Mechanical Engineering project

Capstone Project
Lovely Professional University (Punjab)
Project Domain: Mechatronics
Sub-Domain: Material Handling
Project Title: Nut Sorting Machine
Project Mentor: Mr. Harinder Pal Singh
Asst. Professor - LSME, Lovely Professional
University, Punjab
Project Undertaken By: Manpreet Singh 11001082
January-May
2014

NUT SORTING MACHINE
CAPSTONE PROJECT
Submitted in Partial Fulfillment of the
Requirement for Award of the Degree
Of
BACHELOR OF TECHNOLOGY/MASTER OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
Manpreet Singh 11001082
Under the Guidance of
Mr. Harinder Pal Singh
DEPARTMENT OF MECHANICAL ENGINEERING
LOVELY PROFESSIONAL UNIVERSITY
PHAGWARA, PUNJAB (INDIA) -144402
2014

Capstone Project | SME ii
School of Mechanical Engineering | Lovely Professional University
Lovely Professional University Jalandhar, Punjab
CERTIFICATE
I hereby certify that the work which is being presented in the Capstone project entitled “Nut
Sorting Machine” in partial fulfillment of the requirement for the award of degree of
Bachelor of technology and submitted in Department of Mechanical Engineering, Lovely
Professional University, Punjab is an authentic record of my own work carried out during
period of Capstone under the supervision of Mr. Harinder Pal Singh, Assistant Professor,
Department of Mechanical Engineering, Lovely Professional University, Punjab.
The matter presented in this dissertation has not been submitted by me anywhere for
the award of any other degree or to any other institute. .
Date: Manpreet Singh 11001082
This is to certify that the above statement made by the candidate is correct to best of
my knowledge.
Date: Mr. Harinder Pal Singh
Supervisor
The B-Tech Capstone project has been held on
Signature of Examiner

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Acknowledgement
Final year Capstone project comes as one of the most valuable phase in the making of an
engineer. The very concept accentuates the correlation of theoretical concepts with the
practical dimensions of their application. This remains to be the key reason for it holding
utmost significance in the development of a promising engineer. As a part of the process, it
becomes particularly important to get the right kind of environment, offering genuine support
& cooperation for successful accomplishment of the anticipated intent. An exact
reciprocation was extended to us by Lovely Professional University, Punjab during the period
Sep-Dec, 2013.
A project is branded by the contributing members associated with it. That being said, I would
by no means overlook any opportunity to acknowledge the efforts of a few esteemed
individuals who have impressed upon their persona as nothing short of exemplified
inspiration & motivation, truly acting as impetus to our project.
Dr. Gurpreet Singh Phull: HOS, SME, Lovely Professional University
Mr. Harinder Pal Singh – Project Mentor: Asst. Prof., SMEM, Lovely Professional University
Mr. Sunil Setia – Asst. Prof., Lovely Professional University
Mr. Jaiinder Preet Singh: COD – SME, Lovely Professional University
Mr. Piyush Gulati: COD – SME, Lovely Professional University
Mr. Rajiv Kumar: Capstone Project Coordinator - Lovely Professional University

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Taking into consideration a project of this scale, ‘Every drop of water counts’, hence we
convey our heartfelt gratitude & appreciation to ‘Logitech Electronics’ for providing us this
excellent opportunity to share their embedded system workshop to work to automation.
Lastly, at this dependent juncture in life, all developments may appear to be the consequence
of one’s own actions but in fact are disguised outcomes concealing the invaluable efforts, co -
operation, patronage & boundless encouragement endowed by our Families. Words fall short
to affirm credibility to articulate their consistent role in each & every success of an
individual. Bearing the same reflection, we would like to communicate our indebted
thankfulness to our Families, without the unimpeded support none of this would
have been remotely possible.
Manpreet Singh 11001082
B Tech ME Hons

Capstone Project | SME v
Preface
In order to address way to cater with the limited man power, increasing competition and
decreasing profits caused by invention of latest technology, three key policy avenues are
considered to be appropriate to meet the challenge of sustainable manufacturing industry for
the future: reduction of human power; shift to automation; and, improvement of material
handling systems.
From the viewpoint of reducing human effort and improvement in material handling system
automation has become very important need. In fact, automation is not a recent invention. It
has a history as old as that of the conventional machining. However, taking the negative effects
of conventional machining into account, automation has been recognized by many in the
nascent manufacturing industry. Developed industries are increasingly supportive in this
department because automotive manufacturing development is vital economic opportunity.
To integrate automation in the current urban manufacturing system, a series of appropriate
measures should be taken not only in the machining and packing, but also in material handling.
This not only reduces manufacturing cost but also increase quality of the manufactured
products.
Thus in order to provide industries the same benefit we have tried to make a nut sorting
machine based on the principles of electronic and mechanical science.

Capstone Project | SME vi
Abstract
One of the exciting work that a mechanical engineer would like to do in the field of
Mechatronics can be The Nut Sorter Project.
The goal of the project is to design a Mechatronics system that can sort nut of different sizes
and types. It would also be able to detect other objects in the process and reject them. The
project will be aimed to provide the industry a real machine for direct use in packaging
department at very economical price
The components of this nut sorter will be
 sensors,
 stepper and DC motors and
 some basic electronic components.
The project will be emphasized to function at optimum speed, accuracy and design.
This sorter works based on the shadow a nut casts. Depending on the size of the shadow, the
nut is dispensed into the respective bin.

