AUTOMATIC SCARP COLLECTING SYSTEM

ABSTRACT

The automatic three axis Crane is designed to remove scraps from the work station to the disposal area with the help of electronic sensors and a rail. The use of this automated vehicle system reduces human efforts and and the chances of hazard. The automated crane collecting vehicle system consists of Wireless controller, Drive motors. The collecting work station consists of the work room, two conveyors and a glass shattering machine. The big glass scraps from the work area is collected by a conveyor and is brought to a glass shattering machine to reduce its size. This shattered glass scraps are brought away from the machine to the to the rail module through a conveyor for disposal. The second phase consists of a rail module and a vehicle module, the rail module for guiding the vehicle. This is disposed between the collecting work station and the disposal station. The glass scraps are disposed in the disposal area. The whole process is automated to minimize human efforts and to attain better productivity. Please refer the attached file for more details.

CHAPTER 1

INTRODUCTION

1.1INTRODUCTION This designs efficient Scrap Handling Systems for the Paper & Pulp industries which automatically pick up scrap from a generation point and convey it to a point away from the manufacturing area. Low pressure air systems using material handling blowers continuously pick up the scrap and convey it to a cyclone where the scrap is separated from the air stream and dropped into a baler. Along the production line, trim cutters and shredders produce the scrap where it initially enters the air system.

it will serves companies in the Paper & Pulp industries who require scrap handling equipment for corrugated, paper, folding carton, commercial printing, flexible and paper packaging, foil processing, paperboard, and paper fiber. Recently, according to a clean room for manufacturing a liquid crystal display, human workers collect scrap glass, such as an entire scrap glass substrate or the scrap edge of a glass substrate. For example, according to a method for collecting the edge scrap of a glass substrate, a glass cutting apparatus for cutting a glass substrate is generally provided with a scrap box located thereunder. After the scrap box is full of the scrap glass, the scrap box will be pushed and moved to a warehouse by human worker. However, according to the above-mentioned method for collecting the scrap glass, the scrap box can occupy the space of the first fabrication area. Also, it is not easy to control when the scrap box is full of the scrap glass, and
2

therefore the human work need to patrol, inspect and transfer the scrap box regularly, such that the manpower cost is increased. Furthermore, when the scrap glass is collected into the scrap box, it possibly pollutes the clean room. In addition, the scrap box full of the scrap glass is too heavy to be easily transferred and will easily harm the human worker. If the production quantity of the liquid crystal display is increased, the number of the glass cutting apparatus and the scrap box are increased and the area of the clean room is enlarged, thereby further increasing the manpower cost. Recently, an automatic guided system is widely applied to the manufacturing industry. For example, an automatic guided vehicle or a rail-guided vehicle is usually utilized in the clean room for transferring work for manufacturing a semiconductor device or a flat panel display (FPD), such as a liquid crystal display. U.S. Pat. No. 6,019,563, entitled Automatic Guided Vehicle issued to Murata et al. on Feb. 1, 2000, discloses an automatic guided vehicle or a rail guided vehicle including light sensors can safely, certainly and rapidly finish the transferring work. Accordingly, there exists a need for an automatic guided system for transferring scrap glass for solving the above-mentioned problem of the transferring work of the human worker.

1.2 EMBEDDED SYSTEM

Embedded systems are controllers with on chip control which consist of microcontrollers, input and output devices, memories etc. and it can be used for a specific application. A small computer designed in a single chip is called single chip microcomputer. A single chip microcomputer typically includes a
3

microprocessor, RAM, ROM, timer, interrupt and peripheral controller in a single chip. This single chip microcomputer is also called as a microcontroller. These microcontrollers are used for variety of applications where it replaced the computer. The usage of this microcomputer for specific applications, in which the microcontroller a part of application is called, embedded systems. Computing systems are everywhere. Its probably no surprise that millions of computing systems are built every year destined for desktop computers (Personal Computers, or PCs), workstations, mainframes and servers. Thus an embedded system is nearly any computing system other than a desktop, laptop, or mainframe computer.

1.3 CHARACTERISTICS OF AN EMBEDDED SYSTEM

1.3.1 SINGLE-FUNCTIONED An embedded system usually executes only one program, repeatedly. For example, a pager is always a pager. In contrast, a desktop system executes a variety of programs, like spreadsheets, word processors, and video games, with new programs added frequently.

1.3.2 TIGHTLY CONSTRAINED All computing systems have constraints on design metrics, but those on embedded systems can be especially tight. A design metric is a measure of an implementations features, such as cost, size, performance, and power. Embedded systems often must cost just a few dollars, must be sized to fit on a single chip, must perform fast enough to process data in real-time, and
4

must consume minimum power to extend battery life or prevent the necessity of a cooling fan.

