WIRELESS SENSOR NETWORKS

By
AZKA HAQ NAWAZ

Report submitted for the

Degree of B.E. Electronic Engineering

Department of Electronic Engineering

NED University of Engineering & Technology
University Road, Karachi-75270, Pakistan

2018
“In a changing world, by the time you master the game the rules have
changed.”

–Innu Reno
 WIRELLESLY CONTROLLED
AUOTMATED AUTOMOTIVE PAINT
BAKIN SYSTEM
FINAL YEAR PROJECT REPORT
By

AZKA HAQ NAWAZ

(EL-14104)
FAROOQUE ADIL
(EL-14073)
IRTIZA HAIDER
(EL-14127)
AYMEN BATOOL
(EL-14098)
Batch: 2014-2015
Supervisor:
Hani Hassan Mahmood
Co-supervisor:
Muhammad Amir
2018
Department of Electronic Engineering
NED University of Engineering & Technology
University Road, Karachi-75270, Pakistan
 CERTIFICATE

This project “WIRELLESLY CONTROLLED AUTOMATED AUTOMOTIVE PAINT

BAKING SYSTEM” presented by AZKA HAQ NAWAZ, FAROOQUE ADIL, IRTIZA
HAIDER and AYMEN BATOOL under the direction of their project advisor’s and approved by
the project examination committee, has been presented to and accepted by the NED
UNIVERSITY of Engineering and Technology, in partial fulfillment of the requirements for
Bachelor of Engineering (Electronics).

_____________________ ____________________________
Hani Hassan Mahmood (Project Advisor) (Member)

____________________________ ____________________________
Muhammad Amir (Co-Supervisor) (Member)

____________________________
____________________________ (Member)
Prof. Usman Ali Shah
(Chairman Electrical Engineering ____________________________
Department) (Member)
 DEDICATION

The report is dedicated to our beloved parents, our project coordinators and our supervisor.

i
 Acknowledgements

First of all, would thank almighty Allah for His countless blessings which has enabled to

withstand and overcome the challenges during this project. The supervisor Hani Hassan owes

gratitude for providing the opportunity and guiding through different phases of the work. At

NED University, the Vice Chancellor deserves special thanks. The co-supervisor Muhammad

Amir have always supported and facilitated us.

Among colleagues, it is a privilege to have the company of Sheikh Hassam Moinuddin who

helped us through some of the challenges task. We cherish the time that we have spent

together.

The life in the last year had been preoccupied we were not able to give due time to our

families. We heartily acknowledge our parents for their patience and support. At the end,

there are many more people among the staff of NED University. Thank you all, for what you

have done.

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Contents

DEDICATION.................................................................................................................................................. i
Acknowledgements.................................................................................................................................... ii
Abstract........................................................................................................................................................ vi
CHAPTER 1 Introduction and Background......................................................................................... 1
1.1 Problem Statement:..............................................................................................................1
1.2 Motivation:............................................................................................................................3
1.3 Objectives..............................................................................................................................5
1.4 Challenges Faced:..................................................................................................................6
1.5 Conveyor Belt:.......................................................................................................................7
1.6 Sensor....................................................................................................................................9
1.7 MOTORS:.............................................................................................................................14
1.8 Organization of Thesis.........................................................................................................16
CHAPTER 2 SIMULATION AND ALGORITHM.................................................................................... 17
CHAPTER 3 METHOD AND MATERIAL............................................................................................... 30
3.1 Conveyor Belt......................................................................................................................30
3.2 Sensors................................................................................................................................32
3.3 Robotic Arm........................................................................................................................33
3.4 Furnace................................................................................................................................34
3.5 Keypad and Panel Box.........................................................................................................36
3.6 Controller............................................................................................................................37
CHAPTER 4 IMPLEMENTATION AND RESULTS............................................................................... 38
4.1 Connections and Wiring......................................................................................................38
4.1.1 Block Diagram..............................................................................................................38
4.1.2 Connections of Robotic Arm:.......................................................................................39
4.1.3 Connection of Furnace................................................................................................40
4.1.4 Connection of Conveyor..............................................................................................41
4.1.5 Connection of NRF.......................................................................................................42
4.1.6 Connection of Panel Box..............................................................................................44

