PORTABLE DRAGON FRUIT GRADE SORTER (POWER SUPPLY AND STRUCTURE DESIGN) NOOR RAFIZA BINTI RAMLI

Transcription

1 PORTABLE DRAGON FRUIT GRADE SORTER (POWER SUPPLY AND STRUCTURE DESIGN) NOOR RAFIZA BINTI RAMLI May 2008

2 I hereby declared that I have read through this report and found that it has comply the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering (Power Electronic and Drive) Signature Supervisor s Name Date : : PN. ALIZA BINTI CHE AMRAN :

3 PORTABLE DRAGON FRUIT GRADE SORTER (POWER SUPPLY AND STRUCTURE DESIGN) NOOR RAFIZA BINTI RAMLI This Report is submitted in Partial Fulfillment of Requirements for The Degree of Bachelor in Electrical Engineering (Power Electronic and Drive) Faculty of Electrical Engineering Universiti Teknikal Malaysia Melaka May 2008

4 ii I hereby declared that this report is a result of my own work except for the excerpts that have been cited clearly in the references. Signature Name Date : : NOOR RAFIZA BINTI RAMLI :.

5 Dedicated to my beloved parents iii

6 iv ACKNOWLEDGMENTS Assalamualaikum warahmatullahi wabarakatuh, First and foremost, I would like to thank to Allah the Almighty for blessing me to complete my Project Sarjana Muda 1 and 2. I would like to enlarge my appreciation to my supervisor, Pn.Aliza binti Che Amran because of her kindness heart to accept me as one of the student under her supervision. Special thanks also dedicated to her for all comments, idea, and a guideline begin from the first day I start doing this project. I would also like to thank to all my friends that always give support, opinion, and advices for me to complete this report especially my project team members Nur Azlina and Mohd Hidayat. To my family especially my beloved parents; Hj.Ramli and Wan Zainun, I would like to forward my obliged for their continuous support during my study period, their patience and benevolence. Lastly, I would like to thank to everyone who has contributed during my Project Sarjana Muda 1and 2. Your kindness and cooperation in completion of my paper work is much appreciated. Thank you very much!!!!!

7 v ABSTRACT This project focuses on building a Power Supply and Structure Design for Portable Dragon Fruit Grade Sorter. This Portable Dragon Fruit Grade Sorter machine is an automatic machine that used to sort the dragon fruits according to their standards, grade and size. Sorting and grading process were done based on various criteria such as weight, shape and size. This project combines the knowledge of electrical and engineering drawing. This project is divided into three stages. The first stage is to design an adaptor to supply the system from 240Vac. Also to propose the best structure or design for the machine and then try to assemble the machine parts into one system using SolidWorks software. Hence, by using the Portable Dragon Fruit Grade Sorter machine, the human errors that always occurred in manual operations can be minimized and most important of all, number of human labor is reduced thus making the production more efficient and productive.

8 vi ABSTRAK Projek ini berfokus pada binaan unit sumber bekalan kuasa dan struktur-struktur binaan mesin untuk Mesin Pengasingan Buah Naga Mengikut Gred Mudah Alih. Mesin ini adalah mesin kawalan secara automatik yang digunakan untuk proses pengasingan buah naga merujuk pada piawaian, gred, dan saiz. Proses mengasing dan menggred buah naga berdasarkan pada beberapa ciri-ciri seperti berat, bentuk dan saiz. Projek ini menggabungkan pengetahuan asas tentang elektrikal dan lukisan kejuruteraan. Projek ini terbahagi kepada tiga peringkat. Pada peringkat pertama, merekabentuk pembekal kuasa yang sesuai untuk membekalkan kuasa voltan serta arus yang cukup daripada 240 volt AC kepada voltan DC yang berlainan bergantung kepada bahagian unit sistem tersebut. Di samping itu, turut mengutarakan idea untuk struktur rekabentuk binaan mesin yang terbaik dan menghimpunkan bahagian-bahagian mesin tersebut di dalam suatu sistem menggunakan perisian SolidWorks. Dengan itu, dengan menggunakan Mesin Pengasingan Buah Naga Mengikut Gred Mudah Alih, kesilapan yang sering dilakukan oleh manusia dapat dikurangkan dan yang paling penting penggunaan tenaga kerja manusia dapat dikurangkan. Demikian menjadikan pengeluaran buah naga lebih cekap dan banyak.

