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CHAPTER 1
PROJECT INTRODUCTION
1.1 INTRODUCTION
These machines have six process sequences which are; initializing I/O card, user
verification, menu selection, item selection, confirm item and collects item. The machine
comes with systems that make it intelligent enough to perform its task with minimum
supervision. Besides, to make it compatible with other machine, the system is complete
with user friendly unlimited items requested (e.g. user can request for any items several
times) and some additional safety features for both; product and the user.
The SSRS is eventually an ideal method for the lecturer and trainees to acquire or
review basic theoretical and practical knowledge in Mechatronics field. It is a combination
of electrical, electronics, mechanical, PLC and computer programming. Every module is
designed to perform a specific function such as smart storage, loading, inspection and etc.
Standard components such as motors and sensor are integrated into each module to
achieve the desired function.
1.2 OBJECTIVE
The main objectives of this Final Year Project is to let us gain experience in
designing, electrical wiring, programming and troubleshooting a machine. We also apply
the knowledge learned in GMI especially in the Mechatronics field. The given opportunity is
to change idea with group member and deal with other members to exchange information.
We were also having learned the communication skill when dealing with the
vendors. This is also to expose us to the real working life experience as a project team in
the engineering field.
SSRS applies all the knowledge that Mechatronics student gained all through the
previous semester. Furthermore, this project also has advantages that enhance its
specialty. As a result, this machine could help to improve the lifestyle of humanity to
become more organized.
Before we propose this project to the project committee, we have started our
feasibility studies on the main problems involved stationery issue in an office management.
The problems were inventory system for stationery and uncontrolled usage of stationery.
We choose Industrial Electronics (IE) department as a reference to gain more information
about that issue.
Diagram 1 : IE Department.
From the list of items, we went to the stationery shop to get the dimension of the
products for a design purpose.
For drive mechanism, we decide to use two stepper motor, four DC motor, pulleys
and belting. But, after propose the project; we were advised to used just one stepper motor
and two DC motor and also during project implementation, there were some problems
occur and we have to change the design from using pulley and belting to using chain and
gear.
In order to make this project successful, there are several factors should be
considered. This project fulfils these factors by means of profit return in investments. It is
efficient enough to increase the production rate in ways of shorter and constant. The
safety features provided is also secured both user and product harm.
PC I/O CARD
The I/O card we are using in this project is EX 94632. This I/O Card is used to send
signal from Visual Basic 6 button to PLC Siemens S7-200. The I/O Card has it own
terminal block to distribute the input and output from either PC or PLC. We install this card
at the PCI Slot. The output trigger from I/O card is 5 Volts, so we need something to switch
from 5 Volts with 24 Volts. This I/O card has it own code to be programmed in the Visual
Basic 6; we need to configure which code is suitable for Initializing and set ON and OFF.
OPTO-COUPLER
Besides that, this project involves very highly skill in Mechatronics. In example, the
electronic circuit is design and done by ourselves. The electronic circuit contains Opto-
Coupler for switching the voltage from 5 volts with 24 volts. The opto-coupler used to
trigger Programmable Logic Control (PLC) Siemens S7 – 200 from I/O card. The output
from I/O card is 5 volts, so, to trigger the PLC it need 24 volts. Besides, the opto-coupler is
far faster switching compared to relays. That the reason why we used Opto-Coupler.
VISUAL BASIC 6
Visual Basic 6 is used as the interface for the machine and the database for the
inventory. We decided to do this project with visual basic because of the increasing of the
computer based control lately. We do the research and study the basic programming code
to implement the proposed project. We managed to finish the interface within 3 months of
study. After that we developed it to make it more interesting and finally we learn on how to
communicate from the Visual Basic 6 with Siemens s7-200. Our system consists the
inventory of item has been dispense by user and selection menu for user to choose
stationary items.
SYSTEM COMMUNICATION
The communication system using in this project is, for PC to PLC programming we
used PPI Cable that is RS 232 to RS 485. For I/O card to Terminal Block we used flat
Ribbon Cable as a connector.
