CHAPTER 4 ANALYSIS AND DESIGN

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Eugene Jefferson
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9 CHAPTER 4 ANALYSIS AND DESIGN 4.1 Analysis In this project, the sorting activity of the item or packet delivery is done automatically with the computer (integrated with Arduino microcontroller).

cell sensor. Illustration 4.1: Ultrasonic Sensor HC-SR04 Illustration 4.

1 9 CHAPTER 4 ANALYSIS AND DESIGN 4.1 Analysis In this project, the sorting activity of the item or packet delivery is done automatically with the computer (integrated with Arduino microcontroller). The components and sensors used in this prototype include: Arduino Mega 1280 microcontroller, conveyor, ultrasonic sensor HC-SR04, laser sensor, ldr sensor, DC geared motor, LCD display, and load cell sensor. Illustration 4.1: Ultrasonic Sensor HC-SR04 Illustration 4.2: How Ultrasonic Sensor Work In General In general, ultrasonic sensors are only used to measure the distance of an object by reflecting sound waves to an object. Sound waves sent by an ultrasonic transmitter will lead to a targeted object, then the sound waves will be reflected again to the ultrasonic receiver. With the process of sending and receiving back

2 10 sound waves (reflections), the distance from the object or object will be obtained. Because, ultrasonic sensors work by utilizing sound waves as signals to transmit and receive data. And in this project, ultrasonic sensors are used to calculate the thickness (width) and also the height (height) of a package. The principle of measuring the distance of an object and the thickness / height of a package is almost the same. Measuring the thickness and height of packets is done by measuring the maximum measurement distance first, which is then reduced by the distance from the sensor to the surface of the object / package to be measured. So that the thickness and height of objects / packets can be calculated and known the results.

Laser sensor as sender (in the form of red light) and ldr sensor as receiver.

3 11 Illustration 4.4: Module Laser Illustration 4.3: Module LDR Laser sensor and ldr sensor are combined into 1 tool, which serves to measure the length of packets in this project. Laser sensor as sender (in the form of red light) and ldr sensor as receiver. The light / laser beam will be directed right at the ldr sensor. The packet to be measured in length, will be placed on top of the conveyor running. When the packet first touches the laser (the front of the package), then the first ms (milisecond) value will be stored.

12 When the back of the package is about the laser beam, the length calculation of the packet will be considered completed and the second ms (milisecond) value will be stored, since there is no

4 12 When the back of the package is about the laser beam, the length calculation of the packet will be considered completed and the second ms (milisecond) value will be stored, since there is no longer any object. Thus, to obtain a long value, it is done by subtracting the second ms value by the first ms value (when the laser beam first touches the object, and when the last object touches the laser light). Illustration 4.5: Load Cell Sensor Straight Bar (5 Kg) To measure the mass or weight of the packet, in this project using a load cell sensor Straight Bar with a capacity of 5 kg. The load cell sensor is designed by attaching or installing the left arm of the load cell to the base, and installing the wooden board as a weighing board in the right arm of the load cell. Packages that have been calculated and obtained the value of volume, will be taken to the weighing board using a conveyor. When the package is above the weighing board, it will take ms (milliseconds) to optimize the mass or weight calculation of the packet. So, to get the result of calculating the mass of an object, the object must be placed on the weighing board, then wait a while, and the result will come out.

13 Illustration 4.6: Module HX711 (Load Cell Amplifier) This is a supporting component for load cell sensors. This component is commonly called the HX711.

5 13 Illustration 4.6: Module HX711 (Load Cell Amplifier) This is a supporting component for load cell sensors. This component is commonly called the HX711. HX711 is a module that serves to strengthen the signal for the load cell sensor. By using this module, microcontroller can read and know the existence of signal sent by load cell sensor. Because of the deficiencies in the load cell sensor, which can only send signals with small voltage, to overcome the problem, this load cell sensor is usually combined with HX711 module so that the transmitted signal can be captured by microcontroller with 0V - 5V capacity.

