CHAPTER 3: ELECTRICAL AND ELECTRONIC DEVELOPMENT

3.1 INTRODUCTION

Besides mechanical part, electrical and electronic components also have an important
role in making sure the machine running smoothly. It is important to have a good planning
and deep understanding on the machine’s flow system before designing the circuit and
selecting components. In order to have components that suit the machine’s operation and to
minimize the power lose, some criteria and specification of each component need to be
considered before selecting them.

For this project, the main electrical components used in this machine are two DC geared
motor which will be controlled by L298N motor driver. The driver will be connected to the
main controller, ESP8226 NodeMCU. The first DC motor will be used for sweeping process
while the second one will be used for flipping process. Besides that, incandescent light bulb
also will be used as heating element. Meanwhile, the main electronic component used in the
machine is DHT22 temperature and humidity sensor also for heating process. The NodeMCU
will connect and power up the minor electrical and electronic components such as cooling fan
and LCD display.

In this chapter, further discussion on electrical and electronic part will be made such as
the block diagram, the schematic circuit diagram, the function and specification for each
component and also the electrical calculations that used in this project.
3.2 BLOCK DIAGRAM

Figure 4.1 below shows the block diagram of relationship between all the electrical
and electronic components used in this project. It shows which components belongs to which
section either they are used for input, control unit or output. Switch mode power supply will
convert 240VAC to 12VDC and supply it to NodeMCU. Humidity and temperature value
measured by DHT22 will be sent to NodeMCU for controlling the ON/OFF of the light bulb.
Since light bulb needs AC supply to operate, it will be connected indirectly to the NodeMCU
which relay contactor will be used.

Input Control unit Output

Switch mode DC geared motor 1

power supply (sweeping)
Motor driver
L298N
DC geared motor 2
DHT22 (flipping)
temperature and
humidity sensor PIC16F877A
NodeMCU
ESP8226 Light bulbs
Relay
Contactor
Figure 4.1: Cooling fan
Block
diagram of
relationship LCD display
between all components
3.3 SCHEMATIC CIRCUIT DIAGRAM

Schematic circuit diagram in figure below shows the connection between all the
electrical and electronic components used in the machine. Switch mode power supply will
supply 12VDC to power up L298N motor driver, TB6560 stepper driver and NodeMCU.
Meanwhile, DHT22 temperature and humidity sensor will get supply from 5V pin
NodeMCU.

As mention before, incandescent light bulb and cooling fan will be connected
indirectly to the NodeMCU. As shown in the circuit, 240VAC supply will be connected to
the normally open contactor of the relay switch before being connected to the bulb. Relay
switch will be connected directly to NodeMCU. Same goes to cooling fan but it get supply
from 12VDC power supply. By doing this indirect connection, NodeMCU still can control
the light bulb and cooling fan by controlling the ON/OFF of the relay switch.

DC Power Supply

AC Supply

LCD Display

DHT22 DC Geared
Sensor Motor 1

DC Geared
L298N Motor 2
Driver

Relay
Switch 2

Light Bulbs
PIC16F877A Cooling
Relay
Switch 1 Fan

Figure 4.2: Schematic Circuit Diagram

3.4 ELECTRICAL AND ELECTRONICS COMPONENTS

After selection have been made, below are the list of all the electrical and electronic
components with specification

3.4.1 NodeMCU ESP866

In this project, NodeMCU ESP866 contained microcontroller which can

control and operate the whole machine’s process. This NodeMCU can receive inputs
from humidity sensor and toggle switch used in this project. From the input signal
received, it can give output signal such as to the relay switch to turn ON/OFF the light
bulbs. Besides, by the programming made and load onto the NodeMCU, it can control
the operation of the DC motor and other components.

Figure 4.3: NodeMCU ESP866

NO. FEATURES SPECIFICATIONS

1. Operating Voltage 3.3V DC

2. Input Voltage 7-12VDC
3. Digital I/O Pins (DIO) 16
4. Analog Input Pins (ADC) 1
5. Flash Memory 4MB

Table 4.1: Specification of NodeMCU ESP866

3.4.2 DHT22 TEMPERATURE AND HUMIDITY SENSOR

In this project, DHT22 is used to measure temperature inside the machine.

When DHT22 measure the desired temperature value, it will give input signal to the
NodeMCU to control the ON/OFF of the light bulb. Besides, DHT22 also is needed to
measure humidity. Moisture in air inside the machine needs to be blown out by
cooling fan. As long as humidity inside the machine measured by DHT22 did not
achieve the desired percentage, cooling fan will keep blowing out the moist air.

This type of sensor is selected because it is one of low-cost temperature and

humidity measuring sensor in the market. It consists of thermistor for temperature
measurement and capacitive humidity sensor for humidity measurement which
needed in this project. It easy to connect and has higher accuracy and precision. Table
below show its specification.

Figure 4.4: DHT22 Temperature and Humidity Sensor

NO. FEATURES SPECIFICATIONS

1. Operating Voltage: 3.5V - 5.5V DC

2. Operating current 0.3mA (measuring) 60uA (standby)
3. Output Serial data
4. Temperature Range -40°C to 80°C
5. Humidity Range 0% to 100%

Table 4.2: Specification of DHT22 Temperature and Humidity Sensor

3.4.3 L298N MOTOR DRIVER

During the machine’s sweeping and flipping process, speed of motor need to
be controlled to make sure slices of fruit can be arranged neatly. The L298N motor
driver will be used to control the speed of both DC motors. It also used to control the
angle of flipper tray inside the machine. Since two motors are used in this project,
L298N is selected because it can control the speed and direction of the two DC
motors at the same time. The module can drive DC motors that have voltages between
5 and 35V, with a peak current up to 2A as stated in table below.