9 vii CONTENT CHAPTER TITLE PAGE TITLE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF APPENDICES i ii iii iv v vi vii xi xii xiv I INTRODUCTION 1.1 Introduction Problem Statement Project Objectives Project Scope Project Methodology Thesis Outline 7

10 viii II LITERATURE REVIEW 2.1 Introduction Introduction in Fruit Sorting System Latest Technology in Sorting Fruit Process OMI Pineapple Sorting Machine Compac In Vision 5000 Blemish Sorting AWETA GS: The Cup Grader AWETA GS: computer cucumber sorting 15 machine 2.4 Example Existing Machine Design Rotary Cylinder Sizer Citrus Juice Extractors The Cherry Kg Grader Introduction to Linear Power Supply Introduction to Full-wave rectifiers 19 converting ac-dc The Bridge Rectifier The Positive Half-cycle The Negative Half-cycle Introduction to Solidworks Design CAD 24 software III PORTABLE DRAGON FRUIT GRADE SORTER 3.1 Introduction The Fruit Sorting System System Concept and Algorithm Station 1: Loading Process Station 2: Sorting Process Station 3: Storing Station Design Phases for the Machine 29

11 ix Formulation Concept design Configuration design Parametric design Detail design The Linear Power Supply for the portable 31 dragon fruit grade sorter machine vdc stabilized power supply with 32 current control A Technical Specifications-characteristics Features Circuit operation Exalibur Low-noise High-speed precision 36 Operational amplifier Introduction Complementary Silicon Power Transistor 39 2N3055 (NPN) IV RESULTS AND ANALYSIS OF DESIGN ASPECT 4.1 Introduction Design Specification Design Concept and Design Comparison First Concept Second Concept The Result Analyzing and Concept Evaluate Analysis for the 12VDC power supply Problem Occur From the Stabilized Power Supply The Hardware Configuration of stabilized Power supply 51

12 x V CONCLUSION 5.1 Conclusion Recommendation 52 REFERENCES 54 APPENDIX A - G 56-83

13 xi LIST OF TABLES NUM. TITLE PAGE 1.1 Difference types of dragon fruit weights and sizes Fruit Grade Truth Table 28

14 xii LIST OF FIGURES NUM. TITLE PAGE 1.1 Hylocereus undatus Hylocereus polyrhizus Project methodology Fruit sorting machine vision User control console CCD Camera and Weight Sensor Channelizer Apple weighting (Single Line Sorter) Baggers interfaced to Compac 4 lane Apple 8 lane pre-grade line with InVision 5000 Blemish grading System Fruit grading line The cup grader Cucumber sorting tray Rotary cylinder sizer Citrus Juice Extractors The Cherry KG Grader Diagram of Simple Series Power Supply Basic diagram of rectifier conversion Full-wave rectifier circuit using two-diodes The Diode Bridge Rectifier The Positive Half-cycle The Negative Half-cycle 23

15 xiii 2.20 Full-wave bridge rectifier (a) alternative presentation (b) Voltages and current The Solidworks software user interface Whole system Loading Station Five phases of design, emphasizing the crucial nature of design problem formulation Schematic diagram Symbol for TLE TLE2141 op-amp Block Diagram of TLE Power Transistor 2N3055 (NPN) 4.1 Design for first concept Flowchart of the sorting process Design for second concept Front view of the design Back view of the design Top view of the design Components part Circuit for 12vdc motor Waveform of 12VDC motor Revised circuit for TLE2141 operational amplifier Modified circuit for 0-30vdc stabilized power supply The electronics components placed on the printed circuit board Overall view of the stabilized power supply 51