6 14 DC geared yellow motor, used as a motor or conveyor drive in packet sorting process. This motor is attached to one side of the conveyor roller that serves as the prime mover, while one roller on the other hand only serves to help the conveyor base to work. Illustration 4.7: DC Geared Motor (Yellow)

7 15 To control the DC geared motor running as desired, then needed a module / driver support. The module is the l298n module. In this project, the l298n module is used to control the speed and direction of motor rotation on the DC geared motor. Illustration 4.8: Module L298n (Motor Driver)

16 Illustration 4.9: LCD Display LCD display is one component of microcontroller has a function to display the results of program processing in this project.

8 16 Illustration 4.9: LCD Display LCD display is one component of microcontroller has a function to display the results of program processing in this project. The result of calculating the volume value (value of length, width value, high value), volumetric conversion value, mass value or packet weight, will be displayed into this 16 x 2 display LCD screen.

9 17 Illustration 4.10: Board Arduino Mega 1280 Microcontroller is a tool where there is a chip embedded in it. This tool has a function to control an electronic circuit, and generally this microcontroller can also save a program that has been made. This tool is equipped with various components that are small, very small, or even invisible to the eye. On this board, there is a CPU (Central Processing Unit), input and output, memory, analog to digital converter, and various other components that are already integrated into one such device, called a microcontroller. In this project, the microcontroller used is Arduino Mega 1280 microcontroller. Because in this microcontroller has many pins or slots that can be used for various components and sensors. In this packet delivery sorting project, the slots or pins required are quite large. Because in this project there are 3 ultrasonic sensor, 1 laser sensor, 1 ldr sensor, 1 DC geared motor, 1 module / driver l298n, 1 led, 1 load cell sensor, and 1 module HX711.

10 18 Konveyor OFF Ketika Benda Datang Benda 1 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.1: Object Testing 1 (Conveyor OFF Delay) (Table 4.1) Percentage Error 1 ( P : 11 cm ; L : 7.5 cm ; T : 4.2 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

11 19 Benda 2 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.2: Object Testing 2 (Conveyor OFF Delay) (Table 4.2) Percentage Error 2 ( P : 5.8 cm ; L : 4.3 cm ; T : 4.3 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : 2 % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

12 20 Benda 3 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.3: Object Testing 3 (Conveyor OFF Delay) (Table 4.3) Percentage Error 3 ( P : 9.5 cm ; L : 6 cm ; T : 4.8 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

13 21 Benda 4 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.4: Object Testing 4 (Conveyor OFF Delay) (Table 4.4) Percentage Error 4 ( P : 7.9 cm ; L : 3.9 cm ; T : 3.8 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value: Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

14 22 Benda 5 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.5: Object Testing 5 (Conveyor OFF Delay) (Table 4.5) Percentage Error 5 ( P : 9.6 cm ; L : 5 cm ; T : 3.6 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

15 23 Konveyor ON Ketika Benda Datang Benda 1 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.6: Object Testing 1 (Conveyor ON, No OFF Delay) (Table 4.6) Percentage Error 1 ( P : 11 cm ; L : 7.5 cm ; T : 4.2 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

16 24 Benda 2 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.7: Object Testing 2 (Conveyor ON, No OFF Delay) (Table 4.7) Percentage Error 2 ( P : 5.8 cm ; L : 4.3 cm ; T : 4.3 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : 2 % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

17 25 Benda 3 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.8: Object Testing 3 (Conveyor ON, No OFF Delay) (Table 4.8) Percentage Error 3 ( P : 9.5 cm ; L : 6 cm ; T : 4.8 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

18 26 Benda 4 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.9: Object Testing 4 (Conveyor ON, No OFF Delay) (Table 4.9) Percentage Error 4 ( P : 7.9 cm ; L : 3.9 cm ; T : 3.8 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

19 27 Benda 5 Sampel Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Rata-rata Rata-rata Prosentase Error % % % % % % Table 4.10: Object Testing 5 (Conveyor ON, No OFF Delay) (Table 4.10) Percentage Error 5 ( P : 9.6 cm ; L : 5 cm ; T : 3.6 cm ; M : kg ) Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : % Value : Actual Weight (Digital Scales) : kg Value : Real Volume : cm 3