13.3 REACTIVE AND REAL-TIME Many embedded systems must continually react to changes in the systems environment, and must compute certain results in real time without delay. For example, a car's cruise controller continually monitors and reacts to speed and brake sensors. It must compute acceleration or decelerations amounts repeatedly within a limited time; a delayed computation result could result in a failure to maintain control of the car.

1.4. EMBEDDED PROCESSOR TECHNOLOGY 1.4.1 STANDARD GENERAL PURPOSE PROCESSORS (SGPP)

Standard general purpose processors (SGPP) are carefully designed and offer a maximum of flexibility to the designer. Programming SGPPs can be done in nearly every high-level language or assembly language and requires very little knowledge of the system architecture. As SGPPs are manufactured to high numbers, NRE is spread upon many units. Nevertheless SGPPs are more expensive than other solutions like FPGAs or single purpose processors, when used in products with a large number of selling units. These devices are produced to work in a broad range of environments since those are not designed to be energy efficient nor high-performance for specific applications.

Examples for standard general purpose processors are:

5

 Motorola ARM Atmel AVR Microchip PIC Intel Pentium-(I/II/III/IV)-Series 1.4.2. STANDARD SINGLE PURPOSE PROCESSORS (SSPP)

Standard single purpose processors, sometimes called peripherals, are off-the-shelf pre-designed processors, optimized for a single task, such as digital signal processing, analog to digital conversion, timing, etc. SSPPs are manufactured in high quantities, so NRE is spread upon many units. The total costs per SSPP unit are lower than for custom single purpose processors.

1.4.3. CUSTOM SINGLE PURPOSE PROCESSORS (CSPP)

Custom single purpose processors are designed for a very specific task. This implies less flexibility, longer time-to-market and high costs. On the other hand CSPP can be designed to be very small, fast and power-efficient. Examples for such CSPP are FPGAs or more general PLDs.

1.4.4.

APPLICATION

SPECIFIC

INSTRUCTION-SET

PROCESSORS (ASIP)

ASIPs are basically standard general purpose processors which are extended by domain-specific instructions. This allows domain-relevant tasks
6

to be performed highly optimized, while keeping the flexibility of general purpose processors.

1.4.5. SPECIFIC DESIGN OF EMBEDDED SYSTEM PROCESSOR

When designing an embedded system, usually, the first step is to specify the intended or required functionality. This is mostly done using natural language, after the functionality is specified it is formalized in some sort of definition language such as VHDL or Verilog. Subsequently the resulting design is converted into hardware or software components which are then implemented.

CHAPTER 2

PROPOSED SYSTEM PROPOSED SYSTEM

It is an object of the present invention to provide an automatic guided system for transferring scrap glass, wherein the automatic guided system decreases the wasted space of the first fabrication area (FAB) and the manpower cost by utilizing automatically transferring the scrap glass in the second fabrication area (SUB-FAB). The present invention provides an automatic guided system for transferring scrap glass resulted from at least one scrap glass source of a clean room to a scrap exit. The automatic guided system for transferring the scrap glass includes a rail module and a vehicle module. The rail module connects a first predetermined location to a second predetermined location. The first predetermined location is a garage for providing the vehicle module to await an order or a collecting workstation for treating the scrap material resulted from the scrap source. The second predetermined location is a scrap exit for providing the vehicle module to dump the scrap material resulted from the scrap source or a collecting workstation for treating the scrap material resulted from the scrap source. The vehicle module is disposed and moved along the rail module for transferring the scrap glass from the scrap glass source to the scrap exit The automatic guided system for transferring scrap glasses according to the present invention can decrease the wasted space of the first fabrication area and avoid interfering with the movement of the first fabrication area. Furthermore, the automatic guided system can collect the bigger scrap glass and shatter the scrap glass, thereby preventing the human worker from harm. In addition, the automatic guided system can reduce the manpower cost, and

the automatic guided system does not increase the manpower cost when the production quantity is increased. The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

APPLICATIONS: INDUSTRIAL application In manufacturing industries Commercial application ADVANTAGES: Reliable operations at large currents Controls the process Ease of operation

3.3 BLOCK DIAGRAM

TRANSMITTER

MICRO CONTROLLER POWER SUPPLY

RF TRANSMITTER

RECEIVER

POWER SUPPLY

MOTOR 1 8051

MICRO CONTROLLER RF RECIEVER

H BRIDGE DRIVER

MOTOR 2

10

Fig 4.3.1.Block Diagram of Proposed System

fHARDWARE REQUIREMENTS MICROCONTROLLER IR SENSOR CONVEYAR SYSTEM POWER SUPPLY H-BRIDGE DRIVER DC MOTORS SOTWARE REQUIREMENTS KEIL COMPILER EMBEDDED C

11

CHAPTER 5

HARDWARE DESCRIPTION

5.1 POWER SUPPLY 5.1.1 CIRCUIT DIAGRAM

Fig 5.1.2Circuit Diagram of Power Supply

5.1.2 WORKING PRINCIPLE The AC voltage, typically 220 rms, is connected to a transformer, which steps that ac voltage down to the level of the desired DC output. A diode rectifier then provides a full-wave rectified voltage
12

that is initially filtered by a simple capacitor filter to produce a dc voltage. This resulting dc voltage usually has some ripple or ac voltage variation. A regulator circuit removes the ripples and also remains the same dc value even if the input dc voltage varies, or the load connected to the output dc voltage changes.

