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Industrial Conveyors Belt Counting Object System

INTRODUCTION:

Industrial conveyors belt counting object
System, the aim of the project is to count number of object
passed through conveyors belt automatically. Its save man-
power and time. In this project we are using LDR and LASER
as a sensors, controller, LCD display and DC motor.

However, in this project work on the basic principle
of LDR and LASER. For count number of objects, LDR and
LASER are used and according to there output objects count.
The control circuit is designed using micro-controller. The
outputs of count value compare with operational amplifier and
are fed to micro-controller. The output of the micro-controller is
used to drive the LCD display, so that the number of objects can
be displayed.








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BLOCK DIAGRAM:



























M
I
C
R
C
O
N
T
R
O
L
L
E
R


DISPLAY

LDR
A
M
P

LASER

MEMORY

POWER
SUPPLY

MAX232

MOTOR
DRIVER

MOTOR

COMPUTER
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BLOCK DIAGRAM DESCRIPTION:

Micro-controller board: It is a low power, high-performance CMOS 8-
bit microcomputer with 8K bytes of Flash Programmable and Erasable
Read Only Memory ROM). The device is manufactured using Atmels
high-density nonvolatile memory technology and is compatible with the
MCS-51. 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 Flash on a monolithic chip, it provides a highly flexible and cost
effective solution so many embedded control applications.

Memory Block: Memory stored number of objects which on conveyors
belt.

Display Block: LCD (Liquid Crystal Display) screen is an electronic
display module and find a wide range of applications. A 16x2 LCD
display is very basic module and very commonly used in various devices
and circuits. These modules are preferred over seven segments.

MAX Block: Max used for serial communication. As object counting
stored in memory that data can downloaded through max 232.

LASER: When any object move on conveyors belt then laser give
information to LDR that connected with operational amplifier.

LDR: LDR or light dependence resistor is very useful especially in
light/dark sensor. The lasers output given to LDR.

Motor Driver: L293D is a dual H-bridge motor driver, so with one IC
we can interface two motors that can interface two DC motors that can be
controlled in both clockwise and counter clockwise direction and fix
direction of motion.

Power Block: For our project we require + 5 Volt, and +12 Volts supply.
+5 Volts and. 5Volts is given to Micro-controller board, memory,
max232etc. +12 Volts are used for motor driver IC to drive motor.
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COMPONENT DESCRIPTION:

POWER SUPPLY:

Power supply block consists of following units:

Step down transformer.
Bridge rectifier circuit.
Input filter.
Voltage regulators.
Output filter.
Indicator unit.

Step down transformer:

The step-down transformer is used to step down the supply voltage of
230v ac from mains to lower values, as the various ICs used in this
project require reduced voltages. The transformer consists of primary
and secondary coils. To reduce or step down the voltage, the transformer
is designed to contain less number of turns in its secondary core. The
outputs from the secondary coil which is center tapped are the ac values
of 0v, 15v and 15v. The conversion of these ac values to dc values to dc
values is done using the full wave rectifier unit.

Rectifier Unit:

A diode bridge is an arrangement of four diodes connected in a bridge
circuit. That provides the polarity of output voltage of any polarity of the
input voltage. When used in its most common application, for conversion
of alternating current (A.C) input into direct current (D.C) output, it is
known as a bridge rectifier. The diagram describes a diode-bridge design
known as a full wave rectifier. This design can be used to rectify single
phase A.C. when no transformer center tap is available. A bridge rectifier
makes use of four diodes in a bridge arrangement to achieve full wave
rectification. This is a Widely used configuration, both with individual
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diodes wired as shown and with single component bridges where the
diode bridge is wired internally.

For both positive and negative swings of the transformer, there is a
forward path through the diode bridge. Both conduction paths cause
current to flow in the same direction through the load resister,
accomplishing full-wave rectification. While one set of diodes is forward
biased, the other set is reverse biased and effectively eliminated from the
circuit.

Input Filter:

Capacitors are used as filters.The ripples from the dc voltages are
removed and pure dc voltage is obtained. The primary action performed
by capacitor is charging and discharging. It charges in positive half cycle
of the ac voltage and it will discharge in negative half cycle. So it allows
only ac voltage and does not allow the dc voltage. This filter is fixed
before the regulator.Capacitors used here are of the value 1000uF

Regulator unit:

Regulator regulates the output voltage to a specific value. The output
voltage is maintained irrespective of the fluctuations in the input dc
voltage. Whenever there are any ac voltage fluctuations, the dc voltage
also changes, and to avoid this regulators are used.