16 xiv LIST OF APPENDICES NUM. TITLE PAGE A Gantt chart 56 B Instruction to use the Solidworks software 58 C Component List 66 D Circuit for 0-30vdc stabilized power supply 68 E Operational Amplifier (TLE2141) 70 F Operational Amplifier (TL081) 74 G Power Transistor 2N

17 1 CHAPTER I INTRODUCTION 1.1 Introduction Malaysia is blessed with good tropical climate. Besides fruits, many crops can be grown here like rubber, oil palm, paddy and cocoa. One of the most recent newcomers in the Malaysian fruit industry is dragon fruits (Hylocereus polyrhizus). After many trials and errors, dragon cultivation has made its way in the Malaysian fruit industry. The local name for dragon fruit is buah naga or buah mata naga. The dragon fruit growing areas are in the states of Johor, Perak, Negeri Sembilan, Pahang, Pulau Pinang and Sabah [4]. The fruit comes in three types, all with leathery, slightly leafy skin which is white flesh with pink skin (Hylocereus undatus), red flesh with pink skin (Hylocereus polyrhizus) and white flesh with yellow skin (Selenicereus megalanthus) [5]. But only two types of variety can be grow in Malaysia which is the red and white flesh. Figure below show the two variety types of dragon fruit: Figure 1.1: Hylocereus undatus Figure 1.2: Hylocereus polyrhizus

18 2 Dragon fruits have different weights and sizes. Table 1.1 shows the different weight and grade of the dragon fruit: Table 1.1: Difference types of dragon fruit weights and sizes. GRADE AA A B C D WEIGHT 601gm and above 451gm 450gm 356gm 450gm 350gm 250gm 250gm and below For this project its combines the knowledge of electrical and engineering drawing in designing the Portable Dragon Fruit Grade Sorter. This project is to design an automatic machine that used to sort the dragon fruits according to their standards, grade and size. Sorting and grading process were done based on various criteria such as weight, shape and size. This project is divided into three stages. The first stage is to propose the best design for the Portable Dragon Fruit Grade Sorter Machine in low cost but still effective. For the second stage, to design and assemble the machine parts into one system using the SolidWorks software. For the last stage, to design and develop an adaptor to supply the system from 240Vac to the desired input value for the actuator, motor and sensors. For the power supply design, a linear high quality power supply with a continuously variable stabilized output adjustable at any value between 0 and 30VDC is build. The circuit also incorporates an electronic output current limiter that effectively controls the output current from a few miliamperes (2mA) to the maximum output of three amperes that the circuit can deliver. [9]

19 3 1.2 Problem Statement In Malaysia, the fruit grade sorting is based on shape, weight, or size. Fruit sorting is still in the initial stage and most of the sorting process still done manually. Currently, the manual sorting is more popular and cheaper where the process is done by a number of labors. Automatic fruit grading and sorting has not been implemented widely for this type of fruit. The process is time consuming and error prone as human labor efficiency and consistency will decrease with time. To overcome this problem, the Portable Dragon Fruit Grade Sorter is proposed. Grading is done on several of criteria like weight, shape, size and etc [6]. This machine is designed to overcome the human error and reduce labor work in a short time and the design will not be fully automated, but can sort the fruits in a short time with less number of labor works. The main advantages of the present machine is it will facilitate automatic grading and sorting of dragon fruit in a non destructive method. The purposed machine is cheaper compared to other existing machines where robotic arms are used and cost around RM500, 000 per unit depending on its performance. 1.3 Objectives The objectives of the project that need to be accomplished are: 1) To propose the best design for the Portable Dragon Fruit Grade Sorter Machine in low cost but still effective. 2) To design and assemble the machine parts into one system using the SolidWorks software. 3) To design and develop an adaptor to supply the system from 240Vac to the desired input value for the actuator, motor and sensors.

