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A Project Report
On
Quality Inspection & Segregation System
In partial fulfilment of requirement for the award of the degree of
Bachelor of Engineering
In
Production and industrial Engineering
Session: 2015-2019
1
CANDIDATE’S DECLARATON
We hereby declare that the work which is being presented in the project entitled “Quality
Inspection & Segregation System” in the partial fulfilment of requirement for the award of
the degree of Bachelor of Engineering in Production and industrial Engineering, submitted
in the department of Production & Industrial Engineering, M.B.M. Engineering College,
Jodhpur (Rajasthan) , is an authentic record of our own work carried out during the period
from March 2019 to May 2109, under the supervision of Mr. Manish Kumar, Professor,
Department of Production & Industrial Engineering, M.B.M. Engineering College, Jodhpur
(Rajasthan).
The matter embodied in this project has not been submitted by us for the award of
any other degree.
Date:
Place:
Divya Thakurani
Madhav Garg
Shahrukh Khan
Mohd. Nadeem Behlim
Mahendra Deora
B.E. Final (P&I Engg.)
CERTIFICATE
This is certified that the above statement made by the candidates is correct to the best of my
knowledge.
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ACKNOWLEDGMENT
We would like to thank and express our gratitude to the Production and Industrial Engineering
Department of MBM Engineering College, Jodhpur and all our professors for giving us this
opportunity to work on this project.
It has been our privilege that we had worked under the expert guidance of Dr. Manish Kumar
Professor, Department of Production and Industrial Engineering, M.B.M Engineering College,
Jodhpur. We would like to express our sincere gratitude to him for the keen interest he took
and for being a constant encouragement and support throughout this project. His way of
patiently and objectively observing the work and pinpointing the proper directions has led me
to the right track and made this a wonderful learning experience.
Our sincere heartfelt gratitude to our families whose prayers, best wishes, support, concern and
encouragement has been a constant source of inspiration to us.
Date:
Place:
Divya Thakurani
Madhav Garg
Shahrukh Khan
Mohd. Nadeem Behlim
Mahendra Deora
B.E. Final (P&I Engg.)
3
TABLE OF CONTENTS
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1. Introduction
This inspection system is developed to inspect the products produced in any manufacturing
system and to separate the defective products.
This system is able to inspect the dimensions (height and length) and color of product.
After inspecting the product the system will segregate defective products in one stack and non-
defectives in another stack.
Inspection should take place with great accuracy and at high speed with little or no human
intervention.
It should be able to inspect at least one critical dimension (say height) and should be able to
separate the conforming items from the non-conforming ones.
Amongst the non-conforming items the system should be able to segregate the conforming and
non-conforming items.
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2. Description of parts
II. IR Module :
The IR Sensor-Single is a general purpose proximity sensor. Here we use it for collision
detection. The module consist of a IR emitter and IR receiver pair. The high precision IR
receiver always detects a IR signal.
The module consists of 358 comparator IC. The output of sensor is high whenever it IR
frequency and low otherwise. The on-board LED indicator helps user to check status of the
sensor without using any additional hardware. The power consumption of this module is low.
It gives a digital output.
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Pin No. Connections Description
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IV. Color Sensor (TCS3200) :
The Color Sensor is a complete color detector. It consists of a TAOS TCS3200 RGB sensor
chip and 4 white LEDs. It can detect and measure a nearly limitless range of visible colors to a
certain degree. The color of an object we can see in fact is the chromatic light the object reflects
in the white light (sunlight) after it absorbs the rest ones. The white color is a mixture of various
visible colors, which means it includes each colored light like red (R), yellow (Y), green (G),
blue (B), and purple (P). Based on the theory of three primary colors, any color is made by
mixing the three primary colors (red, green, and blue) in a certain proportion.
Thus, knowing the proportion you can get the color of the tested object. For TCS3200, when a
color filter is selected, it only allows a specific primary color to pass through and blocks the
other two colors. With the light intensity value of the three primary colors, by analysis we can
know the color of light reflected to TCS3200.The TCS3200 sensor has 4 types of filter: red
filter, green filter, blue filter, and clear with no filter.