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 4.2 Power Supply.......................................................................................................................45
4.3 Working and Mechanism....................................................................................................45
4.3.1 Working of Conveyor:..................................................................................................45
4.3.2 Working of Robotic Arm..............................................................................................46
4.3.3 Working of furnace......................................................................................................46
4.3.4 Working of Panel Box..................................................................................................46
CHAPTER 5 CONCLUSION AND FUTURE WORK............................................................................... 48
5.1 Conclusion.............................................................................................................................48
5.2 Future Advancements.....................................................................................................50
References.................................................................................................................................................. 51

TABLE OF FIGURES

Figure 1-1 Problem in Painting Automobile.............................................................................3

Figure 2-1 keypad with Arduino mega....................................................................................28

Figure 2-2 LCD with Arduino UNO.......................................................................................28

Figure 3-1 conveyor belt..........................................................................................................31

Figure 3-2 furnace structure.....................................................................................................36

Figure 4-1 block diagram of entire system..............................................................................38

Figure 4-2 servo with Arduino mega.......................................................................................39

Figure 4-3 DHT11 WITH ARDUINO....................................................................................40

Figure 4-4 Nichrome coil inside furnace.................................................................................41

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Figure 4-5 NRF Arduino UNO................................................................................................42

Figure 4-6 NRF WITH MEGA................................................................................................43

Figure 4-7 Arduino and keypad...............................................................................................43

Figure 4-8 Arduino and LCD..................................................................................................44

Figure 4-9 power supply..........................................................................................................45

v
 Abstract

The purpose of the project was to implement an efficient, time saving, compact and cost

effective car paint baking system. The tasks were achieved using the knowledge of Arduino

UNO programming as well its interfacing with sensors and actuators. Automation is a great

source for industrial world. We fabricated a prototype model of Wirelessly Controlled

Automated Automotive Paint Baking System. Considering automotive paint baking because

of the reasons that the process of car painting is done automatically by robotic arms which

reduce the time and labour. The wirelessly controlled furnace saves time and it is not

required anymore to paint an automobile by holding fire for the paint to scorch up. The

process is amalgamated on single platform reducing space.

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CHAPTER 1

Introduction and Background

1.1 Problem Statement:

In Pakistan, the worldwide trusted companies of paints, paints the cars providing anti-

corrosive, heavy duty protective coatings. Along with these normal protective coatings, the

powder coatings are also the fragment of their business. This method of enhancing and

protective coating is used by both, the industrialists and the retailers. They use finely

powdered paint which is electrically charged, mixed with resin, is sprayed on the car’s

surface which is electrically grounded.

There is very less amount of these paint companies which paint the cars with all the

precautions, focusing more on the cosmetic appearance and the quality of paint. The issue of

health and care arises. The workers in these automobile industries work with all their efforts

to win the heart by making the car more and more attractive and eye-catching.

The exposure to chemicals, paints and metals is hazardous for human life. The process of car

painting, sanding, metal fabrication, all come with long term serious health dangers. [1]

 The sanding process releases silica which increases the chances for lung cancer.

 Paints and their solvents are prepared with such chemicals which when come in

contact with human body, can increase the risk of cancer.

 Sanding release silicoses that is the silica dust, which can cause permanent damage of

lungs.

1
  The ingredients of the paints and the protective coating spray include such toxins

which causes occupational asthma. Asthma-Isocyanates can be caused by these

painting and polishing products.

The list of problem continues, but there is no way to reduce or minimize these effects on

human life. We cannot change the process of sanding, the texture of sand, or we can’t even

change the products used in paints or protective coating.

Due to these reasons more serious preventive measures are necessary. We have devised a

solution to the said problem. The automatic and wireless system is the only possible solution

that can keep the humans safe from the hazards of these toxins. [2] The human life is the

most precious thing, and to assure them a healthy life we have designed this process.

