HC-SR04 Ultrasonic Sensor - Working
CHAPTER 4 Methodology
4.1 Methodology
Creating an idea for Design and construction of automatic bottle filling, counting and liquid tank level monitoring system. And drawing and listed of components/materials to know which components / materials need to construct it. Collecting the all components / materials for construct the system. Finally, we constructed this system & checked it finally that working very well.
4.2 Complete Project Prototype Image :
Figure 4.1: Complete Project Picture
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4.3 Working Principle
The way the whole project works is that we take 220V ac power from the supply voltage and then feed it to a Switch Mode Power Supply or in short SMPS module. Basically, inside the SMPS what we have is a 12V Step Down Transformer, Diodes formed in Full Wave Bridge Rectifier formation, some Capacitors, Voltage Regulator ICs and Resistors. The SMPS simply converts the 220V ac to a pure dc of 12V. We will use this 12V dc output from the SMPS to run our Arduino Nano, the main processing brain of the circuit and the LCD Unit, Sensor, transistor are going to take voltage from the Arduino to power themselves.
Our project is designed to bottle filling, counting and liquid tank level monitoring purpose.
We are using Arduino Nano for controlling our project, which is acting as the main controller here. Also used here sensors, relays, mini water pump motors and gear motor. Everything comes connected with Arduino. Here the current from AC is entering the circuit at 12 volts via SMPS. The Arduino Nano is equipped with two sensors. The IR sensor are useful for sensing the bottle. When it sense the bottle then stop conveyor belt and fill the bottle with liquid in a fixed delay time. After filling this bottle conveyor belt will be start and when the bottle will be in front of second IR sensor then conveyor belt will stop and count bottle number. On the other side an ultrasonic sensor sense the tank liquid level by using ultrasonic sound. In this process we will filling a bottle, counting bottle number and sensing liquid tank level.
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4.4 Cost Analysis:
Table 1: Cost Analysis.
No Product Name Specification Qty. Unit Price (BDT)
Total Price (BDT)
Market Price
01. Arduino Nano 1 480 480
02. SMPS 12V 1 650 650
03. IR sensor 2 180 360
04. Gear Motor 12V DC 1 700 700
05. Ultrasonic Sensor HC SR04 1 180 180
06. Mini Pump DC 1 180 180
07. LCD Display 16*2 1 180 180
08. Relay 5V 5Amp 2 35 70
09. Others 1500
Total = 4300/= 10,000/=
30 CHAPTER 5
RESULT AND DISCUSSION
5.1 Result
After followed all objectives and plan to build our project. We finally establish our project. In this project first we create our project circuit with sufficient equipment. After that a conveyor belt we make for object moving smoothly. After making all the structure then we upload our code in Arduino microcontroller. All the setup is working well with our accurate implementation and plan.
Table 02: 1st IR Sensor Reading
Reading 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
1st IR Sensor (Second)
2.30 2.18 2.30 2.00 2.07 2.00 2.19 2.15 2.20 2.24 2.10 2.00 2.13 2.30 2.28
Figure 5.1: 1st IR Sensor Reading Graph
Table 03: 2nd IR Sensor Reading
31 Reading Liquid Nozzle to Counting Sensor
(Second)
01 2.66
02 2.60
03 2.58
04 2.56
05 2.59
06 2.60
07 2.62
08 2.60
09 2.58
10 2.57
11 2.59
12 2.56
13 2.62
14 2.66
15 2.65
Figure 5.2: 2nd IR Sensor Reading Graph
32 After we place the bottle on the conveyor belt here, it takes a maximum of 2.30 seconds to reach the first IR sensor. Which we measured manually with the help of stopwatch. It takes 9 seconds to fill the bottle with water. It is fixed through this program of microcontroller. And when the liquid is full, it will take maximum of 2.66 seconds for the second IR sensor to reach. Here, Filling Accuracy is 99% cause if the motor gets less or more current then the motor will draw less or more water. But it will fill minimum 250ml liquid in 9 seconds. And counting accuracy is 100 %. Bottled water refilled time and the bottle counting is done correctly, we have agreed with everyone that the accuracy of our system is 99%.
5.2 Discussion
The Automatic bottle filling, counting and liquid tank level monitoring system works accurately, effectively and makes bottle filling system process easy, more precise and reliable and is more advantageous than the conventional methods reducing manual efforts, errors and being much efficient. The proposed prototype allows achieving an economical and a low-cost automation. The automation system can be made flexible according to the industrial needs. In case of any breakdown, the system can be easily restored and commissioned upon diagnosis.
5.3 Limitation
It is a demo project so we found some limitation. In future we will work for reduce this kind of limitation. It is a demo project so its accuracy is 99%. Our project may delay in work because it’s a demo project. After filling liquid in bottle there is no option of capping. After counting bottle, we collect the bottle manually.
33 CHAPTER 6
CONCLUSION
6.1 Conclusion:
The main objective of this project was to develop a bottle filling, counting and liquid tank level monitoring system based on certain specifications. This was successfully implemented. We consider this project as a journey where we acquired knowledge and also gained some insights into the subject which we have shared in this report. Arduino was used to control the various operations. More features can be added to this system as follows: depending on the size, shape and weight of the objects, bottle filling, count & liquid tank level monitoring operations can be implemented.
6.2 Future Scope
The model can be improved by making some changes in the program and components. Some suggestions are given below-
• We can add in future, automatic capping system.
• We can add in future, automatic collecting system.
• We can add an IoT automatic monitoring system.
• We will increase its working accuracy level.
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