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Enable A and Enable B pins are used for enabling and controlling the speed of the motor. If a
jumper is present on this pin, the motor will be enabled and work at maximum speed, and if
we remove the jumper we can connect a PWM input to this pin and in that way control the
speed of the motor. If we connect this pin to a Ground the motor will be disabled.
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VII. Optical Encoder:
The optical encoder has an LED light source, a light detector, a “code” disc/wheel mounted on the
shaft, and output signal processor. The disc has alternating opaque and transparent segments and is
placed between the LED and detector so it intermittently interrupts the LED’s beam as it rotates. The
detector responds to the series of light pulses it receives and sends that information to the processor,
which actually extracts the motion information (both amount of rotation and direction).
VIII. Rollers:
Rollers are mounted on the wooden pillars and conveyor belt is rotating over hub. Two rollers
are used to drive the conveyor belt. This rollers are made up of Aluminum alloy.
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IX. Rack and Pinion:
The push arrangement is made by rack and pinion. The pinion has 16 teeth and rack of 15cm
with 32 teeth. The rack and pinion arrangement is energized with the motor which is getting
instructions from motor driver L298N.
X. Other Components: Bread board, Wires, Adapters, Conveyor Belt, Wooden work-table.
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3. Design and Circuit Diagram
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Design of optical encoder disk for width measurement:
Inner axis diameter (diameter of roller) =28.127mm
Diameter of optical encoder = 64.685mm
Numbers of holes on disc= 50
Now,
1 wheel revolution= 1 motor revolution
1 motor revolution = 50 encoder ticks (i.e. 50 times a light is detected by a photo
sensor)
Now again,
Circumference of roller = π*D
= 3.14*28.127 mm
= 88.31878 mm
Now in 1 revolution of wheel, the distance moved by conveyor is equal to the
circumference of roller
Hence,
Distance moved in 1 wheel revolution = 88.31878 mm,
Distance moved in one move of hole = 88.31878/50 mm
= 1.76637 mm
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4. Working of System
The inspection system consist of a conveyor system fitted with readily available Ultrasonic
Sensor, IR Sensor, Color Sensor, DC Motor, DC Motor driver, rack and pinion
arrangement (to push the defective work piece) etc. the arrangement is shown in figure.
The conveyor carries the parts from the loading point of the system, at which parts are
placed manually, for the purpose of inspection.
1. Measurement of length:
For the measurement of length optical encoder arrangement has been used.
When the conveyor presents the part in front of 1st IR Sensor (a). This IR Sensor detects
the presence of product and from this point the microcontroller starts counting the number
of holes passing in front of the photodiode and LED (this is the IR sensor which is mounted
on the bottom side of the optical encoder disc). Now, microcontroller performs its
calculation and confirms the length of the product with the desirable length.
2. Measurement of height:
For the measurement of height ultrasonic sensor and two IR sensors are used.
Now, when the part moves and come in front of two IR’s (mounted on both side of the
supporting frame), the ultrasonic sensor receives an indication, that parts are just below it,
and at this time the sensor sends the wave from transmitting end and receive it from
receiving end. Now, as speed of sound in air is constant (i.e. 343m/s), which is much higher
than the speed of conveyor. So, the sensor measures the time of travel of wave and by this
the distance between the sensor and the item is computed. Now for the measurement of
height, this distance is subtracted from the distance between conveyor and sensor.
3. Measurement of Color:
When the item passes in front of the color sensor, it measures the color of object using
following principle.
TCS3200 chip is designed to detect the color of light incident on it. It has an array of
photodiode (a matrix of 8x8, so a total 64 sensors). These photodiodes are covered with
four type of filters. Sixteen sensor have RED filter over them thus can measure only the
component of red in the incident light. Likewise other sixteen have GREEN filter and
sixteen have BLUE filter. Any visible color can be broken into three primary colors. So
these three type of filtered sensors helps measure the weightage of each of primary colors
in incident light. The rest 16 sensors have clear filter. TCS3200 converts the intensity of incident
radiation into frequency. Pins S0 and S1 are used for scaling the output frequency. It can be
scaled to the following preset values: 100%, 20% or 2%. Scaling the output frequency is
useful to optimize the sensor readings for various frequency counters or microcontrollers.