5.1.3 BLOCK DIAGRAM

TRANSFORME R

RECTIFIER

FILTER

IC REGULATOR

LOAD

Fig 5.1.3 Block Diagram of power supply 5.1.4 TRANSFORMER

The potential transformer will step down the power supply voltage (0230V) to (0-6V) level. Then the secondary of the potential transformer will be connected to the precision rectifier, which is constructed with the help of opamp. The advantages of using precision rectifier are it will give peak voltage output as DC; rest of the circuits will give only RMS output.

5.1.5 RECTIFIER

A rectifier is an electrical device that converts alternating current to direct current or at least to current with only positive value, a process known as rectification. Rectifiers are used as components of power supplies and as detectors of radio signals.

13

5.1.6 BRIDGE RECTIFIER

When four diodes are connected as shown in the power supply circuit diagram, is called Bridge rectifier. The input to the circuit is applied to the diagonally opposite corners of the network, and the output is taken from the remaining two corners.

5.1.7 VOLTAGE REGULATORS

Voltage regulators comprise a class of widely used ICs. Regulator IC units contain the circuitry for reference source, comparator amplifier, and overload protection all in a single IC. IC units provide regulation of either a fixed positive voltage, a fixed negative voltage, or an adjustably set voltage. The regulators can be selected for operation with load currents from hundreds of milli amperes to tens of amperes, corresponding to power ratings form milli watts to ten watt. A fixed three-terminal voltage regulator has an unregulated dc input voltage, Vi, applied to one input terminal, a regulated dc output voltage, Vo , from a second terminal, with the third terminal connected to ground.

AT89s52 Microcontroller: Features: Compatible with MCS-51 Products 8K Bytes of In-System Programmable (ISP) Flash Memory Endurance: 1000 Write/Erase Cycles 4.0V to 5.5V Operating Range
14

Fully Static Operation: 0 Hz to 33 MHz Three-level Program Memory Lock 256 x 8-bit Internal RAM 32 Programmable I/O Lines Three 16-bit Timer/Counters Eight Interrupt Sources Full Duplex UART Serial Channel Low-power Idle and Power-down Modes Interrupt Recovery from Power-down Mode Watchdog Timer Dual Data Pointer Power-off Flag Fast Programming Time Flexible ISP Programming (Byte and Page Mode) Green (Pb/Halide-free) Packaging Option

Description: The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8K bytes of in-system programmable Flash memory. The device is manufactured using Atmels high-density nonvolatile memory technology and is compatible with the Indus-try-standard 80C51 instruction set and pin out. The on-chip Flash allows the program memory to be reprogrammed in-system or by a conventional nonvolatile memory programmer. By combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip, the Atmel AT89S52 is a powerful microcontroller which provides a highly-flexible and cost-effective solution to many embedded control applications. The AT89S52 provides the following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the AT89S52 is designed with static logic for operation down to zero frequency and supports two software selectable power saving modes. The Idle Mode stops the CPU while allowing the RAM, timer/counters, serial port, and interrupt system to continue functioning. The Power-down mode saves the RAM con-tents but freezes the oscillator, disabling all other chip functions until the next interrupt or hardware reset.

15

16

17

Pin Description VCC Supply voltage. GND Ground. Port 0 Port 0 is an 8-bit open drain bidirectional I/O port. As an output port, each pin can sink eight TTL inputs. When 1s are written to port 0 pins, the pins can be used as high-impedance inputs. Port 0 can also be configured to be the multiplexed low-order address/data bus during accesses to external program and data memory. In this mode, P0 has internal pull-ups. Port 0 also receives the code bytes during Flash programming and outputs the code bytes during program verification. External pull-ups are required during program verification. Port 1 Port 1 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 1 output buffers can sink/source four TTL inputs. When 1s are written to Port 1 pins, they are pulled high by the inter-nal pull-ups and can be used as inputs. As inputs, Port 1 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. In addition, P1.0 and P1.1 can be configured to be the timer/counter 2 external count input (P1.0/T2) and the timer/counter 2 trigger input (P1.1/T2EX), respectively, as shown in the following table. Port 1 also receives the low-order address bytes during Flash programming and verification.