Before starting work on designed wirelessly controlled automatic car paint baking system, its

key elements were studied like conveyor belt, painting mechanism using robotic arm, heating

in the furnace, controlling by a controller, programming the controller, selecting appropriate

sensors and its different techniques to gain sufficient knowledge in order to meet the

hardware requirements to design automated car paint baking system. [3]

2
 Figure 1-1 Problem in Painting Automobile

1.2 Motivation:

The process, automobile production is an expensive project with every step consuming an

average energy of about 700-900kWh per car bodyi, whose impact is visible in the figures of

the balance sheets. The involvedness of the painting process implicates number of

methodologies to make better use of energy, space and material. There are dozens of

problems in paint industries, so the target is to make an automated and wireless process

controlled paint baking heat oven system. The aim of this project is to make it on a conveyer

belt, with the help of robotic arm which can make it more efficient and economical. The

whole process will be constructed on a single conveyor belt, provided with number of

sensors which sense the body at different spots. The robotic arm is for coating the body of

car, it is programmed in such a way, that whenever the body of car is detected the arm

identifies its axis and according to its axis location, starts painting it. Then the main target of
3
this project is to dry the pain, which is an automated and wirelessly controlled mechanism.

The system will be automated and it will reduce the labour work and whole process is

operated at one place not in parts that is our main objective. Currently, the process of car

painting is being done but with many limitations, which are mentioned below.

 There is a lot of power consumption in these systems operated by industries.

During the whole car processing mechanism, the paint spray booth is the most

sensitive and delicate step, affecting the power consumption the most.

 The whole process is divided in parts and operated in different departments.

So what we want is to sum up the whole painting plus drying process at a

single platform and instead of waiting for the body to get dried.

 Operating this system in parts consumes much time. As the process is

amalgamated onto a single conveyor belt, the process will get automatically

shifted to the drying chamber that is the furnace, which for sure saves the

time. To make the process time efficient, this is the most beneficial automated

wireless controlled mechanism.

 The previous systems are wired, which makes this simple process look

complicated and complex. The wireless keypad system makes it the process

convenient for the technicians.

 In industries, order pickers are used to carry objects (load). So according to

OSH act, the hazardous manual handling at work should be eliminated, as it

causes serious health injuries and back pains.

 In industries, the whole process is operated manually and automatically both,

but we prefer to make the system fully automatic.

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  In automotive industries, the object is not any small sized package; it’s a

whole giant car structure. Presently most of the work is done by labours,

which have to lift these heavy bulky loads. This manual lifting causes serious

injuries, accidents, illness, sick leaves and disabilities.

1.3 Objectives

This project is providing an automated mechanism to paint or repaint the automobile using

robotic arm. It also includes controlling the heat and temperature of furnace (baking oven)

wirelessly using a controller. All the process will be combined on a single conveyor belt. It is

a process control project.

When the structure of the car is placed on conveyer belt, the body will be painted by the help

of robotic arm. As the body is detected, the robotic arm will identify the axis of the body and

paint it. After the body is painted, in order to get dried it will be stepped into the baking oven,

with an automatic front and back door. This furnace is provided with IR sensor

 To build a smart baking oven which is providing a complete process to cure the

coatings and turn the finished paint into a perfect surface.

 To install and extend our existing automobile painting system using the automated

technology.

 To make the car painting process smart

 To implement a less costly system.

 To develop a system based on real time data.

 To develop a process controlled system through wireless communication.

5
  To develop a system that is more accurate.

1.4 Challenges Faced:

The challenges we will face during the implementation of this system are following:

 Calibration of the robotic arm.

 Making and Controlling of robotic arm to paint the desired object is one of the

difficult tasks.

 Temperature controlling.

 To take the temperature to its desired level is arduous.

 Conveyer belt

 Sequential and step-wise performance of conveyer belt is another challenge.

 Painting through robotic arm.

 To paint the object properly with paint nozzle through robotic arm is a challenging

task

 Baking in the furnace:

 It needs to be heated at an appropriate temperature. The heating system is run by AC

source which is a challenging task.

 Wireless panel for controlling the whole process.

Controlling and operating temperature measurements through wireless communication are

big challenges.

6
Another challenge is making algorithms for this whole system using sensors. It is one of

difficult tasks to work with different sensors and make them in properly working condition.

Calibrating sensors and then making of algorithms to operate this system successfully.

1.5 Conveyor Belt:

Figure 1 - shows a conveyor belt system.