Capstone Project | SME vii
Executive Summary
As part of our Final Year Mechanical Engineering project, we studied the problems faced by
the assembling industries related to the material handling of the parts used like hardware which
are difficult to sort mechanically and selected topic as well as completed individual research
and study on the theories of the topic. After thorough study was conducted we were able to
design and develop our own working model of the automatic nut sorting machine. We’ve
explored the machine frame and body fabrication, motor, storage system, guiding system, and
electrical and control systems. The team has come to the conclusion that it is best for both the
short and long term that we work on improving the material handling system.
For this conceptual design, the deliverables are as follows:
· Fabrication model refinement.
· Suitable material & equipment selection & procurement.
· Prototyping & development.
· Model, diagram and documentation of the Electrical System.
· Complete or refine circuit protection for the electrical and control systems.
· Combining & simplifying the multiple fragmented control circuits.
· Exceptional performance feature – Sensor based handling
The merits of the design will include much enhanced user ability to control and use,
higher efficiency, reduced chances for circuit failure, and a knowledge database that will be
passed to future projects to be undertaken.

Capstone Project | SME viii
Abbreviations & Symbols
AC: Alternating Current
DC: Direct Current
LED: Light Emitting Diode
CCD: Charged Coupled Device
LDR: Light Dependent Resistor
IC: Integrated Circuit
VR: Voltage Regulator
PCB: Printed Circuit Board
MCU: Microcontroller
ROM: Random Access Memory
CMOS: Complementary Metal Oxide Semiconductor
POT: Potentiometer
Op AMP: Operation Ampliphier

Capstone Project | SME ix
List of Figures
Figure 1.1 Different types of products undergo sorting in the industry……………….. 3
Figure 1.2 Nut Sorter……………………………………………………………….. 4
Figure 1.3….……………………………………………………………………………… 5
Figure 1.4..………………………………………………………………………………… 5
Figure 1.5……………………………………………………………………………….… 6
Figure 1.6……………………………………………………………………………… 6
Figure 1.7………………………………………………………………………………… 6
Figure2.1: Block Diagram Microcontroller……………………………………………… 13
Figure2.2: Pin Diagram AT89C51………………………………………………………… 14
Figure2.3: Types of resistors ………………………………………………………...…… 15
Figure2.4: Variable Resistor…………………………………………………………… 16
Figure2.5: Polar Capacitor………………………………………………………………… 16
Figure2.6: Non Polar Capacitor…………………………………………………………… 16
Figure2.7: Electrolytic Capacitor……………………………………………………… 17
Figure2.8: Ceramic capacitor…………………………………………………/………… 17
Figure2.9: IN4001 Diode……………………………………………………………… 18
Figure2.10: OP-AMP as comparator …..………………………..…………………… 19
Figure2.11: Pin Diagram of LM324…………………………………………………… 19
Figure2.12: Primary and Secondary windings of Transformer………………………… 20
Figure2.13: Symbol of Transistor…………………………………………………… 21
Figure2.14: Description of terminals of Transistor……………………………………… 21
Figure2.15: Types of LED S…………………………………………………………….. 21
Figure2.16: Pin description of LM7805………………………………………………… 22
Figure2.17: Circuit Diagram of Power Supply…………………………………………… 22
Figure2.18: DC Motor and its internal structure……………………………………… 24
Figure2.19: H-Bridge circuit……………………………………………………………… 25

Capstone Project | SME x
Figure2.20: The two basic states of an H bridge………………………………………… 25
Figure 2.21; Servo Motor drive…………………………………………………………. 27
Figure 2.22: General LDR…………………………………………………………….. 27
Figure 3.1 Basic Transformer………………………………………………………….. 28
Figure 3.2 Circuit Diagram of Power supply…………………………………………… 28
Figure 3.3 Sensor LDR and LED as in the Machine…………………………………… 29
Figure 3.4 General layout of comparator circuit………………………………………… 29
Figure 3.5 Comparator as used in the Machine………………………………………… 30
Figure 3.6 General Layout of the LM 8051…………………………………………….. 30
Figure 3.7 Microcontroller as used in the Machine……………………………………… 31
Figure 3.8 Guide Tube …………………………………………………………………… 31
Figure 3.9 General layout of Circuit diagram…………………………………………… 32

Capstone Project | SME xi
List of Tables
Table 1.1…………………………………………………………………………………..5
Table 1.2…………………………………………………………………………………..6
Table 1.3…………………………………………………………………………………..6
Table 1.4 Project Charter………………………………………………………………….11
Table 2.3: Logic table for DC motor……………………………………………………...26
List of Flow Charts
Flow Chart 1.1 General Layout of the Nut Sorting Machine…….………………………...3
Flow Chart 1.7……………………………………………………………………………...9

Table of Contents
Acknowledgement III
Preface V
Abstract VI
Executive Summary VII
Abbreviations & Symbols VIII
List of Figures IX
List of Tables XI
List of Flow Chart XI
Table of Contents 1
1.) Introduction 3
1.1) Sorting 4
1.2) Some of the examples used in industries 5
1.3) Problem Statement 7
1.4) Scope Of the Machine 7
1.5) Project Objective 8
1.6) Flow Chart 9
1.7) Complete Work Plan 10
2.) Literature 12
2.) Hardware Description 12
2.1) Microcontroller (mcu) 12
2.2) Resistors 15
2.3) Capacitors 16
2.4) Diode 17
2.5) LM324 (OPERATIONAL AMPLIFIER) 18
2.6) Transformer 19
2.7) Transistor 20
2.8) LED 21
2.9) Voltage Regulator 22
2.10) Power Supply 22
2.11) DC Gear motor 24
2.12) Servo Drive 26
2.13) LDR 27
3.) Working of the machine 28
3.1) Transformer 28
3.2) Power Supply 28
3.3) Sensor LDR 29