STEPPER SECTION
POSITIONING
TABLE
For the drive mechanism section, the design at first involved 2 stepper motor to
moved it. But, it cause more cost. After discussion, we decided to use only one stepper
motor. So we start to fabricate the drive mechanism which is involving lot of mechanical
movement. The drive mechanism section contains, two power window motor for forward
and reverse of the pusher rod, positioning table to move the pusher rod, chain to move the
positioning table taken from the movement of stepper motor. The design at first used
timing belt, but due to GMI payment policy we cannot use the timing belt. We find the
solution on how to replace it by using chain
STEPPER SECTION
This section is fully designed and fabricated by our group. This section contains
table mounting, stepper motor and drives mechanism. This section is static due to only
gear is moved by stepper to rotate the chain to move the positioning table.
POSITIONING TABLE
This positioning table consists of DC Motor, Pusher Rod, Positioning Table, Limit
Switch, Gear and Chain. This section is one of the most important part because the used
of pusher to dispense items. Positioning table is fully designed and fabricated by our own.
We put lot of effort to finish and to align the position of this table.
BEARING FLANGE
LOCK
GUIDE RAIL
UPPER DRAWER
BOTTOM DRAWER
This kind of drawer is fabricated by us with user friendly design. So, it makes the
drawer easy to put in or put out. The drawer contains guide rail attach with bearing in the
middle to smoothing the movement of the rail. At the back of the rail, it has stopper to
prevent the drawer from over limit of the rail. Beside that, the rail also has lock to prevent it
from slide.
This machine consists of six sequence of protocol to be complete to get the end
product. This protocol shows the features of this project on the machine:
Initializing for I/O card is important because it is to activate the card for the next
operation. Only by activating this card, user can proceed to the verification protocol.
2) USER VERIFICATION
3) SELECTION MENU
Selection Menu is use to select next protocol. It is contains of Items Menu and
Purchase History. Items Menu is used to select item and Purchase History is used to view
user history profile. Once selection had been made, it will go to the next menu.
4) ITEMS SELECTION
This protocol consist list of items. User can select any items enormously.
5) CONFIRM ITEMS
Once user had chosen the needed item, system will prompt the user with
confirmation task bar for each item. Finish with the confirmation, then the drive mechanism
will move the positioning table to extend the pusher at selected item magazine. The item
will dispense at silo and discharge section.
This is the end of the protocol. User may collect their items after completing all the
protocol. Collect items can be made at the discharge section.
CHAPTER 2
PROJECT IMPLEMENTATION
1. Assembly drawing
2. Front view
3. Side view
4. Top view
ASSEMBLY DRAWING
A5 OPTOCOUPLER
B5 OPTOCOUPLER
C5 OPTOCOUPLER
D5 OPTOCOUPLER
E5 OPTOCOUPLER
F5 OPTOCOUPLER
G5 OPTOCOUPLER
H5 OPTOCOUPLER
I5 OPTOCOUPLER
J5 OPTOCOUPLER
K5 OPTOCOUPLER
L5 OPTOCOUPLER
M5 OPTOCOUPLER
N5 OPTOCOUPLER
O5 OPTOCOUPLER
P5 OPTOCOUPLER
K1 RELAY (FORWARD DC MOTOR)
K2 RELAY (REVERSE DC MOTOR)
K3 RELAY (FORWARD DC MOTOR)
K4 RELAY (REVERSE DC MOTOR)
H1 TOWER LAMP(GREEN)
H2 TOWER LAMP(YELLOW)
H3 TOWER LAMP(GREEN)
LAGEND
LAGEND
Component Description
Material : Aluminum
Block with flange Size : 200X280mm
Function : Positioning Table
Size : 40x40mm
Bearing Flange D= 27.4mm, d= 10.6mm
Function : Bearing Flange
Material : Mild Steel
Drawer Magazine
Function : To placed items in magazine
Material : Aluminum
Pusher Size : D= 12.7mm
Function : To dispense items from magazine
Material : Mild Steel
Gear (14 tooth) Size : 14 tooth
Function : Drive chain for positioning table
Material : Mild Steel
Size : 27 tooth
Gear (27 tooth) Function : Drive chain for positioning table
Material : Mild Steel
Chain Size : 324 (Industrial Standard)
Function : To move the positioning table
Table: Mechanical component specification.