20 28 Prosentase Total Erorr Konveyor OFF Ketika Benda Datang Benda Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Benda Benda Benda Benda Benda Rata-Rata % % % % % % Table 4.11: Percentage of Total Errors (Conveyor OFF Delay) (Table 4.11) Percentage of Total Errors Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : %

21 29 Prosentase Total Erorr Konveyor ON Ketika Benda Datang Benda Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Aktual (Timbangan) Volume (Asli) Benda Benda Benda Benda Benda Rata-Rata % % % % % % Table 4.12: Percentage of Total Errors (Conveyor ON, No OFF Delay) (Table 4.12) Percentage of Total Errors Value : (P) : % Value : (L) : % Value : (T) : % Value : (V) : % Value : Volumetric Weight : % Value : Actual Weight : %

22 30 Prosentase Error (Conveyor OFF Delay) : Konveyor OFF Ketika Meletakkan Barang % Benda 2 Benda 4 Benda 1 Benda 3 Benda 5 Rata-Rata Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Sample Illustration 4.11: Chart - Percentage of Total Errors (Conveyor OFF Delay) (Illustration 4.11) The diagram above is the result of the average calculation of the error value obtained by using a conveyor that there is a delay of a few seconds to stop. (the conveyor will stop when it wants to put the package on the conveyor).

23 31 Prosentase Error (Conveyor ON, No OFF Delay) : Konveyor Tetap ON Ketika Meletakkan Barang % Benda 2 Benda 4 Benda 1 Benda 3 Benda 5 Rata-Rata Panjang Lebar Tinggi Volume (Sensor) Volumetrik Aktual (Load Cell) Sample Illustration 4.12: Chart - Percentage of Total Errors (Conveyor ON, No OFF Delay) (Illustration 4.12) The above diagram is the result of the average calculation of the error value obtained by using a conveyor that always ON / keep running without any delay to stop (conveyor still running when the object will be placed on the conveyor).

24 Desain Explanation : Illustration 4.13: Flowchart This is a flowchart diagram of the "package sorting" prototype project. The first thing to do is the process of declaration and initialization. Declare the variables used, then initialize the serial board (230400), initialize the input / output pins (I / O), initialize the load cell and also the LED light. After that, the core process of this project will start soon.

25 33 Initialize the conveyor with the off state as the start of the packet sorting process. When the conveyor is off, the LED will light up as a marker for the officer to immediately place the package on the conveyor. In this process the conveyor will not run until the LED lights off. Time given to the officer to place the package on the conveyor +/- 5 seconds (the LED light will turn on and off, for 5 seconds). If it has not passed 5 seconds, the LED light will not die, and the conveyor will not run (the path is 'False'). However, if the time has passed 5 seconds, the LED light will die and the conveyor will start running (the road is 'True') to deliver the packet. If the path is already 'True', the conveyor will continue until the packet volume counting on the conveyor is completed. The package will run on the conveyor until the package is about the laser. When a laser beam detects an object / packet (the front end of the packet), the conveyor stops for several ms (100 ms = 0.1 sec) and will resume running. The laser beam will store the value of ms as long as the laser beam detects any packets that pass through it. In other words, as long as the laser detects the packet, the conveyor will continue to run and will not stop until the laser beam does not detect the packet anymore (detects from the front end to the rear end of the package). Not only calculate the ms value to get the value of the length of the packet, but also there is a process of calculating the high value and value of the width of the object using the ultrasonic sensor. The package will run through a tunnel already equipped with several ultrasonic sensors to calculate the height and width value of the packet. If the laser beam has not detected the packet anymore, then the value of the obtained length will be accumulated with the high value and the width value obtained from the ultrasonic sensor calculation. The packet will be forwarded to weighing board to calculate the actual mass / weight of the packet. When the package has fallen onto the weigh board, the conveyor will stop / off for some time. The package will be calculated using a load cell sensor for thousands of calibrations to get a fairly accurate weight rating. After getting the volume and

