ICTS Project : Sensors Application Part1

Today we have a meeting with Omron engineer Ms Yee Von to discuss the best sensors to be used to detect our mooncake. The criteria for the chosen sensors are :
1- 12VDC input,
2- 2 Wires,
3- Able to detect the mooncakes variations from at least 100mm distance to 1m
4- Possible to be placed on top of the conveyor

She proposed the photoelectric E3Z series, and the actual model would only be informed once she tested it in her lab. She promised to issue the quotation by latest next tuesday.

We also request her to quote several other related components for the project such as :
1- MY4N 12VDC Omron relay (10 pcs)
2- Rotary and push button switches (3 pcs each)

As for future expansion, in case we have to use the PLC, we also ask her to quote a package of the minimal expandable model (30 IO) together with software and necessary cabling in addition to the handheld loader.

As the reason we need the sensors and relays are to do further test for the best design for the4 ICTS control system. Once we have those components, we can do better simulation. Meanwhile, to replace those components, I will use toggle switches only.

This is the latest design options that use sensors :

Inter Conveyor Project Control Logic Version2

Today I upgrade the logic design of the Inter Conveyor Project. Indeed this is just enough to run the test, but not bullet proof yet. It needs some more additional features to aoid accident and smooth operation the automation later on.
So late afternoon today we did the test. Everything works perfectly as designed. However, as usual a few kaizen is required before proceed to the next stage. They are :
1- The pusher height should be lowered as low as possible.
2- The first slider before pusher must be shorten and curvy to ensure smooth landing on the pusher platform
3- The second slider must be curvy some more and shorten a bit to allow smooth landing of the mooncake into packaging conveyor especially the snowy mooncake
4- For conveyor A, a sensor is required especially at the supplying side.guides causinng some delay perhaps an angular conveyor is preverable for better movement.
5- Conveyor B guides should be lenghten up to the slider for better alignment of the mooncake.

So from this stage we are progressing to the next where the vendor for the conveyors would be contacted for meeting. Meanwhile I would assemble some electrical wiring for the control system using hardwires and some toggle switches to replace some sensors as test.

The Upgrade Design of the UIB Connector Verifier Part3

I got a slight problem with the current design as when the second transistor is triggered, the voltage for that particular logic gate that I share with the LED indicator drop that make it impossible to see the light. As such I redesign the buzzer circuit using the unused NOR gate of the 4001. Here is the refined circuit diagram.Here is the truth table of the circuit design.

This is the finished UIB boardhttp://www.gigafiles.co.uk/files/4310/USBproject/DSC01981.JPG

This is the top view of the board:
http://www.gigafiles.co.uk/files/4310/USBproject/DSC01980.JPG


Inter Conveyor Test
We did some preliminary test of the two existed conveyors. It seems like the idea of putting the guide is workable. However, thorough testing is required so that the best result can be achieved. We are targeting by end of this week we can get the best guide to be used for the Inter Conveyor.
Next for second slider, it almost done. As for the time being we havent get the sensor as well as new longer pusher. When all of them are available I plan to mix all so that they can work syncronously and in harmony with all equipment and devices.

The upgrade design of the UIB input selector part2

Due to IC components inavailability in the nearest shop in SS2, so I have to redesign the UIB Input Connectors Verifier. This is my new design.
As you can see there is no more actual XOR IC is used, instead I made my own XOR circuit.

Anyway as for Inter Conveyor Transfer System Project, here is my conceptual sketch of how I'm going to try out next week. I will use the two existed 6 foot conveyors at 90 degree alignment, where I will add a curvy support so that the Mooncake would be transfered from one conveyor to another without any big problem.

This design is inspirational by High 5 bread transfer concept. Hopefully it woulkd works fine with our Mooncake.

The upgrade design of the UIB input selector part1

The ports wiring for UIB have been completed by 7/3/07. Now what only left is the selector input connections. As in the previous design, nothing is being taken care of which connector is beinng connected. However, I realized that it's better if I can put some precaution so that no two inputs are being used simultaneously. In fact, this UIB can only work for either one USB or PCI once at a time. Due to this I add on an indicator that would light on once either of the connectors being connected.

As to avoid the second connection being made while the first one is being use, I plan to autodisconnect one of the supply once the second one is add on. Next the LED also would turn off for both to signal that there is incorrect task is being done. Perhaps a buzzer would be a good idea to alert the error.

So this is the new circuit to the kaizen of the UIB.
I prefer to use the XOR concept with some minimal other logic for easier tracing of the circuit. However, I found that I have to use the relay as DC segregator in order to ensure 5V DC is being output at port out.

Mr Khow and Eluis are quite free already. So today they started to make another Inter Conveyor Sliders with extended version. The reason I ask them to fabricate another one is simply because I want more options and flexibility in the prototype so that once it is being tested, it would almost accomplish the actual design.

The UIB another proven transfer concept

This is the one they used in one of the two famous bread in Malaysia. Just look at the conveyor exchange concept once the bread coming out from oven then when it reach the corner, a simple 90 degree sector do the job.

The fabrication of the udated design of UIB

I did some modifications for the UIB board. This is due to the available parts and time constraint. As for the time being I will use 3 main IDC connectors only. 2 for input and 1 for output. As for input I will use 1 male 34P and 1 male 40p PCB type. As for output I will retain the unniversal output IDC 40p male connector. This is those three main input IDC connectors pin assignment.
In detail at the back of PCB, it will be connected something like this.
As you can see I dismantled the negative voltage. This is simply because for the time being, there is no usage of negative voltage. Yet there is no supply available yet for the negative since the failure of the ISA 8255 board. The 12VDC from now on would be supplied from external AC to DC source. This board once completed can be used with USB, ISA, and existed interface board from ISA 8255 projects without further design of the output hardwares. As for software, each of the unique ports would have its own one.