Capstone Project | SME 2
3.4) Comparator 29
3.5) Microcontroller 30
3.6) Guide 31
3.7) Program for algorithms of
microcontroller
33
4.) Conclusion & Discussion 36
4.1) Application 36
4.2) Advantage 36
4.3) Future Scope 36
4.4) Conclusion 37
5.) References & Bibliography 38

Introduction
With the rising competition in the every industry the need of automation is becoming very
important. Automation in industries began many years ago but in earlier days it was focused to
production of precise jobs, but now when the industries are not only looking to maintain
quality but also reducing cost of production the need of automation is begin released in very
aspect not only in manufacturing but in packaging and material handling.
Moving to the fasteners packaging and handling, fastener industry produces huge variety of
jobs not only different in physical or chemical properties but having small variation in size
with all other parameters remaining same, in this scenario the need of creating cheap and
reliable equipment is becoming of prime importance.
Now getting particularly to nut they can be of huge variety only by change in the hole
diameter, which if mingled can become very cumbersome job.
To provide automation we observed that with change in diameter the height og nut also
changes and this can be used to detect the dimensional variation by using very cheap and
reliable sensor and in accordance to this idea we designed the automated nut sorter machine
Flow Chart 1.1 General Layout of the Nut Sorting Machine
Figure 1.2 Nut Sorter Machine
Transfo
rmer
Compar
ator
Sensor
Power
Supply
Microco
ntroller
AC to DC
converto
r
Gear
Motor
Servo
Motor
Rotor
Guide
C
o
n
t
a
i
n
e
r

Sorting
Sorting is any process of arranging items according to a certain sequence or in different sets,
and therefore, it has two common, yet distinct meanings:
1. Ordering: arranging items of the same kind, class or nature, in some ordered sequence,
2. Categorizing: grouping and labeling items with similar properties together (by sorts).
The main purpose of sorting information is to optimize its usefulness for specific tasks.
Sorting can be of any product and can be done by using various methods.
In this report sorting of fastener – Nut is given main emphasis.
Sorting In fasteners industries
Optical sorting machine can also be used to do automatic sorting. The optical sorting machine
product line offers users flexibility over a wide range of parameters that can be measured as
well as sorting machines that are designed specifically for certain objects such as screws, rivets
or bolts. One sorting system from the optical sorting machine product line is designed to
discriminate metallic objects based on hardness. Each optical sorting machine offers powerful
technology to any production line.
Figure 1.2 Different types of products undergo sorting in the industry
Inspection parameters
• Diameter, Hole diameter • Length
• Width • Height, Thickness
• Surface defect • Deformed, Broken
• Different shape • Crack
• Burrs, Chips • Across Corner
• Across Flat • Chamfer angle
• Included angle • Arc radius
• Concentricity • Roundness
• With coating • With mark

• With cut/tapering • Parallel edge length
• Broken pin, Recess depth • With thread
• Fine or coarse thread • Thread numbers
• Pitch • Slanted thread
• Minor diameter • Major diameter
• Hardness • Recognition of different materials
• Heat treatment
Some of the examples used in industries
Optical Sorting Machine QSS-C07
This optical sorting machine measures all the standard parameters (see above). It is designed
for nuts, rivets, rollers, washers, studs and objects that can sit stably on a conveyor belt.
Table 1.1
Figure 1.3 Figure 1.4

Optical Sorting Machine QSS-D07
This optical sorting machine measures all the standard parameters (see above). It is designed
for screws, bolts, bolts and nuts, bolts and washers.
Table 1.2
Figure 1.5 Figure 1.6
Automatic Sorting Machine QSS-V08
This automatic sorting machine measures hardness,
differences in material (composition) and whether or
not the object has been heat treated or not.
Table 1.3
Figure 1.7

Problem Statement
To evaluate & analyse the viability of automation system in sorting fasteners which are time
consuming to sort mechanically.
Fasteners are the basic hardware for any sector of fabrication or construction society. Fasteners
are used in all the industries for its specific use.
There are various size of fasteners used in the industries and due to the close variation in
dimensions they can easily be mixed if not taken care and once they are mingled it can be
cumbersome and time consuming to sort them.
Scope of the Machine
 The machine can solve the problem of time consumption and
 Waste of resources in face of labor cost
The machine can be used
 In the industry where it is manufactured , at the packaging sector.
 Where it is used as hardware in large quantity like in fabrication of machine
 Construction of buildings and towers where nuts of close dimension are used

Objectives of the study
Project Title
Design & Development of an Efficient industrial NUT SORTING MACHINE.
Project Objective
 General Objective
1. To cater to the issue of competition in mechanical industry the need for automation is assess
by all the industry
2. To identify the key policy avenues considered to be appropriate to meet the challenge
of sustainable manufacturing and packaging industry for the future.
3. To provide alternative for industries aiming toward reducing human effort and
improvement in material handling system by implementing automation
4. Sustainable and practical automation solutions for the future industrial environment.
 Technical Objectives
1. Design & Analysis.
2. Prototyping, fabrication & development.
3. Adding functionality for enhanced utility.