Figure 4.5: L298N Motor Driver

NO. FEATURES SPECIFICATIONS

1. Logical Voltage 5V DC
2. Drive Voltage 5V-35V DC
3. Logical Current 0-36mA
4. Drive Current 2A (MAX single bridge)
5. Max Power 25W

Table 4.3: Specification of L298N Motor Driver

3.4.4 DC GEARED MOTOR

Two 260RPM 18V DC motor is used in this project. This DC geared motor is
connected to L298N motor driver to control the motor speed for sweeping and
flipping process. This type of motor is selected because of its high rated torque as
stated in table below. High starting torque motor is required to rotate a flipper tray
which contains many slices of fruit on it.

Figure 4.6: DC Geared Motor

NO. FEATURES SPECIFICATIONS

1. Nominal Voltage 18V DC

2. Rated Current 40mA
3. Rated Speed 260 RPM
4. Shaft Diameter 8mm
5. Rated Torque 92kgf.cm (9N.m)
6. Rated Power output 250W
7. Compatible motor driver: MD30C, MDDS30, MDDS60

Table 4.4: Specification of DC Geared Motor

3.4.5 LCD DISPLAY

While the machine is operating, LCD display is used to display the

temperature and humidity value measured by DHT22 for user purpose. Table below
show its specification.

Figure 4.7: LCD Display

NO. FEATURES SPECIFICATIONS

1. Supply Voltage 5VDC

2. Compatible with Arduino/Genuino UNO, Leonardo, Mega, 101(Intel
Curie), Micro, Nano, Mini

Table 4.5: Specification of LCD Display

3.4.6 SWITCH MODE POWER SUPPLY

The fruit dry machine needs both AC and DC supply to operate. For
components which use DC supply to work, this switch mode power supply will
convert AC to DC and supply it to them. This power supply is adjustable which the
output voltage can be adjusted from 5V to 12VDC.
 Figure 4.8: Switch Mode Power Supply

NO. FEATURES SPECIFICATIONS

1. Output Voltage 5 - 12 VDC

2. Output Current 2-6A
3. Power Rating 54W
4. Number of Outputs 2
5. Efficiency 79%
6. Input Voltage 88 - 264 VAC

Table 4.6: Specification of Switch Mode Power Supply

3.4.7 INCANDESCENT LIGHT BULB

For drying process, bulb will be used as heating element. Heat that release
from bulb as energy loss will dry the slices fruit. Bulb with low wattage and low energy
efficient will be used since higher heat release as power loss compared to other bulb.
 Figure 4.9: Incandescent Light Bulb

NO. FEATURES SPECIFICATIONS

1. Wattage 25W

2. Input Voltage 220 – 240 VAC

Table 4.7: Specification of Incandescent Light Bulb

3.4.8 COOLING FAN RADIATOR

Dry environment is required to dry the slices fruit. Cooling fan will blow the
moist air out from the machine until the humidity inside the machine achieved desired
percentage.

Figure 4.10: Cooling Fan

 NO. FEATURES SPECIFICATIONS

1. Input Voltage 12 VDC

2. Power Rating 15W

Table 4.8: Specification of Cooling Fan

3.4.9 EMERGENCY STOP BUTTON

Just in case of emergency, emergency stop button will stop the whole machine
process as it being pressed.

Figure 4.11: Emergency Stop Button

NO. FEATURES SPECIFICATIONS

1. Support Voltage 660V

2. Support Current 10A

3. No. of terminals 4

Table 4.9: Specification of Emergency Stop Button

3.4.10 TOGGLE SWITCH

 Toggle switch functions to start or stop the whole machine process.

Figure 4.12: Toggle Switch

3.4.11 RELAY SWITCH

As mention before, relay switch will be used for the indirect connection of
light bulb and cooling fan to the NodeMCU. NodeMCU will trigger output to latch
relay switch to turn ON/OFF light bulb and cooling fan.

Figure 4.13: Relay Switch

3.5 ELECTRICAL CALCULATION

Doing electrical calculations is important to make sure the power consumed by the
machine is sufficient. Besides, by doing calculation also can ensure that no current overload
will happen. Table below shows calculations that have been made for every component. The
formula for calculating power supplied (watt) is 𝑃=𝑉𝐼=𝑉2𝑅

Where, V =Voltage Supplied, V

I = Current Consumption, A

R = Resistant in system, Ω

Total power
List of electrical
Power, P = I × V Unit(s) consumption
components
of component
1. NodeMCU DC current per pin = 0.02A
ESP8266 Operating Voltage = 5V

Power = 0.1𝑊 1 1.2 W

Number of pin used =1 2

𝑃𝑡𝑜𝑡𝑎𝑙=12×0.1𝑊 =1.2𝑊
2. Temperature and Operating current: 0.3 mA
Humidity Sensor Voltage supply: 5.5 V 1 0.00165 W
DHT22
Power = 0.00165 W
3. DC Geared Operating current: 2A
Motor Voltage supply: 18 V 2 36 W

Power = 36 W
4. Cooling Fan Operating current: 0.1 A
Radiator Voltage supply: 12V DC 1 1.2 W

Power = 1.2 W
5. L298N motor Operating current: 0.036 A 1 0.18 W
driver Voltage supply: 5 V
 Power = 0.18 W
6. LCD Display Operating current: 0.2 A

Voltage supply: 5V DC 1 1W

Power = 1 W
Total power consumption 39.54 W

Table 4.10:Electrical Power Calculation

Total power of Switch Mode Power Supply:

Operating current: 0.225 A

Voltage supply: 240V AC

Power = 54 W

The total power consumption of components is 39.54 W while total power of DC

power supply is 24 W. Since the supply power is higher than the power consumes, no
overload current will happen so that we can use the power supply for this project.