18

Port 2 Port 2 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 2 output buffers can sink/source four TTL inputs. When 1s are written to Port 2 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 2 pins that are externally being pulled low will source current (IIL) because of the internal pull-ups. Port 2 emits the high-order address byte during fetches from external program memory and during accesses to external data memory that uses 16-bit addresses (MOVX @ DPTR). In this application, Port 2 uses strong internal pull-ups when emitting 1s. During accesses to external data memory that uses 8-bit addresses (MOVX @ RI), Port 2 emits the contents of the P2 Special Function Register. Port 2 also receives the high-order address bits and some control signals during Flash programming and verification. Port Pin Alternate Functions P1.0 T2 (external count input to Timer/Counter 2), clock-out P1.1 T2EX (Timer/Counter 2 capture/reload trigger and direction control) P1.5 MOSI (used for In-System Programming) P1.6 MISO (used for In-System Programming) P1.7 SCK (used for In-System Programming)

Port 3 Port 3 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 3 output buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins, they are pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 3 pins that are externally being pulled low will source current (IIL) because of the pull-ups. Port 3 receives some control signals for Flash programming and verification. Port 3 also serves the functions of various special features of the AT89S52, as shown in the following table.

19

RST Reset input. A high on this pin for two machine cycles while the oscillator is running resets the device. This pin drives high for 98 oscillator periods after the Watchdog times out. The DISRTO bit in SFR AUXR (address 8EH) can be used to disable this feature. In the default state of bit DISRTO, the RESET HIGH out feature is enabled. ALE/PROG Address Latch Enable (ALE) is an output pulse for latching the low byte of the address during accesses to external memory. This pin is also the program pulse input (PROG) during Flash programming. In normal operation, ALE is emitted at a constant rate of 1/6 the oscillator frequency and may be used for external timing or clocking purposes. Note, however, that one ALE pulse is skipped during each access to external data memory. If desired, ALE operation can be disabled by setting bit 0 of SFR location 8EH. With the bit set, ALE is active only during a MOVX or MOVC instruction. Otherwise, the pin is weakly pulled high. Setting the ALE-disable bit has no effect if the microcontroller is in external execution mode. PSEN

20

Program Store Enable (PSEN) is the read strobe to external program memory. When the AT89S52 is executing code from external program memory, PSEN is activated twice each machine cycle, except that two PSEN activations are skipped during each access to external data memory. EA/VPP External Access Enable. EA must be strapped to GND in order to enable the device to fetch code from external program memory locations starting at 0000H up to FFFFH. Note, however, that if lock bit 1 is programmed, EA will be internally latched on reset. EA should be strapped to VCC for internal program executions. This pin also receives the 12-volt programming enable voltage (VPP) during Flash programming. XTAL1 Input to the inverting oscillator amplifier and input to the internal clock operating circuit. XTAL2 Output from the inverting oscillator amplifier.

Memory Organization MCS-51 devices have a separate address space for Program and Data Memory. Up to 64K bytes each of external Program and Data Memory can be addressed. Program Memory If the EA pin is connected to GND, all program fetches are directed to external memory. On the AT89S52, if EA is connected to VCC, program fetches to addresses 0000H through 1FFFH are directed to internal memory and fetches to addresses 2000H through FFFFH are to external memory. Data Memory

21

The AT89S52 implements 256 bytes of on-chip RAM. The upper 128 bytes occupy a parallel address space to the Special Function Registers. This means that the upper 128 bytes have the same addresses as the SFR space but are physically separate from SFR space. When an instruction accesses an internal location above address 7FH, the address mode used in the instruction specifies whether the CPU accesses the upper 128 bytes of RAM or the SFR space. Instructions which use direct addressing access the SFR space. For example, the following direct addressing instruction accesses the SFR at location 0A0H (which is P2). MOV 0A0H, #data Instructions that use indirect addressing access the upper 128 bytes of RAM. For example, the following indirect addressing instruction, where R0 contains 0A0H, accesses the data byte at address 0A0H, rather than P2 (whose address is 0A0H). MOV @R0, #data Note that stack operations are examples of indirect addressing, so the upper 128 bytes of data RAM are available as stack space. Watchdog Timer (One-time Enabled with Reset-out) The WDT is intended as a recovery method in situations where the CPU may be subjected to software upsets. The WDT consists of a 14-bit counter and the Watchdog Timer Reset (WDTRST) SFR. The WDT is defaulted to disable from exiting reset. To enable the WDT, a user must write 01EH and 0E1H in sequence to the WDTRST register (SFR location 0A6H). When the WDT is enabled, it will increment every machine cycle while the oscillator is running. The WDT timeout period is dependent on the external clock frequency. There is no way to disable the WDT except through reset (either hardware reset or WDT overflow reset). When WDT over-flows, it will drive an output RESET HIGH pulse at the RST pin. Using the WDT To enable the WDT, a user must write 01EH and 0E1H in sequence to the WDTRST register (SFR location 0A6H). When the WDT is enabled, the user needs to service it by writing 01EH and 0E1H to WDTRST to avoid a WDT overflow. The 14-bit counter overflows when it reaches 16383 (3FFFH), and this will reset the device. When the WDT is enabled, it will increment every machine cycle while the oscillator is running. This means the user must reset the WDT at least every 16383 machine cycles. To reset the WDT the user must write 01EH and 0E1H to WDTRST. WDTRST is a writeonly register. The WDT counter cannot be read or written. When WDT overflows, it will generate an output RESET pulse at the RST pin. The
22