Input : 12VDC
Limit switch
Model : MYCOM
Motor Driver Input : 24VDC
Output : 24VDC
Power Socket Type : 3 Pin
PROTOCOL 2:
PROTOCOL 1:
USER VERIFICATION
INITIALIZING I/O CARD
PROTOCOL 4: PROTOCOL 3:
ITEM SELECTION USER MENU
PROTOCOL 5:
PROTOCOL 6:
CONFIRM ITEM
COLLECT ITEM
No
Initializing
ok?
Yes
Yes
Login User selection
ok? menu
No
1.0 2.0
Select View item
Item select
ok? history
1 Report of
dispense
End items
1
2
No No No No
Ok? Ok? Ok? Ok?
3 3 3
3
End
2
Stapler Paper
A4 Paper bullet Clip Blue Pen
No No No No
Ok? Ok? Ok? Ok?
3 3 3 3
End
2
Pusher Extend
Pusher Retract
Positioning table
back to initial
End
In order to use the SSRS, users have to follow the sequence to dispense item.
Stated below is the sequence on how to operate the vending machine.
Protocol 1:
• User need to initialize I/O card as 1
• Then click enter for the next protocol
Protocol 2:
• User need to identify themselves to activate the system using user ID and
password
• Wait for the identification success for the next step to activate
Protocol 3:
• After identification successful, user needs to choose Select Items to select items or
Purchase History to view profile. (Select Profile is nothing to do with the sequence
to dispense items. It’s to view user profile only such as balance and total of items
that has been dispensing from user)
• Choose Select Items to continue the process
Protocol 4:
• New menu for items will pop-up
• Select the item that user wanted
Protocol 5:
• Clicks the item to confirm and proceed for the dispense item
Protocol 6:
• Collect item at the discharge section
2.4 START-UP, COMMISSIONING AND TEST
First thing to do before use the recycled parts from previous or receives the items
from vendors, we need to have a quality checking to ensure the items are in good
condition and function well. The following table is the checking procedure for electrical
equipment.
2.4.2 START-UP
For a convincing and proper start-up, please follow the instructions given
below to operate the machine.
1. Plug-in the power cord to a 415V AC/ 230V AC/ 240V AC supply
and turn the Selector Switch.
2. Switch ON the ELCB and all the MCBs.
3. Release the EMERGENCY STOP Buttons.
4. Turn ON the PC and monitor.
5. Key in user ID and password on the monitor to be allowed to use the
machine.
6. Double click on Stationery Storage And Retrieval System Icon at the
Start Menu.
7. Follow the instruction given in the system.
ITEMS FUNCTIONALITY
MCB and ELCB Good
5 VDC, 12 VDC, 24 VDC Power Supply Good
Emergency Stop Button Good
PLC Good
Inductive Sensor Good
Stepper Motor Good
Motor driver Good
After finish the project implementation process, we must run the commissioning
and testing procedure to get the result of the project performance.
Due to the testing, it shows result that this machine able to run upon expectation.
The entire components function well and give an excellent result.
There were some problems occurs during the implementation process but we
manage to overcome the problems efficiently.
1) The stepper positioning is not fix to the place for pusher to stop due to the
used of chain. The pusher have idle before the operation
2) Items unable to dispense from magazine because of the design and the quantity
of items in the packaging.
CHAPTER 3
PROJECT SUMMARY
As a safety precaution, we have included all the safety equipments to provide the
safety features for our SSRS machine.
2. Circuit Breaker
3. Control Panel Box Use as the container for the wiring and
connection. It can keep away from human reach.
