machine.

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References
[1] https://www.trendmicro.com/vinfo/us/security/definition/industrial-control-
system
[2] https://www.squareone.ca/resource-centres/getting-to-know-your-
home/electrical-panel

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