System Flow Chart
Flow Chart 1.2
Concept Selection

Complete Work Plan
Project Charter
Project Title Business Unit
Nut Sorting Machine
Mechatronics
and
Material Handling
Project Support Structure Business Case
Project
Mentor
Mr. Harinder Pal Singh, Asst.
Professor, LSME - Lovely
Professional University, Punjab From the viewpoint of competition in mechanical
industry the need for automation is assess by all the
industry. It is also important from the viewpoint
of reducing human effort and improvement in
material handling system automation has
become very important need
To integrate automation in the current urban
manufacturing system, a series of appropriate
measures should be taken not only in the
machining and packing, but also in material
handlingProject
Team
Manpreet Singh & Abhishek
Planning
Manage-
ment
Decision
Making
Mandeep Singh & Sushant
Procure-
ment
Execution Logistics
Darshprit Singh
Finance
Content
Database
Procure-
ment
Collective
Misc Resource Execution
Technical
Aid
Logistic Electrical, Ludhiana,
Punjab
Shubham Yadav, Btech ME
(4th Yr) LPU, Punjab
Problem Statement
To evaluate & analyze the viability of a personal cost effective two-wheel plug-in electric vehicle
prototype for short distance applications such as campus mobility.
Project Objective
1.) To cater to the issue of limited fossil fuel availability, increasing CO2 emissions and air & noise
pollution caused by conventional vehicles with combustion engines.
2.) To identify the key policy avenues considered to be appropriate to meet the challenge of sustainable
urban transport for the future.
3.) Reduction of travel distance; Transition to environment friendly transport modes; and, Improvement
of fuel and vehicle technologies.

Project Scope
Is Is Not
To review the work advancements till date on
subject matter & proceed accordingly.
To review work advancements in alternatives such
as mechanical sorter, optical sorter,etc.
To design & analyse a prototype to assess
feasibility for long term applications.
To design & analyse a prototype to assess
feasibility for long range applications.
To maintain efficiency, cost-effectiveness. To optimize efficiency, escalate cost.
Deliverables Support Required
Design & Analysis.
Mr.
Harinder
Pal Singh
Asst. Professor, SME, LPU
Prototyping, fabrication & development.
Design & Analysis (Estimate 3-4 days)
Added functionality for enhanced utility.
Road Map
Activity Plan Timeline
Project Start Saturday, September 7, 2013 Targeted Months
Status
Project End Friday, December 13, 2013 February March April
Define
Project topic selection, finalisation Complete
Literature review & related content Complete
Brainstorming - Idea development Complete
Detailed concept selection & design Complete
Measure Costing & budgeting Complete
Analyse
Analysis - Design & failure On going
Prototype fabrication, development On going
Identification of real time problems On going
Improve
Contingent design modifications Planning
Correction of problems identified On going
Control
Mentor-Team interaction sessions On going
Aesthetics & finishing Planning
Conclusion & future scope Planning
Documentation & report On going
Report revision & presentation Complete
Prepared by: Gravity Group ME
(4th Yr), LPU, Punjab
Date: 24-4-14
Validated by: Mr. Harinder Pal Singh
Asst. Prof, SMEM, LPU, Punjab
Table 1.4 Project Charter

Literature
HARDWARE DESCRIPTION
Material Used
1. Microcontroller
2. Transformer
3. LDR
4. Servo Drive
5. Capacitor
6. Voltage Regulator (7805)
7. Resistors
8. LED
9. LM324 (Comparator)
10. IC bases
11. Transistors
12. Gear Motors(100rpm)
13. Ribbon wire
14. Soldering Iron
15. Soldering Wire
16. Multimeter
17. PCB
18. Screw & Nuts
The detailed description of the components is given:
2.1 MICROCONTROLLER (MCU)
The Intel 8051 is an 8-bit microcontroller available in DIP (dual in-line package) form.8051
can all be programmed using 8051 assembly language as well as embedded C++. Once the
microcontroller is programmed it acts as the brain of the system. We are stepping towards the
automation we need a body that centrally controls the full device and in this project we use

microcontroller 8051 for the same purpose. The block diagram of a typical microcontroller,
which is a true computer on a chip is shown in fig 2.1. The design incorporates all of the
features found in micro-processor CPU, ALU, PC, SP, and registers. It also added the other
features needed to make a complete computer: ROM, RAM, I/O,timer & counters,and clock
circuit.
Figure2.1: Block Diagram Microcontroller
2.1.1 8051 MICROCONTROLLER
The AT89C51 is a low-power, high-performance CMOS 8-bit microcontroller with
8Kbytes of in-system programmable Flash memory. The device is manufactured using Atmel’s
high-density non-volatile memory technology and is compatible with the industry-standard
80C51 instruction set and pin out. The on-chip Flash allows the program memory to be
reprogrammed in-system or by a conventional non-volatile memory programmer. By
combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip, the
Atmel AT89C51 is a powerful microcontroller which provides a highly-flexible and cost-
effective solution to many embedded control applications. The AT89C51 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
AT89C51aa 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.
2.1.2 FEATURES
1. 8K Bytes of In-System Programmable (ISP) Flash Memory
2. Endurance: 1000 Write/Erase Cycles
3. 4.0V to 5.5V Operating Range
4. Fully Static Operation: 0 Hz to 33 MHz
5. Three-level Program Memory Lock
6. 256 x 8-bit Internal RAM
7. 32 Programmable I/O Lines