20 4 1.4 Scope In this project, the scope is based on three main parts. The first scope for this project starts with conducting research on information for example fruit grading and sorting, to get the basic idea to design the sorting machine. The second scope is, after find the best structure design for this project try to assemble the machine parts into one system using SolidWorks software. Then for the last scope, it follows with designing a power supply for the motor, actuator and sensors then simulate the circuit using Proteus s Lite software. The power supply is then built and be part of the sorter machine. 1.5 Project Methodology In order to complete this project, a necessary project planning should be arranged. For this project, there are several steps should be taken to achieve the project s scope and objectives. Basically, Project Methodology defines the planning process flow and principles that are essentials guide to produce a well planning project. Besides, selected approach or methodology will be described the activities that may do in every stage. The requirements that are requisite in this system will be explained in project requirements and followed with project schedule and milestones. The flow chart that describes the methodology for this project is shown in the flow chart below: Start Literature review Determine the objectives of the project. Identifying problem and study the system. Research about the project throughout resources like internet and books. Discussion among team members, supervisor and from experienced person

21 5 Engineering Drawing Design Power supply design Find the best structure design Simulate the circuit using Proteus software Assemble the machine parts into one system using SolidWorks software Construct the circuit Troubleshooting Build the structure design using suitable material Circuit operate correctly? End Yes Figure 1.3: Project methodology 1) Literature review The first stage for completing the final year project is determining the objectives of the project and identifying the problems for this project and study the system. Besides, doing the research and finds information that related to the project through out resources such as internet, books and etc. By doing this literature review, the high understanding of the project can be achieved

22 6 2) Discussion After gather all the information and identifying the problem, discussion among team members and supervisor is important. In this stage, supervisor will give the explanation and guideline throughout the project. 3) Engineering Drawing Design using SolidWorks. The next step is find the best design for the main structure of the machine and then tries to sketch the design machine. The designs parts including sorting system design, power supply, computer system and etc. Learn about SolidWorks software and assemble the machine parts into one system. 4) Power supply design Find the suitable circuit design for adaptor to supply the system from 240Vac and simulated the design using Proteus s Lite software. After the simulation is complete, the circuit for the power supply will be constructing along with the troubleshooting process. 5) Build the machine structure The design parts for the structure are complete and the machine structure needs to be done. Doing some research among team members and supervisor for choosing the best material for the structure. 6) Build the adaptor supply hardware. By completing the simulation on Proteus s Lite, all the data and analysis had been retrieved. The circuit is build using printed board. 7) Analyzed the results of simulation and hardware. After complete the hardware, the output will be observed and analyzed so that a comparison can be make to see any differences between the simulation and actual output.

23 7 1.6 Thesis Outline Chapter 1 is basically the introduction part of the project chosen. In this chapter, the project background and problems statements will be discussed clearly. Besides, elaboration on the project objectives and project scope will be explained in details so that a better view of the project can be obtained. The project methodology is the most important part that describes the flow of the project, also be mentioned and elaborated in details in this chapter. In chapter 2, the literature review of the project will be discussed. The literature review is the method for collecting information regarding the machine, and the result based on the information will be analysis and examine for the purpose to know the benefit or the scarcity of the machine. In this section, it will be discuss about the theory and concepts that is accordingly to the project in details. Also, it will inform about the perspective and method that have been using in this project. The information for this project according: 1) Introduction in fruit sorting and grading system. 2) The latest technology in fruit sorting and grading process. 3) Example existing design from the fruit sorting machine application. In chapter 3, the methodology is the method and tools that used to achieve the objective and the goal of the project. In this chapter, a few methods have been chosen to get the good solution for all the problems in sorting the dragon fruit. This chapter explains and elaborates about the methods, material and tools used to create this project and reasons of choosing such methods and tools. Problems arises in the methods used are also discussed. In chapter 4, it will discuss about the design specification, design concept and design comparison of the sketch design. The design specification is one of the method need for designing a new product. In this chapter also will be discussed about the 0-30VDc stabilized power supply experiments results and data collection. The simulation and experimental results of the project will be analysis and discuss.

24 8 In chapter 5, the conclusion and necessary recommendation will be highlighted. The recommendation that recommend by the author will be useful for the final year project next semester.