RESET pulse duration is 98xTOSC, where TOSC = 1/FOSC. To make the best use of the WDT, it should be serviced in those sections of code that will periodically be executed within the time required to prevent a WDT reset. WDT during Power-down and Idle In Power-down mode the oscillator stops, which means the WDT also stops. While in Power-down mode, the user does not need to service the WDT. There are two methods of exiting Power-down mode: by a hardware reset or via a level-activated external interrupt which is enabled prior to entering Power-down mode. When Power-down is exited with hardware reset, servicing the WDT should occur as it normally does whenever the AT89S52 is reset. Exiting Power-down with an interrupt is significantly different. The interrupt is held low long enough for the oscillator to stabilize. When the interrupt is brought high, the interrupt is serviced. To prevent the WDT from resetting the device while the interrupt pin is held low, the WDT is not started until the interrupt is pulled high. It is suggested that the WDT be reset during the interrupt service for the interrupt used to exit Power-down mode. To ensure that the WDT does not overflow within a few states of exiting Powerdown, it is best to reset the WDT just before entering Power-down mode. Before going into the IDLE mode, the WDIDLE bit in SFR AUXR is used to determine whether the WDT continues to count if enabled. The WDT keeps counting during IDLE (WDIDLE bit = 0) as the default state. To prevent the WDT from resetting the AT89S52 while in IDLE mode, the user should always set up a timer that will periodically exit IDLE, service the WDT, and reenter IDLE mode. With WDIDLE bit enabled, the WDT will stop to count in IDLE mode and resumes the count upon exit from IDLE. RELAY

A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and they are double throw (changeover) switches. Relays allow one circuit to switch a second circuit which can be completely separate from the first. For example a low voltage battery circuit can use a relay to switch a 230V AC mains circuit. There is no electrical
23

connection inside the relay between the two circuits; the link is magnetic and mechanical. The coil of a relay passes a relatively large current, typically 30mA for a 12V relay, but it can be as much as 100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils directly without amplification. Relays are usually SPDT or DPDT but they can have many more sets of switch contacts, for example relays with 4 sets of changeover contacts are readily available. For further information about switch contacts and the terms used to describe them please see the page on switches. Most relays are designed for PCB mounting but you can solder wires directly to the pins providing you take care to avoid melting the plastic case of the relay.

Advantages of relays:

Relays can switch AC and DC, transistors can only switch DC. Relays can switch high voltages, transistors cannot. Relays are a better choice for switching large currents (> 5A). Relays can switch many contacts at once.

Disadvantages of relays:

Relays are bulkier than transistors for switching small currents. Relays cannot switch rapidly (except reed relays), transistors can switch many times per second. Relays use more power due to the current flowing through their coil. Relays require more current than many ICs can provide, so a low power transistor may be needed to switch the current for the relay's coil.
24

DC MOTOR: 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 currentcarrying conductor and an external magnetic field to generate rotational motion. The shunt motor is different from the series motor in that the field winding is connected in parallel with the armature instead of in series. You should remember from basic electrical theory that a parallel circuit is often referred to as a shunt. Since the field winding is placed in parallel with the armature, it is called a shunt winding and the motor is called a shunt motor. Figure shows a diagram of a shunt motor. Notice that the field terminals are marked Fl and F2, and the armature terminals are marked Al andA2. You should notice in this diagram that the shunt field is represented with multiple turns using a thin line. 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).