Figure 1-2 Conveyor Belt System

It is the basic tool in material handling industry used in transportation of bulk materials. It is a machine

with a moving belt. To move the belt and carry the material forward one or two motors or pulleys are

powered. The powered pulley is called drive pulley and the unpowered one is known as idler pulley. [1]

The machine is made with following parts:

1. BED

The upper surface belt is its bed which can be placed on a stand.

2. Motor

The motor can be placed under and within the conveyor BED. A sprocket is a wheel

with teeth on the outside.

7
 3. Shaft

A pulley like an iron pipe can be placed on end of the bed. Pulley has a steel shaft through it. The shaft

turns on a bearing and the pulley turns with the shaft.

Material of conveyor:

It is manufactured with various materials, specifications, properties and benefits. The

material must be resistant to temperature, moisture and chemicals. The five main materials

that make conveyor belts are:

a) Thermoplastics: It includes polyester, polyvinyl chloride, silicone and

polyethylene. b) Metal: It can be stainless and carbon steel c) Rubber: It is flexible,

resistant, smooth and seamless.

d) Fabric: It is canvas or cotton e) Leather [5]

Function and Usage:

The belt conveyor system operates in a damp and dusty environment. It rotates for 16

hours a day under varying loads depending on the bearings calculated life. It is used

to transport and move large and heavy industrial and agricultural material. A belt

conveyor system transports objects over long distances. The endless conveyor belt is

moved by a drive system. [6] Conveyor systems use conveyor belts with by motors

that continually loop over the material that rotates over them.

8
1.6 Sensor

A device used to detect any change in physical environment and responds according to that

physical input, such a device is called as a sensor. That physical input can be light, pressure,

heat or any other physical environmental phenomenon. The detected output can be a signal

which is a human readable format at the location of sensor or any electronically transmitted

format over a network for signal processing further.

Numerous types of sensors are found in the world, which requires input signal in the form of

any physical phenomenon and produces an output in the form of signals (electrical). The

sensor needs an input device which provides input to the control system.

CLASSIFICATION OF SENSORS

Sensors are classified into many classes in many different ways. A simplest way of

classifying the sensors is discussed below.

FIRST CLASSIFICATION:

In the first kind, the sensors can be classified as active or passive sensors.

1. Active sensors:

When external excitation signal or a power signal is required by a sensor, then such kind of

sensors is called as active sensors.

2. Passive sensors: When external excitation signal or a power signal is not required by

a sensor, then such kind of sensor is called as passive sensors.

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SECOND CLASSIFICATION:

This classification is based on conversion phenomenon, i.e. the inputs and the outputs.

Photoelectric, Thermoelectric, Electrochemical, Electromagnetic, Thermo-optic, etc are some

of the common conversion phenomena.

THIRD CLASSIFICATION:

Analog and Digital Sensors are the final classification of the sensors.

1. Analog output is produced by analog sensors i.e. a continuous output signal with

respect to the quantity being measured.

2. Digital Sensors, work with discrete or digital data. The data in digital sensors, is

digital in nature which is used for conversion and transmission.

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TYPES OF SENSORS:

The following is a list of different types of sensors that are used in numerous applications

commonly. The physical properties like Temperature, Resistance, Capacitance, Conduction,

Heat Transfer etc. can be measured by these sensors.

 TEMPERATURE SENSOR:

The temperature sensors vary from simple ON/OFF thermostatic devices which

switch a domestic hot water heating system to highly sensitive semiconductor types.

The sense the change in the temperature of the surroundings and generate an

electrical signal.

 PROXIMITY SENSOR:

The sensors which detect the presence of any object without the actual physical

contact, those sensors are called as proximity sensors. Now a day, the cell phones use

these proximity sensors to switch the screen off.

 PRESSURE SENSOR:

A pressure measurement of gases or liquids can be measured by using pressure

sensor. A pressure sensor usually acts as a transducer.

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 LIGHT SENSOR:

A light sensor is an electronic device used to detect light. The resistance of a

photocell or photo resistor (these are the light sensors) changes when light shines on

it.

 ULTRASONIC SENSOR:

Ultrasonic Sensors are intended to detect solid or liquid by using sound waves.