Regulators can be classified as:
Positive regulator, which regulates the positive voltage(7805,7812)

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> input pin
> ground pin
> output pin

Negative regulator, which regulates the negative voltage (7912)

> ground pin
> input pin
> output pin


Regulators used in this application are:
7805 which provides 5v dc

Out put Filter:

This filter is fixed after the Regulator circuit to filter any of the possibly
found ripples in the output received finally. Capacitors used here are of
value 10F.

















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AT89S52 MICROCONTROLLER

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 industry- standard 80C51
instruction set and pinout. 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 contents but freezes the oscillator, disabling
all other chip functions until the next interrupt or hardware reset.









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EEPROM MEMORY:

EEPROM (also written E
2
PROM and pronounced "e-e-prom," "double-e
prom," "e-squared," or simply "e-prom") stands
for Electrically Erasable Programmable Read-Only Memory and is a type
of non-volatile memory used in computers and other electronic devices to
store small amounts of data that must be saved when power is removed,
e.g., calibration tables or device configuration.

When larger amounts of static data are to be stored (such as in USB flash
drives) a specific type of EEPROM such as flash memory is more
economical than traditional EEPROM devices. EEPROMs are realized as
arrays of floating-gate transistors.

EEPROM is user-modifiable read-only memory (ROM) that can be
erased and reprogrammed (written to) repeatedly through the application
of higher than normal electrical voltage generated externally or internally
in the case of modern EEPROMs. EPROM usually must be removed
from the device for erasing and programming, whereas EEPROMs can be
programmed and erased in circuit. Originally, EEPROMs were limited to
single byte operations which made them slower, but modern EEPROMs
allow multi-byte page operations. It also has a limited life - that is, the
number of times it could be reprogrammed was limited to tens or
hundreds of thousands of times. That limitation has been extended to a
million write operations in modern EEPROMs. In an EEPROM that is
frequently reprogrammed while the computer is in use, the life of the
EEPROM can be an important design consideration. It is for this reason
that EEPROMs were used for configuration information, rather than
random access memory.





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MAX 232
Features:

Operates From a Single 5-V Power Supply With 1.0-_F Charge-
Pump Capacitors
Operates Up To 120 Kbit/s
Two Drivers and Two Receivers
30-V Input Levels
Low Supply Current . . . 8 mA Typical
ESD Protection Exceeds JESD 22
2000-V Human-Body Model (A114-A)

Applications:

TIA/EIA-232-F, Battery-Powered Systems, Terminals, Modems,
and Computers

Description:

The MAX232 is a dual driver/receiver that includes a capacitive voltage
generator to supply TIA/EIA-232-F voltage levels from a single 5-V
supply. Each receiver converts TIA/EIA-232-F inputs to 5-V TTL/CMOS
levels. These receivers have a typical threshold of 1.3 V, a typical
hysteresis of 0.5 V, and can accept 30-V inputs. Each driver converts
TTL/CMOS input levels into TIA/EIA-232-F levels. The driver, receiver,
and voltage-generator functions are available as cells.









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The Serial Port

In computing, a serial port is a serial communication physical interface
through which information transfers in or out one bit at a time
(contrast parallel port). Throughout most of the history of personal
computers, data transfer through serial ports connected the computer to
devices such as terminals and various peripherals.

While such interfaces as Ethernet, FireWire, and USB all send data as a
serial stream, the term "serial port" usually identifies hardware more or
less compliant to the RS-232standard, intended to interface with
a modem or with a similar communication device.

Modern computers without serial ports may require serial-to-USB
converters to allow compatibility with RS 232 serial devices. Serial ports
are still used in applications such as industrial automation systems,
scientific instruments, shop till systems and some industrial and consumer
products. Server computers may use a serial port as a control console for
diagnostics. Network equipment (such as routers and switches) often use
serial console for configuration. Serial ports are still used in these areas as
they are simple, cheap and their console functions are highly standardized
and widespread. A serial port requires very little supporting software
from the host system.














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LCD Display

The liquid-crystal display has the distinct advantage of having low power
consumption than the LED. It is typically of the order of microwatts for
the display in comparison to the some order of milli watts for LEDs. Low
power consumption requirement has made it compatible with MOS
integrated logic circuit. Its other advantages are its low cost, and good
contrast.

The main principle behind liquid crystal molecules is that when an
electric current is applied to them, they tend to untwist. This causes a
change in the light angle passing through them. This causes a change in
the angle of the top polarizing filter with respect to it. So little light is
allowed to pass through that particular area of LCD. Thus, that area
becomes darker comparing to others.