By selectively choosing the photodiode filter’s readings it is able to detect the intensity of
the different colors. The sensor has a current-to-frequency converter that converts the
photodiodes’ readings into a square wave with a frequency that is proportional to the light
intensity of the chosen color. This frequency is then, read by the Arduino and it gives the
color of given object
If any of these three measured characteristics does not match to the characteristics of the
desired item/part, the rack pushes the product sideways and if all specifications are met
then product reach to the end point of conveyor.
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5. Arduino Coding for Inspection System
VOID SETUP() {
// DECLARATION OF PIN FOR INPUT/OUTPUT PURPOSE
PINMODE(A0, INPUT);
PINMODE(A1, OUTPUT);
PINMODE(BUZZER, OUTPUT);
PINMODE(ERROR_LED,OUTPUT);
PINMODE(12,INPUT_PULLUP);
PINMODE(31,INPUT_PULLUP);
PINMODE(5,INPUT);
PINMODE(M_A,OUTPUT);
PINMODE(M_B,OUTPUT);
PINMODE(MM_A,OUTPUT);
PINMODE(MM_B,OUTPUT);
DIGITALWRITE(MM_A,LOW);
DIGITALWRITE(MM_B,HIGH);
PINMODE(40,OUTPUT);//S0
PINMODE(41,OUTPUT);//S1
PINMODE(42,OUTPUT);//S2
PINMODE(43,OUTPUT);//S3
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PINMODE(44,INPUT);// OUTPUT OF COLOR SENSOR
VOID LOOP() {
// FOR CALCULATION OF LENGTH OF SAMPLE
WHILE(DIGITALREAD(INTERRUPT_PIN)==HIGH){
IF (DIGITALREAD(ENCODER_PIN) == CHANGE)
{
TICKS++;
DELAY(72);
}
IF (DIGITALREAD(INTERRUPT_PIN)==LOW)
{
NEXT_TICKS=TICKS;
NET_TICKS=NEXT_TICKS - PREVIOUS_TICKS;
LENGTH_OF_BOX = (NET_TICKS)*(0.176637);
////FOR PRINTING THE PARAMETERS OF OPTICAL ENCODER
/*SERIAL.PRINT(TICKS);
SERIAL.PRINT(" ");
SERIAL.PRINT(PREVIOUS_TICKS);
SERIAL.PRINT(" ");
SERIAL.PRINT(NEXT_TICKS);
SERIAL.PRINT(" ");
SERIAL.PRINT(NET_TICKS);
SERIAL.PRINT(" ");
SERIAL.PRINT(LENGTH_OF_BOX);
SERIAL.PRINTLN("CM");
*/
PREVIOUS_TICKS=TICKS;
BREAK;
}
}
// FOR HEIGHT OF SAMPLE
DIGITALWRITE(TRIG, HIGH);
DELAY(10);
DIGITALWRITE(TRIG, LOW);
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A = PULSEIN(ECHO, HIGH)/2;
B = A/74;
C = A;
//SERIAL.PRINT(B);
//SERIAL.PRINT(" ");
//SERIAL.PRINT(C);
//SERIAL.PRINT(" ");
HEIGHT = MAP(C,90,345,9,0);
//SERIAL.PRINT(HEIGHT);
//SERIAL.PRINTLN("CM");
X=DIGITALREAD(12);
Y=DIGITALREAD(31);
IF(C>349 && C<352)
{
C=350;
}
IF(C>110 && C>120){
C=105;}
// FOR COLOR SENSOR
// FOR RED
DIGITALWRITE(42,LOW);
DIGITALWRITE(43,LOW);
FREQUENCY = PULSEIN(44,LOW);
RED=FREQUENCY;
// FOR GREEN
DIGITALWRITE(42,HIGH);
DIGITALWRITE(43,HIGH);
FREQUENCY = PULSEIN(44,LOW);
GREEN=FREQUENCY;
// FOR BLUE
DIGITALWRITE(42,HIGH);
DIGITALWRITE(43,HIGH);
FREQUENCY = PULSEIN(44,LOW);
BLUE=FREQUENCY;
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SERIAL.PRINT(LENGTH_OF_BOX);
SERIAL.PRINTLN("CM");
DIGITALWRITE(ERROR_LED,HIGH);
DELAY(100);
DIGITALWRITE(ERROR_LED,LOW);
DELAY(2500);
}
ELSE{
ERROR=0;
RED=0;BLUE=0;
GREEN=0;
}
// FOR REJECTION
IF(ERROR==1){
DELAY(1100);
DIGITALWRITE(BUZZER,HIGH);
DIGITALWRITE(M_A,HIGH);
DIGITALWRITE(M_B,LOW);
DELAY(200);
DIGITALWRITE(M_A,LOW);
DIGITALWRITE(M_B,LOW);
DIGITALWRITE(M_A,LOW);
DIGITALWRITE(M_B,HIGH);
DELAY(200);
DIGITALWRITE(M_A,LOW);
DIGITALWRITE(M_B,LOW);
DIGITALWRITE(BUZZER,LOW);
ERROR=0;
RED=0;
BLUE=0;
GREEN=0;
}
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6. Cost Estimation
The cost report of Quality Inspection and Segregation System is represented here:
S Component QTY. Specifications Cost
No.