25

Every DC motor has six basic parts -- axle, rotor (a.k.a., armature), stator, commutator, field magnet(s), and brushes. In most common DC motors (and all that BEAMers will see), the external magnetic field is produced by high-strength permanent magnets1. The stator is the stationary part of the motor ,this includes the motor casing, as well as two or more permanent magnet pole pieces. The rotor (together with the axle and attached commutator) rotate with respect to the stator. The rotor consists of windings (generally on a core), the windings being electrically connected to the commutator. The above diagram shows a common motor layout -- with the rotor inside the stator (field) magnets. The geometry of the brushes, commutator contacts, and rotor windings are such that when power is applied, the polarities of the energized winding and the stator magnet(s) are misaligned, and the rotor will rotate until it is almost aligned with the stator's field magnets. As the rotor reaches alignment, the brushes move to the next commutator contacts, and energize the next winding. Given our example two-pole motor, the rotation reverses the direction of current through the rotor winding, leading to a "flip" of the rotor's magnetic field, driving it to continue rotating.

In real life, though, DC motors will always have more than two poles (three is a very common number). In particular, this avoids "dead spots" in the commutator. You can imagine how with our example two-pole motor, if the rotor is exactly at the middle of its rotation (perfectly aligned with the field magnets), it will get "stuck" there. Meanwhile, with a two-pole motor, there is a moment where the commutator shorts out the power supply (i.e., both brushes touch both commutator contacts simultaneously). This would be bad
26

for the power supply, waste energy, and damage motor components as well. Yet another disadvantage of such a simple motor is that it would exhibit a high amount of torque "ripple" (the amount of torque it could produce is cyclic with the position of the rotor).

Diagram of DC shunt motor.

27

Two factors are important in the selection of a motor for a particular application: the variation of the speed with a change in load, and the variation of the torque with a change in load. A shunt motor is basically a constant speed device. If a load is applied, the motor tends to slow down. The slight loss in speed reduces the counter emf and results in an increase of the armature current. This action continues until the increased current produces enough torque to meet the demands of the increased load. As a result, the shunt motor is in a state of stable equilibrium because a change of load always produces a reaction that adapts the power input to the change in load. The basic circuit for a shunt motor is shown in figure. Note that only a shunt field winding is shown. Figure shows the addition of a series winding to counteract the effects of armature reaction. From the standpoint of a schematic diagram, figure represents a compound motor. However, this type of motor is not considered to be a com pound motor because the commutating winding is not wound on the same pole as the field winding and the series field has only a few turns of wire in series with the armature circuit. As a result, the operating characteristics are those of a shunt motor. This is so noted on the nameplate of the motor by the terms compensated shunt motor or stabilized shunt motor. DC MOTOR CONTROL CHARACTERISTICS: A shunt-wound motor is a direct-current motor in which the field windings and the armature may be connected in parallel across a constant28

voltage supply. In adjustable speed applications, the field is connected across a constant-voltage supply and the armature is connected across an independent adjustable-voltage supply. Permanent magnet motors have similar control

DC MOTOR CHARACTERISTICS: It will be easier to understand the operation of the DC motor from a basic diagram that shows the magnetic interaction between the rotating armature and the stationary field's coils. Below Figure shows three diagrams that explain the DC motor's operation in terms of the magnetic interaction. In Fig. (a) you can see that a bar magnet has been mounted on a shaft so that it can spin. The field winding is one long coil of wire that has been separated into two sections. The top section is connected to the positive pole of the battery and the bottom section is connected to the negative pole of the battery. It is important to understand that the battery represents a source of voltage for this winding. In the actual industrial-type motor this voltage will come from the DC voltage source for the motor. The current flow in this direction makes the top coil the north pole of the magnet and the bottom coil the south pole of the magnet. The bar magnet represents the armature and the coil of wire represents the field. The arrow shows the direction of the armature's rotation. Notice that the arrow shows the armature starting to rotate in the clockwise direction. The north pole of the field coil is repelling the north pole of the armature, and the south pole of the field coil is repelling the south pole of the armature.

29

(a) Magnetic diagram that explains the operation of a DC motor. The rotating magnet moves clockwise because like poles repel. (b) The rotating magnet is being attracted because the poles are unlike. (c) The rotating magnet is now shown as the armature coil, and its polarity is determined by the brushes and commutator segments. As the armature begins to move, the north pole of the armature comes closer to the south pole of the field, and the south pole of the armature is coming closer to the north pole of the field. As the two unlike poles near each other, they begin to attract. This attraction becomes stronger until the armature's north pole moves directly in line with the field's south pole, and its south pole moves directly in line with the field's north pole (b). When the opposite poles are at their strongest attraction, the armature will be "locked up" and will resist further attempts to continue spinning. For the armature to continue its rotation, the armature's polarity must be switched. Since the armature in this diagram is a permanent magnet, you can see that it would lock up during the first rotation and not work. If the armature is an electromagnet, its polarity can be changed by changing the direction of current flow through it. For this reason the armature must be changed to a coil (electromagnet) and a set of commutator segments must be added to provide a means of making contact between the rotating member and the stationary member.
30