For making an LCD screen, a reflective mirror has to be setup in the
back. An electrode plane made of indium-tin oxide is kept on top and a
glass with a polarizing film is also added on the bottom side. The entire
area of the LCD has to be covered by a common electrode and above it
should be the liquid crystal substance. Next comes another piece of glass
with an electrode in the shape of the rectangle on the bottom and, on top,
another polarizing film. It must be noted that both of them are kept at
right angles. When there is no current, the light passes through the front
of the LCD it will be reflected by the mirror and bounced back. As the
electrode is connected to a temporary battery, the current from it will
cause the liquid crystals between the common-plane electrode and the
electrode shaped like a rectangle to untwist. Thus the light is blocked
from passing through. Thus, that particular rectangular area appears
blank.

One of the main disadvantages of these types of LCDs is the size. Most
manufacturers try to reduce the height than gain it. This is because more
transistors and greater pixels will be needed to increase the length. This
will increase the probability of bad pixels. It is very difficult or also
impossible to repair a LCD with bad pixels. This will highly affect the
sale of LCDs.
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LDR:

LDRs or Light Dependent Resistors are very useful especially in
light/dark sensor circuits. These help in automatically switching ON /OFF
the street lights and etc., normally the resistance of an LDR is very high,
sometimes as very high as 1000000 ohms, but when they are illuminated
with light, resistance drop dramatically. Electronic opto sensors are the
devices that alter their electrical characteristics, in the presence of visible
or invisible light. The best-known devices of these types are the light
dependent resistor (LDR), the photo diode and the phototransistors.

LASER:

A laser diode is an electrically pumped semiconductor laser in which the
active medium is formed by a p-n junction of a semiconductor diode
similar to that found in a light-emitting diode. The laser diode is distinct
from the optically pumped semiconductor laser, in which, while also
semiconductor based, the medium is pumped by a light beam rather than
electric current.

















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LM 358 OP-AMP:

The LM158 series consists of two independent, high gain, internally
frequency compensated operational amplifiers which were designed
specifically to operate from a single power supply over a wide range of
voltages. Operation from split power supplies is also possible and the low
power supply current drain is independent of the magnitude of the power
supply voltage. Application areas include transducer amplifiers, dc gain
blocks and all the conventional op amp circuits which now can be more
easily implemented in single power supply systems. For example, the
LM158 series can be directly operated off of the standard +5V power
supply voltage which is used in digital systems and will easily provide the
required interface electronics without requiring the additional 15V
power supplies. The LM358 and LM2904 are available in a chip sized
package (8-Bump micro SMD) using Nationals micro SMD package
technology.


Unique Characteristics
In the linear mode the input common-mode voltage range includes
ground and the output voltage can also swing to ground, even
though operated from only a single power supply voltage.
The unity gain cross frequency is temperature compensated.
The input bias current is also temperature compensated.

MOTOR DRIVER:

Features:

600ma output current capability per channel
1.2a peak output current (non repetitive) per channel
Enable facility
Over temperature protection
Logical "0" input voltage up to 1.5 v (high noise immunity)
Internal clamp diodes

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General Description:

The device is a monolithic integrated high voltage, High current four
channel driver designed to Accept standard dtl or ttl logic levels and drive
Inductive loads (such as relays solenoids, dc And stepping motors) and
switching power transistors. To simplify use as two bridges each pair of
channels is equipped with an enable input. A separate Supply input is
provided for the logic, allowing operation at a lower voltage and internal
clamp diodes are included. This device is suitable for use in switching
applications at frequencies up to 5 kHz. The l293d is assembled in a 16
lead plastic Package which has 4 center pins connected together and used
for heat sinking the l293dd is assembled in a 20 lead surface Mount
which has 8 center pins connected together And used for heat sinking.












WORKING:

Indusrtial conveyors belt counting object system can be used in industries
where reqirement of counting number of objects. All these can be done
by control circuit LDR and LASER sensor. It reduce man power and
within a short span of time it counts objects.

As motor starts, conveyors belt start rolling. Objects are placed on it, as
object shifted on conveyors belt. LASER fall on LDR if there is any
object it detect and then LDR give output to op-amp. This output
compared by op-amp and then apply to microcontroller. Microcontroller
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display number of objects on LCD and these process continue. There is
also memory that stored number of objects so that we can download thses
counting value any time by using serial port.