1. Arduino Mega 1 ATmega2560,5V, 54 I/O 800
pins
2. DC Gear Motor 1 30RPM ,12V 180
3. DC Gear Motor 1 100RPM,12V 180
4. IR Sensor 4 30cm obstacle detection 160
sensor FC-51
5. Ultra Sonic Sensor 1 HC-SR04 120
6. Color Sensor 1 TCS 3200 250
7. Supporting Frame 2*2 feet Card-Board 70
(2)
8. Rollers(cylindrical) 2 Ø2cm, L=6cm (metallic) 100
9. Rubber Belt 2 meters Rubber(Material) 100
10. Rack 1 Length 15cm 50
11. Pinion 2 No. of teeth= 16 60
12. Gears 3 No. of teeth= 32 120
13. Adaptor 1 12V-2A 180
14. Adaptor 1 9V-2A 120
12. Wires 90 Male, Female connecting 380
wires
13. Strip wire 4 1 foot 56
14. Glue gun Stick 1 - 30
15. Driver 1 L298D 200
16. Buzzer 1 5-20V (voltage) 25mA 25
(Current)
17. LED 2 3 Volt, 20mA 10
18. Optical Encoder Disc 1 Pine wood disk 50
19. Acrylic sheet 2*2feet For casing 32
20. Breadboard 1 Tie-points = 640, Tie- 80
points = 200. Total Tie-
points = 840.
Dimensions = ( 175 X 67
X 8 mm ).
21. Female jack 2 DC power jack supply 10
socket
22. Grinding Cutter 1 - 150
23. Cable 1 USB 2.0 Cable 50
24. Miscellaneous - Laser cutting of optical 252
encoder, tapes etc.
TOTAL 3815
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7. Advantages and Disadvantages
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8. Conclusion and Future Work
The designed system exhibits satisfactory performance when run with an assortment of
undersized, oversized and right sized products.
It also demonstrate that this system is economical and fulfills the objectives that were
required from the system at design stage.
Improvements that can be done-
1. Robotic arm could have been added to place the products on the products on the
conveyor belt. This would have eliminated the human intervention for placing
them the right side up.
2. The laser based sensor may be used in spite of ultrasonic sensor. This will
increase the cost but it will also improve the accuracy of the system
tremendously.
3. Proximity sensor may be utilized at strategic position to guard against the
toppling of product
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9. References:
https://www.analogictips.com/rotary-encoders-part-1-optical-encoders/
https://www.elprocus.com/infrared-ir-sensor-circuit-and-working/
https://www.instructables.com/id/Use-of-Ultrasonic-Sensor-to-Measure-Distances/
https://www.scribd.com/document/85588416/Color-Sensor-Working
https://www.rhydolabz.com/documents/Color-Sensor-UserManual.pdf
http://files.microjpm.webnode.com/200001259-eb551ec509/Color-Sensor-working-
principle-and-Arduino-Code.pdf
https://www.microsonic.de/en/support/ultrasonic-technology/principle.htm
https://www.instructables.com/id/Everything-you-need-to-know-about-colour-sensors/
https://howtomechatronics.com/tutorials/arduino/arduino-dc-motor-control-tutorial-l298n-
pwm-h-bridge/
http://wiki.sunfounder.cc/index.php?title=Color_Sensor_Module
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