8. Three 16-bit Timer/Counters
9. Eight Interrupt Sources
10. Full Duplex UART Serial Channel
11. Low-power Idle and Power-down Modes
12. Interrupt Recovery from Power-down Mode
13. Watchdog Timer
14. Dual Data Pointer
15. Power-off Flag
16. Fast Programming Time
17. Flexible ISP Programming
2.1.3 PIN CONFIGURATION OF 8051 MICROCONTROLLER
Figure2.2: Pin Diagram AT89C51

2.1.4 WHY 8051 ?
1. Meeting the computing needs of the task efficiently and cost effectively
2. Speed, the amount of ROM and RAM, the number of I/O ports and timers, size,
packaging, power consumption.
3. Easy to upgrade.
4. Availability of software development tools
5. Assemblers, debuggers, C compilers, emulator, simulator, technical support.
2.2 RESISTORS
The flow of charge (or current) through any material, encounters an opposing force similar in
many respect to mechanical friction. This opposing force is called resistance of the material. It
is measured in ohms. In some electric circuits resistance is deliberately introduced in the form
of the resistor.
2.2.1 CARBON RESISTORS:
Carbon resistors are divided into three types:
a. Carbon composition resistors are made by mixing carbon grains with binding material
(glue) and moduled in the form of rods. After this an insulating material seals the
resistor. Resistors are available in power ratings of 1/10, 1/8, ¼ , 1/2 , 1.2 watts and
values from 1 - 20 ohms.
b. Carbon film resistors are made by deposition carbon film on a ceramic rod. They are
cheaper than carbon composition resistors.
c. Cement film resistors are made of thin carbon coating fired onto a solid ceramic
substrate. The main purpose is to have more precise resistance values and greater
stability with heat. They are made in a small square with leads.
Figure2.3: Types of resistors
2.2.2 VARIABLE RESISTORS:
A variable resistor is a device that is used to change the resistance according to our needs in an
electronic circuit. It can be used as a three terminal as well as a two terminal device. Mostly

they are used as a three terminal device. Variable resistors are mostly used for device
calibration
It has a resistive element as the track and a sliding contact called the wiper. The wiper is
connected with the help of another sliding contact to another terminal. The position of the
wiper depends on the type of POT used. For a panel POT, the wiper is kept in the middle. The
resistive element has a terminal on both the ends and can be linear or logarithmic. It is usually
made up of carbon or a mixture of ceramic and metal or even graphite.
Figure2.4: Variable Resistor
2.3 CAPACITORS
A capacitor can store charge, and its capacity to store charge is called capacitance. Capacitors
consist of two conducting plates, separated by an insulating material (known as dielectric). The
two plates are joined with two leads. The dielectric could be air, mica, paper, ceramic,
polyester, polystyrene, etc. This dielectric gives name to the capacitor like paper capacitor,
mica etc.
Types of Capacitors- Capacitors are of two types Fixed and Variable capacitor.
Fixed types of capacitor are further of two types:-
POLAR CAPACITOR: Those capacitor have polarity are known as polar capacitor.
Electrolytic capacitor are the example of polar capacitors.
Figure2.5: Polar Capacitor
NON POLAR CAPACITOR: Those capacitor have no polarity are known as non-polar
capacitor. Ceramic capacitor are the example of non polar capacitors
Figure2.6: Non Polar Capacitor
ELECTROLYTIC CAPACITOR: Electrolytic capacitors have an electrolyte as a dielectric.
When such an electrolyte is charged, chemical changes takes place in the electrolyte. If it’s one

plate is charged positively, same plate must be charged positively in future. Non-electrolyte
capacitors have dielectric material such as paper, mica or ceramic. Therefore, depending upon
the dielectric, these capacitors are classified.
Figure2.7: Electrolytic Capacitor
CERAMIC CAPACITOR: Such capacitors have disc or hollow tabular shaped dielectric made
of ceramic material such as titanium dioxide and barium titanate. Thin coating of silver
compounds is deposited on both sides of dielectric disc, which acts as capacitor plates. Leads
are attached to each sides of the dielectric disc and whole unit is encapsulated in a moisture
proof coating. Disc type capacitors have very high value up to 0.001uf. Their working voltages
range from 3V to 60000V. These capacitors have very low leakage current. Breakdown voltage
is very high.
Figure2.8: Ceramic capacitor
2.4 DIODE
Diodes are semiconductor devices which might be described as passing current in one direction
only. Diodes have two terminal, an anode and a cathode. The cathode is always identified by a
dot, ring or some other mark. Diode is a unidirectional device. In this current flows in only one
direction.
Diodes can be used as voltage regulators, tuning devices in RF tuned circuits, frequency
multiplying devices in RF circuits, mixing devices in RF circuits, switching applications or can
be used to make logic decisions in digital circuits. There are also diodes which emit "light", of
course these are known as light-emitting-diodes or LED's.
A rectifying diode of the 1N4001-07 ( 1A) type or even one of the high power, high current
stud mounting types. You will notice the straight bar end has the letter "k", this denotes the
"cathode" while the "a" denotes anode. Current can only flow from anode to cathode and not in
the reverse direction, hence the "arrow" appearance. This is one very important property of
diodes.