One commutator segment is provided for each terminal of the magnetic coil. Since this armature has only one coil, it will have only two terminals, so the commutator has two segments. Since the armature is now a coil of wire, it will need DC current flowing through it to become magnetized. This presents another problem; since the armature will be rotating, the DC voltage wires cannot be connected directly to the armature coil. A stationary set of carbon brushes is used to make contact to the rotating armature. The brushes ride on the commutator segments to make contact so that Current will flow through the armature coil.In Fig. (C) you can see that the DC voltage is applied to the field and to the brushes. Since negative DC voltage is connected to one of the brushes, the commutator segment the negative brush rides on will also be negative. The armature's magnetic field causes the armature to begin to rotate. This time when the armature gets to the point where it becomes locked up with the magnetic field, the negative brush begins to touch the end of the armature coil that was previously positive and the positive brush begins to touch the end of the armature coil that was negative. This action switches the direction of current flow through the armature, which also switches the polarity of the armature coil's magnetic field at just the right time so that the repelling and attracting continues. The armature continues to switch its magnetic polarity twice during each rotation, which causes it to continually be attracted and repelled with the field poles. This is a simple two-pole motor that is used primarily for instructional purposes. Since the motor has only two poles, the motor will operate rather roughly and not provide too much torque. Additional field poles and armature poles must be added to the motor for it to become useful for industry. Two factors are important in the selection of a motor for a particular application: (1) the variation of the speed with a change in load. (2) the variation of the torque with a change in load.

31

A shunt motor is basically a constant speed device. If a load is applied, the motor tends to slow down. The slight loss in speed reduces the counter emf and results in an increase of the armature current. This action continues until the increased current produces enough torque to meet the demands of the increased load. As a result, the shunt motor is in a state of stable equilibrium because a change of load always produces a reaction that adapts the power input to the change in load. The basic circuit for a shunt motor is shown in figure . Note that only a shunt field winding is shown. Figure 1-10B shows the addition of a series winding to counteract the effects of armature reaction. From the standpoint of a schematic diagram, figure 1-10B represents a compound motor. However, this type of motor is not considered to be a com pound motor because the commutating winding is not wound on the same pole as the field winding and the series field has only a few turns of wire in series with the armature circuit. As a result, the operating characteristics are those of a shunt motor. This is so noted on the nameplate of the motor by the terms compensated shunt motor or stabilized shunt motor. Speed Control A dc shunt motor has excellent speed control. To operate the motor above its rated speed, a field rheostat is used to reduce the field current and field flux. To operate below rated speed, reduce the voltage applied to the armature circuit. A more modem method of speed control is the electronic speed control system. The principles of control are the same as the manual controls. Speeds above normal are achieved by reducing the field voltage electronically and speeds below normal reduce the voltage applied to the armature. Rotation The direction of armature rotation may be changed by reversing the direction of cur rent in either the field circuit or the armature circuit. For a motor with a simple shunt field circuit, it may be easier to reverse the field circuit lead. If the motor has a series winding, or an interpole winding to counteract armature reaction, the same relative direction of cur rent must be
32

maintained in the shunt and series windings. For this reason, it is always easier to reverse the direction of the armature current.

Shunt motor connections: (A) Without Commutating Poles; (B) With Commutating Poles Torque A dc shunt motor has high torque at any speed. At startup, a dc shunt motor develops 150 percent of its rated torque if the resistors used in the starting mechanism are capable of withstanding the heating effects of the current. For very short periods of time, the motor can develop 350 percent of full load torque, if necessary. Speed Regulation The speed regulation of a shunt motor drops from 5 percent to 10 percent from the no-load state to full load. As a result, a shunt motor is superior to the series dc motor, but is inferior to a compound-wound dc motor. Figure shows a dc motor with horse power ratings ranging from 1 hp to 5 hp.

the field coil. In this application the armature coil is usually changed, as was the case with the series motor. the electrical diagram of a DC shunt motor connected to a forward and reversing motor starter. You should notice that the Fl and F2 terminals of the shunt field are connected directly to the power supply, and the Al and A2 terminals of the armature winding are connected to the reversing starter. When the FMS is energized, its contacts connect the Al lead to the positive power supply terminal and the A2 lead to the negative power supply terminal. The Fl motor lead is connected directly to the positive terminal of the power supply and the F2 lead is connected to the negative terminal. When
33