4. Tower Lamp
PURCHASED
MISCELLANEOUS
PURCHASED
RECYCLED
MISCELLANEOUS
For the total costing, we have concluded with the purchase, recycled and
miscellaneous components. As shown below is the total cost for the Mechanical and
Electrical components.
MECHANICAL:
Purchase: RM 6538.00
Recycled: RM 682.10
Miscellaneous: RM 967.90
TOTAL: RM 8188.00
ELECTRICAL:
Purchase: RM 786.30
Recycled: RM 5802.10
Miscellaneous: RM 480.50
TOTAL: RM 7068.90
3.3 CONCLUSION
We can conclude this project does have a lot to offer in terms of the design, cost,
and ability. Besides that, it generates opportunities for the student to develop practical
ability besides gaining a lot of knowledge and information concerning in technical.
This project emphasizes teamwork spirit among students besides being punctual in
completing the task in the given period of time. Therefore, punctuality and teamwork
among the students can be inculcated. It also develops a good relationship among the
group members.
Beside that, we can save a lot of time and money. By completing all the
implementation of the project, each member of the group will get benefit and deserve
some credit as pointed below:-
3.4 RECOMMENDATION
Due to this prototyping project, we have overlooked to improvise this project in the
future. Stated below is the recommendation and improvisation to this project:
Initial Condition
I 1.4
I 1.4
M 0.2
T 37 I 2.5
NS Pusher 1 Extend
Step 3
M 11.0
I 2.6
M 11.1
Q 0.0 I 2.5
M 10.0
Position 2 : Paper Fastener
Initial Condition
I 0.2
I0.2
M 0.3
T 38 I 2.5
NS Pusher 1 Extend
Step 3
M 11.0
I 2.6
M 11.1
Q 0.0 I 2.5
M 10.0
Position 3 : Writing Pad
Initial Condition
I 1.5
I 1.5
M 0.4
T 39 I 2.5
NS Pusher 1 Extend
Step 3
M 11.0
I 2.6
M 11.1
Q 0.0 I 2.5
M 10.0
Position 4 : Memo Pad
Initial Condition
I 1.6
I 1.6
M 0.5
T 40 I 2.5
NS Pusher 1 Extend
Step 3
M 11.0
I 2.6
M 11.1
Q 0.0 I 2.5
M 10.0
Position 5 : Thumb Tacks
Initial Condition
I 1.7
I 1.7
M 0.6
T 41 I 2.5
NS Pusher 1 Extend
Step 3
M 11.0
I 2.6
M 11.1
Q 0.0 I 2.5
M 10.0
Position 6 : Marker Ink Refill - Red
Initial Condition
I 1.0
I 1.0
M 0.7
T 42 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 7 : Marker Ink Refill - Blue
Initial Condition
I 1.1
I 1.1
M 1.0
T 43 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 8 : Marker Ink Refill - Black
Initial Condition
I 0.0
I 0.0
M 1.1
T 44 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 9 : Bullet For Stapler
Initial Condition
I 0.4
I 0.4
M 1.2
T 45 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 10 : Paper Clips
Initial Condition
I 0.5
I 0.5
M 1.3
T 46 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 11 : Ball Pen - Blue
Initial Condition
I 0.6
I 0.6
M 1.4
T 47 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 12 : Ball Pen - Black
Initial Condition
I 0.7
I 0.7
M 1.5
T 48 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 13 : A4 Paper
Initial Condition
I 1.2
I 1.2
M 1.6
T 49 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 14 : Marker Pen - Red
Initial Condition
I 1.3
I 1.3
M 1.7
T 50 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 15 : Marker Pen - Blue
Initial Condition
I 0.1
I 0.1
M 2.0
T 51 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1
Position 16 : Marker Pen - Black
Initial Condition
I 0.3
I 0.3
M 2.1
T 52 I 2.3
NS Pusher 2 Extend
Step 3
M 11.2
I 2.4
M 11.3
Q 0.3 I 2.3
M 10.1