The principal early application of diodes was in rectifying 50 / 60 Hz AC mains to raw DC
which was later smoothed by choke transformers and / or capacitors. This procedure is still
carried out today and a number of rectifying schemes for diodes have evolved, half wave, full
wave and bridge, full wave and bridge rectifiers.
1N400X series Diode:-
2.4.1 FEATURES
i. Diffused Junction
ii. High Current Capability and Low Forward Voltage Drop
iii. Low Reverse Leakage Current
iv. Lead Free Finish
Figure2.9: IN4001 Diode
2.5 LM324 (OPERATIONAL AMPLIFIER)
LM324 is a 14 pin IC consisting of four independent operational amplifiers (op-amps)
compensated in a single package. Op-amps are high gain electronic voltage amplifier with
differential input and, usually, a single-ended output. The output voltage is many times higher
than the voltage difference between input terminals of an op-amp.
These op-amps are operated by a single power supply and need for a dual supply is eliminated.
They can be used as amplifiers, comparators, oscillators, rectifiers etc. The conventional op-
amp applications can be more easily implemented with LM324. 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 LM324-N 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.

Figure2.10: OP-AMP as comparator Figure2.11: Pin Diagram of LM324
2.5.1 OP-AMP COMPARATOR CIRCUIT WORKING
A comparator circuit compares two voltages and outputs either a 1 (the voltage at the plus side;
VDD in the illustration) or a 0 (the voltage at the negative side) to indicate which is larger.
Comparators are often used, for example, to check whether an input has reached some
predetermined value. In most cases a comparator is implemented using a dedicated comparator
IC, but op-amps may be used as an alternative. Comparator diagrams and op-amp diagrams use
the same symbols.
Figure shows a comparator circuit. The circuit does not use feedback. The circuit amplifies
the voltage difference between Vin and VREF, and outputs the result at Vout. If Vin is greater
than VREF, then voltage at Vout will rise to its positive saturation level; that is, to the voltage
at the positive side. If Vin is lower than VREF, then Vout, will fall to its negative saturation
level, equal to the voltage at the negative side. In practice, this circuit can be improved by
incorporating a hysteresis voltage range to reduce its sensitivity to noise
2.6 TRANSFORMER
Transformer works on the principle of mutual inductance. We know that if two coils or
windings are placed on the core of iron, and if we pass alternating current in one winding, back
emf or induced voltage is produced in the second winding. We know that alternating current
always changes with the time. So if we apply AC voltage across one winding, a voltage will be
induced in the other winding. Transformer works on this same principle. It is made of two
windings wound around the same core of iron. The winding to which AC voltage is applied is
called primary winding. The other winding is called as secondary winding. Transformers are of
two types Step Up transformer and Step Down transformer.

Figure2.12: Primary and Secondary windings of Transformer
STEP UP TRANSFORMER: These transformers are used to increase the voltage level at the
output means Voltage at secondary winding is more than the primary winding. In this
transformer secondary winding has more number of turns than primary winding. These types
of transformers are generally used in power station.
STEP DOWN TRANSFORMER: These transformers are used to decrease the voltage level at
the output winding means voltage of secondary winding is less than the primary winding. In
this transformer secondary winding has less number of turns than primary winding. These
types of transformers have major applications in electronics industry.
2.7 TRANSISTOR
The schematic representation of a transistor is shown. Note the arrow pointing down towards
the emitter. This signifies it's an NPN transistor. A transistor is basically a current amplifier.
Say we let 1mA flow into the base. We may get 100mA flowing into the collector. Note: The
currents flowing into the base and collector exit through the emitter (sum off all currents
entering or leaving a node must equal zero). The gain of the transistor will be listed in the
datasheet as either βDC or Hfe. The gain won't be identical even in transistors with the same part
number. The gain also varies with the collector current and temperature.

Figure2.13: Symbol of Transistor
Figure2.14: Description of terminals of Transistor
2.8 LED
LED means light emitting diode. Its function is similar to the diode. But these are not made up
from silicon or germanium. These are generally used as a indicating device. There are variety
of LEDs are available in market depending upon their size and colour.
Figure2.15: Types of LED S

2.9 VOLTAGE REGULATOR
The LM78XX 3-terminal positive voltage regulators employ internal current-limiting, thermal
shutdown and safe-area compensation, making them essentially indestructible. Heat sinking is
provided; they can deliver over 1.0A output current. They are intended as fixed voltage
regulators in a wide range of applications including local (on-card) regulation for elimination
of noise and distribution problems associated with single-point regulation.
Figure2.16: Pin description of LM7805
2.9.1 FEATURES
1. Output current up to 1 A
2. Output voltages of 5; 6; 8; 9; 12; 15; 18; 24 V
3. Thermal overload protection
4. Short circuit protection
2.10 POWER SUPPLY
Power supply is the essential part of any device or project. We are using microcontroller and
LED. These components needs +5V DC supply. So we need a power supply circuit of +5V
DC. Power supply circuit includes step down transformer, rectifier circuit, filter circuit and
regulator circuit. An indicating component is also attached with the power supply to indicate
the power ON condition of power supply unit.
Figure2.17: Circuit Diagram of Power Supply