26 34 weight value of the packet, the result will be displayed on the monitor series. Then the conveyor will be re-initialized to 'False'. Then, the volume value that has the unit of cm 3 will be converted into kilogram (kg). This volumetric conversion formula, obtained from one of the website of an expedition agent in Indonesia. The weight value of the volumetric and the actual weight value that has been obtained will be displayed on the LCD display screen which has dimensions of 16x2. The values shown are P (long), L (width), T (height), value volumetric weight (kg), actual weight value (kg), and cursor or arrow as a sign of the decision to be used. If the arrow leads to a volumetric weight value, it means the volumetric weight value > the actual weight value, and the decision taken is the volumetric weight value. And vice versa, if the arrow leads to the actual weight value, it means the value of volumetric weight < actual weight value, so the decision taken is the actual weight value. After the calculation (volumetric and actual) and decision-making are completed, the conveyor that has been initialized to the 'False' condition will be returned to the cycle again, and the next process will continue to proceed as it is.

27 35 Schematic Illustration 4.14: Wiring Project Explanation : Pin PWM 2 = pin for module l298n (ENA) Pin PWM 3 = pin for module l298n (IN1) Pin PWM 4 = pin for module l298n (IN2) Pin PWM 5 = pin for module ldr Pin PWM 6 = pin for ultrasonic sensor (triggerpin : Right : Width) Pin PWM 7 = pin for ultrasonic sensor (echopin : Right : Width) Pin PWM 8 = pin for ultrasonic sensor (triggerpin : Left : Width) Pin PWM 9 = pin for ultrasonic sensor (echopin : Left : Width) Pin PWM 10 = pin for ultrasonic sensor (echopin : Top : Height) Pin PWM 11 = pin for ultrasonic sensor (triggerpin : Top : Height) Pin PWM 12 = pin for LED Pin Communication TX 14 = pin for LCD (RS)

28 36 Pin Communication RX 15 = pin for LCD (E) Pin Communication TX 16 = pin for LCD (D4) Pin Communication RX 17 = pin for LCD (D5) Pin Communication TX 18 = pin for LCD (D6) Pin Communication RX 19 = pin for LCD (D7) Pin Analog 0 = pin for module HX711 (DT) Pin Analog 1 = pin for module HX711 (SCK) Pin GND Board Arduino Mega 1280 = pin for LCD (RW) Pin GND Board Arduino Mega 1280 = Breadboard (-) Pin 5V Board Arduino Mega 1280 = Breadboard (+) Load cell (red cable) = module HX711 (E+) Load cell (black cable) = module HX711 (E-) Load cell (white cable) = module HX711 (A-) Load cell (green cable) = module HX711 (A+) DC geared motor (+) = module l298n (OUT 1) DC geared motor (-) = module l298n (OUT 2) Module l298n (+5V) = Breadboard (+) Module l298n (+12V) = Output power supply on PCB (+) Module l298n (GND) = Output power supply on PCB (-) Module l298n (GND) = Breadboard (-) Travo (0V/GND) = Input power supply on PCB (-) Travo (15V) = Input power supply on PCB (+)

29 37 Pin PWM 12 = resistor = LED (+) && LED (-) = Breadboard (-) Module laser (GND) = Breadboard (-) Module laser (+5V) = Breadboard (+) Module ldr (VCC) = Breadboard (+) Module ldr (GND) = Breadboard (-) Ultrasonic sensor (VCC : Right : Width) = Breadboard (+) Ultrasonic sensor (GND : Right : Width) = Breadboard (-) Ultrasonic sensor (VCC : Left : Width) = Breadboard (+) Ultrasonic sensor (GND : Left : Width) = Breadboard (-) Ultrasonic sensor (VCC : Top : Height) = Breadboard (+) Ultrasonic sensor (GND : Top : Height) = Breadboard (-)

FABO ACADEMY X ELECTRONIC DESIGN

FABO ACADEMY X ELECTRONIC DESIGN ELECTRONIC DESIGN MAKE A DEVICE WITH INPUT & OUTPUT The Shanghaino can be programmed to use many input and output devices (a motor, a light sensor, etc) uploading an instruction code (a program) to it