the motor is wired in this configuration, it will begin to run in the forward direction. When the RMS is energized, its contacts reverse the armature wires so that the Al lead is connected to the negative power supply terminal and the A2 lead is connected to the positive power supply terminal. The field leads are connected directly to the power supply, so their polarity is not changed. Since the field's polarity has remained the same and the armature's polarity has reversed, the motor will begin to rotate in the reverse direction. The control part of the diagram shows that when the FMS coil is energized, the RMS coil is locked out. Installing a Shunt Motor A shunt motor can be installed easily. The motor is generally used in belt-drive applications. This means that the installation procedure should be broken into two sections, which include the mechanical installation of the motor and its load, and the installation of electrical wiring and controls. When the mechanical part of the installation is completed, the alignment of the motor shaft and the load shaft should be checked. If the alignment is not true, the load will cause an undue stress on the armature bearing and there is the possibility of the load vibrating and causing damage to it and the motor. After the alignment is checked, the tension on the belt should also be tested. As a rule of thumb, you should have about V2 to 1/4 inch of play in the belt when it is properly tensioned. Several tension measurement devices are available to determine when a belt is tensioned properly. The belt tension can also be compared to the amount of current the motor draws. The motor must have its electrical installation completed to use this method. The motor should be started, and if it is drawing too much current, the belt should be loosened slightly but not enough to allow the load to slip. If the belt is slipping, it can be tightened to the point where the motor is able to start successfully and not draw current over its rating The electrical installation can be completed before,

CHAPTER

34

SCRAP HANDLING EQUIPMENT

Components of Scrap Handling Equipment Cyclone Separators REES manufactures paper handling cyclones that are specifically designed to separate light paper dust and scrap by using multiple inlet connections from the production line, a larger waste outlet to efficiently feed balers, and a perforated inner cone to enhance the separation process.

Trim Cutters Trim Cutters are used to remove the edge trim from production lines by cutting continuous scrap material into smaller pieces. This enables the air conveying systems to operate more efficiently by eliminating blockages in the duct and preventing scrap from wrapping around the fan wheel.

Shredders Shredding is an effective way to handle scrap from all types of paper products and other bulky materials. Through waste reduction methods using Shredders, manufacturers can decrease handling time and increase scrap bale density, resulting in overall cost saving efficiency.

Floorsweeps Floorsweeps provide a simple method for sweeping material into the scrap handling system from the plant floor. By using a Shredder at the floorsweep, scrap size is immediately reduced and material handling labor is minimized.

35

Balers Using a Baler is the most cost efficient way to reduce the volume of scrap waste and prepare it for recycling. REES provides balers to handle a variety of scrap materials while ensuring that bale production and bale density are optimized, providing a lower total cost per bale and an increase in return on investment.

CHAPTER-6 CIRCUIT DIAGRAMS

36

37

38

CHAPTER 6

SOFTWARE ANALYSIS

6.1 INTRODUCTION TO KEIL COMPILER

KEIL IDE:

KeiluVision is what the software we are using for the programming. In this software editor we are writing the program in any of the languages like ASM or Embedded C.

Vision3 Overview The Vision3 IDE is a Windows-based software development platform that combines a robust editor, project manager, and makes facility. Vision3 integrates all tools including the C compiler, macro assembler, linker/locator, and HEX file generator. Vision3 helps expedite the development process of your embedded applications by providing the following:

Full-featured source code editor, Device database for configuring the development tool setting, Project manager for creating and maintaining your projects, Integrated make facility for assembling, compiling, and linking your embedded applications,
39

Dialogs for all development tool settings, True integrated source-level Debugger with high-speed CPU and peripheral simulator,

Advanced GDI interface for software debugging in the target hardware and for connection to Keil ULINK,

Flash programming utility for downloading the application program into Flash ROM,

Links to development tools manuals, device datasheets & users guides.

The Vision3 IDE offers numerous features and advantages that help you quickly and successfully develop embedded applications. They are easy to use and are guaranteed to help you achieve your design goals.

Features: The Vision3 Simulator is the only debugger that completely simulates all on-chip peripherals The Vision3 Device Database automatically configures the development tools for the target microcontroller. Identical Target Debugger and Simulator User Interface. Vision3 incorporates project manager, editor, and debugger in a single environment.

40

Benefits: Write and test application code before production hardware is available. Investigate different hardware configurations to optimize the hardware design. Sophisticated systems can be accurately simulated by adding your own peripheral drivers. Mistakes in tool settings are practically eliminated and tool configuration time is minimized.

6.2 ADVANTAGES Higher security provided GSM for user awareness Avoid theft immediately Highly reliable 6.3 EMBEDDED C

Micro controller program is written in Embedded C Language and It Is Compile and Converter D into Hex File Using Code vision Software. The hex file is loaded into the micro controller for performing the operation

41

CHAPTER 8

8.1 CONCLUSION An automatic guided system transfers scrap glass resulted from at least one scrap glass source of a clean room to a scrap exit. The automatic guided system for transferring the scrap glass includes a rail module and a vehicle module. The rail module connects the scrap exit to the scrap glass source. The vehicle module is moved along the rail module for transferring the scrap glass from the scrap glass source to the scrap exit.

42

REFERENCES

43