Now the aim is to design the power supply section which converts 230V AC in to 5V DC.
Since 230V is too high to reduce it to directly 5V DC, therefore we need a step down
transformer that reduces the line voltage to certain voltage that will help us to convert it in to a
5V DC. Considering the efficiency factor of the full wave, we came to a conclusion to choose a
transformer, whose secondary voltage is 3-4 higher than the required voltage. Thus a step
down transformer of 9 V and 500 mA is used to step down the AC power supply. This
transformer can provide current up to 750 mA. Our circuit load is below 750 mA. So there will
not be any loading effect on transformer. Output of transformer is given to the rectifier circuit.
We are using a central tapped full wave rectifier. In this rectifier we are using 1N4007 PN
diode to rectify AC voltage. Output of this rectifier is not purely DC. Output of rectifier is
rippled DC. So we need some filtering section to rectify these ripples. Output voltage of
rectifier can be calculated by:-
Vout = (Vin * √2)- (Forward voltage drop of diode)
1N4007 is a silicon semiconductor material based diode. So in this case forward Voltage drop
is .7 V. Final output of this rectifier be:-
Vout= (12*√2)- .7
Vout= 16.1 V
Total Voltage= Voltage across resistor+ Voltage across LED
LED and resistor are connected in series so same current will flow. Means 8mA current will
flow through the resistor.
Now Total Voltage is =5V
Voltage across resistor is =1.6v
Current is = 10mA
So our equation will be
5V= (10mA * resistance) + 1.6V
3.4V=10mA * resistance
Resistance =3.4/10mA
= 450 ohm
Thus we can calculate the any series resistor for any input voltage and LED.

2.11 DC GEAR MOTOR
DC motor is a device powered from direct current (DC) that converts the current into
mechanical energy and rotates. Here the motor is used to move the lfr through the path. The dc
motor used here is a 100 rpm.
2.11.1 PRINCIPLE OF OPERATION
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. We know 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 current-carrying conductor and an
external magnetic field to generate rotational motion.
Figure2.18: DC Motor and its internal structure
In this project the dc motor acts as the very integral part to deliver the output. Once we obtain
the signals to the motor driven IC the end effector ,through we will obtain the desired result is
the dc motor.

2.11.2 H-BRIDGE CIRCUIT
An H bridge is an electronic circuit which enables a voltage to be applied across a load in
either direction. These circuits are often used in robotics and other applications to allow DC
motors to run forwards and backwards.
The term H bridge is derived from the typical graphical representation of such a circuit.The
term H bridge is derived from the typical graphical representation of such a circuit. An H
bridge is built with four switches (solid-state or mechanical).
When the switches S1 and S4 are closed (and S2 and S3 are open) a positive voltage will be
applied across the motor. By opening S1 and S4 switches and closing S2 and S3 switches, this
voltage is reversed, allowing reverse operation of the motor.
Figure2.19: H-Bridge circuit
Using the nomenclature above, the switches S1 and S2 should never be closed at the same
time, as this would cause a short circuit on the input voltage source. The same applies to the
switches S3 and S4. This condition is known as shoot-through.
Figure2.20: The two basic states of an H bridge

S1 S2 S3 S4 Result
1 0 0 1 Motor moves right
0 1 1 0 Motor moves left
0 0 0 0 Motor free runs
0 1 0 1 Motor brakes
1 0 1 0 Motor brakes
1 1 0 0 Stop
0 0 1 1 Stop
1 1 1 1 Stop
Table2.1: Logic table for DC motor
The H-bridge arrangement is generally used to reverse the polarity of the motor, but can also
be used to 'brake' the motor, where the motor comes to a sudden stop, as the motor's terminals
are shorted, or to let the motor 'free run' to a stop, as the motor is effectively disconnected from
the circuit.
2.12 SERVO DRIVE
A servo drive system consists of a servo drive and a servo motor. The main task of a servo
drive (also called "servo amplifier", "servo inverter", "servo controller", or just "controller") is
the control of the motor current. In addition, ESR servo drives offer a broad spectrum of
functionality .

While most of the electrical drive systems are operated at constant speed, a servo drive has a
rather "hectic" life. Often it has to accelerate to the rated speed within a few milliseconds only
to decelerate a short time later just as quick. And of course the target position is to be reached
exactly with an error of a few hundredths of a millimeter.
Figure 2.21; Servo Motor drive
2.13 LDR LIGHT DEPENDENT RESISTANCE
LDRs or Light Dependent Resistors are very useful especially in light/dark sensor circuits.
Normally the resistance of an LDR is very high, sometimes as high as 1000 000 ohms, but
when they are illuminated with light resistance drops very less time taken
Figure 2.22 General LDR

Working of the Machine
Main parts of machine with their role and working using real picture
Transformer
First the power from main AC house hold supply which is 220 V is given to transformer which
steps down the voltage to 12 V.
Figure 3.1 Basic Transformer
Power Supply
Then the stepped down voltage is given to power supply circuit for changing the AC supply to
DC supply
Figure 3.2 Circuit Diagram of Power supply

Light emitting
source
LDR
SENSOR
Sensor
Here the sensor used is LDR which works on the principle of variable resistance when the light
directed to the LDR panel is obstructed by the nut the light intensity decreases for the sensors
on which the shadow of nut falls according to the height to the nut and this decreases the
resistance and gives signal to comparator circuit
Figure 3.3 Sensor LDR and LED as in the Machine
Comparator
The comparator LM324 compares the voltage difference the sends the output to the
microcontroller in the form of high or low.
Figure 3.4 General layout of comparator circuit

Figure 3.5 Comparator as used in the Machine
Microcontroller
The power converted to DC and output given by comparator is given to the microcontroller
where it applies algorithms to decide that the nut belong to which size range and gives output
to servo on which the guide is supported
Figure 3.6 General Layout of the LM 8051
Microcontroller also controls the motion of gear motor by cutting off power periodically to
stop the rotating disc so that the sensor can has sufficient data to read the change of light
intensity .
Comparator

Guide Tube
Container
Figure 3.7 Microcontroller as used in the Machine
Guide
The nut after recognized according to height falls to the container through the U shaped guide
by gravity method.
Figure 3.8 Guide Tube
Microcontrolle
r

Figure 3.9 General layout of Circuit diagram

Program for algorithms of microcontroller
Program
L1 BIT P1.0
L2 BIT P1.1
L3 BIT P1.2
hall bit p1.3
dc1 bit p3.0
dc2 bit p3.1
servo bit p3.2
ORG 00h
JMP START
ORG 0003h
RETI
ORG 000Bh
RETI
ORG 0013h
RETI
ORG 001Bh
RETI
ORG 0023h
RETI
ORG 002Bh
RETI
ORG 30H
JMP START
START:
jnb hall,action
call dcmotor
jmp start
action:
JNB L3,box3
JNB L2,box2
JNB L1,box1
jmp action
dcmotor:
clr dc1
setb dc2
call delay
setb dc1

setb dc2
call delay2
ret
box3:
mov 70h,#03
call stepper
jmp start
box2:
mov 70h,#02
call stepper
jmp start
box1:
mov 70h,#01
call stepper
jmp start
stepper: mov a,70h
clr c
subb a,71h
jz uu
jc reverse
jmp forward
uu: nop
mov p1,#00h
ret
reverse: mov r2,#02
mov a,78h
ll: rr a
mov 78h,a
mov p1,a
acall delay
djnz r2,ll
inc 70h
mov a,70h
clr c
subb a,71h
jz uu
jmp reverse

forward: mov r2,#02
mov a,78h
ll2: rl a
mov 78h,a
mov p1,a
acall delay
djnz r2,ll2
dec 70h
mov a,70h
clr c
subb a,71h
jz uu
jmp forward
delay: mov r7,0Ffh
aa: mov r6,0ffh
bb: nop
NOP
NOP
djnz r6,bb
djnz r7,aa
ret
delay2: mov r7,0fh
aa2: mov r6,0ffh
bb2: nop
djnz r6,bb2
djnz r7,aa2
ret
end

Advantages & Applications
1. It cater the issue of competition in mechanical industry by automation
2. It helps to meet the challenge of sustainable manufacturing and packaging industry
3. It provide alternative for industries aiming toward reducing human effort
4. It helps to achieve improvement in material handling system by implementing
automation
5. It generates sustainable and practical automation solutions for the future industrial
environment.
6. It can save a lot of time by doing sorting of nuts with little dimensional variation which
otherwise can be cumbersome
7. It saves a lot of cost inventory as the power required for the functioning of machine is
very less as compared to labor cost and also its speed of nut sort is more then that
achievable by humans.
8. In the industry where it is manufactured , at the packaging sector.
9. Where it is used as hardware in large quantity like in fabrication of machine
10. Construction of buildings and towers where nuts of close dimension are used
Future Scope
Fasteners are the basic hardware for any sector of fabrication or construction society. Fasteners
are used in all the industries for its specific use. The machine can improve or has added sorting
options to improve its future scope
Speed of the sorting
At present we can sort at the rate of 44 units per min. This speed may not be fit for industrial
use but it can be increased to more than ten folds by using high sensing capacity and more
accurate sensors, using high speed gear motor, using high speed servo drives which were not
used in this project due to cost inventory limitation
Colour of nut to be sort
The machine can also have a sensor to detect the color of the nut which will allow us to sort
nuts of different nut with their count displaying on LCD screen
Material of the nut to be sort
The machine can also have a sensor to detect the material property by scanning their grain
structure and sort the nut ex nut with bronze alloy can easily be sorted from nut manufactured
from stainless steel or other alloy

Conclusion
After completion of the project, the following points have come to light:
 The machine can sort 44 units of nut for every minute
This speed can be increased many folds by taking high speed and accurate sensors, high
speed servo drives and gear motor
 The machine can be very useful in the sector fasteners packaging and handling
 By using this machine huge variety of jobs produced by fasteners industry which are
not only different in physical or chemical properties but have small variation in size
with all other parameters remaining same, the sorting of mingled nuts will become
 cheap
 reliable
 less time consuming
Thus our aim to achieve realistic and practical sorting with the observation that with change in
diameter the height of nut also changes and this can be used to detect the dimensional variation
by using very cheap and reliable sensor designed as the automated nut sorter
machine is achieved

References & Bibliography
1. Printed Circuit Board Designer's Reference; Basics by Chris Robertson
2. Working of LDR; http://www.engineersgarage.com/electronic-components/ldr-light-
dependant-resistor
3. Electronic and PCB work ; http://www.technologystudent.com/
4. Mechanism of servo drive ; http://www.esr-pollmeier.de/en/FAQ.php
5. MIKELL P. GROOVER et al., Industrial Robotics: Technology, Programming, and
Applications (1986)
6. How to design robotic arm; http://www.societyofrobots.com/robot_arm_tutorial.shtml
7. Existing technology; http://www.worldoftest.com/optical-sorting.htm

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