 TOUCH SENSOR:

This sensor captures and registers physical touch on an object. It enables an object to

detach touch by an operator.

 TILT SENSOR:

The tilt in multiple axes of a reference plane can be measured by the tilt sensor.

 FLOW AND LEVEL SENSOR:

The rate of fuel injected and the flow rate is measured by the flow and level sensor.

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THE SENSORS IN AUTOMATED PAINT BAKING SYSTEM:

The sensors used for this automated system are used for detecting the object as

well as for detecting the temperature of the furnace.

1. IR SENSOR:

An electronic device, infrared sensor is used for measuring the heat of objects as well

as detects the objects. In this project, the IR sensors are used to detect the motion.

These sensors use only infrared radiations instead of emitting them, so they are called

as passive IR sensor. All objects radiate thermal radiation of some kind, usually in the

infrared spectrum which is invisible to our eyes. These radiations are only detected by

the infrared sensor. The IR led is used as the emitter and the photodiode is the

detector that is sensitive to IR light of same wavelength. The output voltage and

resistances change in proportional to the received light when the IR light falls on the

photodiode.

2. DHT11 SENSOR:

The second sensor which is used to detect temperature and humidity is DHT11. It is a

digital temperature sensor which detects the temperature and humidity and the output

is also digital signal. It is used for high stability and long term reliability. It includes a

resistive sense of wet component and NTC temperature measurement devices

connected to an 8 bit microcontroller.

13
1.7 MOTORS:

An electrical machine that converts electrical energy into mechanical energy is called as

motor.

TYPES OF MOTORS:

The type of technology used in motor determines its application and its dependent cost.

Motors can be AC or DC.

AC MOTORS:

AC electric motors are driven by alternating current. The synchronous motor always runs at

synchronous speed. An electromagnet (rotor) which is magnetically locked with rotating

magnetic field (stator) and rotates with it. The speed of these machines are varied by varying

the frequency (f) and the number of poles (P), as Ns = 120 f/P.

DC MOTOR:

DC motor is the only motor which is driven by direct current. It’s the most primitive version

of the electric motor where rotating torque is produced due to flow of current through the

conductor inside a magnetic field.

SERVO MOTORS:

A servo motor is a rotary actuator which permits a control of angular position, acceleration

and velocity. It makes use of a regular motor and a sensor for feedback. As it is specifically

designed for the purpose so the controller is the most sophisticated part of the servo motor.

14
The simplest servo motors use DC motors and a potentiometer for position sensing and also

use big-bang control that is the motor moves at extreme speed until it stops at the selected

position. In industrial motion control it is not widely used as it can be quite imprecise, but

these kinds of servo motors are widespread in radio-controlled devices such as model aircraft

and toy cars. Some servo motors for industries have both position and speed sensing

controlled through algorithms, which allows the motor to be carried to its position quickly

without exceeding, as the speed of the shaft can also be controlled.

TYPES OF SERVO MOTORS

There are two types of servo motors

 AC servo

High current flows, used in industrial machinery are handled by AC servo.

 DC servo

DC servos are not designed for high currents and are suited for smaller applications.

15
1.8 Organization of Thesis

To make sure that whom so ever in the future picks this report to further implement this

project in a more effective manner we divided this report into five chapters for the ease of

any particular individual in layman terms. Each chapter covers different aspects i.e. of how

this idea was initially implemented, how we have made a difference, and how anybody else

in the future would or could make a positive difference in it.

Starting from First chapter which gives a brief overview and literature review of how we

were motivated with the idea of making a FYP that would not only cover the learning of

entire bachelors, but if necessary it would be a near to perfect solution for preliminary use.

Second chapter covers the simulation of project and programming and particular software

needed to interface things in all in one manner.

As the idea starts to make sense so does the study of things required to put in the system, so

third chapter covers the study of methods and materials that were required to cover all

possible aspects needed to make this system.

Fourth comes with the implementation and results which by its name concludes that this

chapter would cover the explanation of how this task was performed and what aspects were

covered.

Fifth chapter covers conclusion and future advancements.

16
CHAPTER 2

SIMULATION AND ALGORITHM

For Arduino Mega:

17
Arduino IDE was used as software for code programming. The algorithms of code

development are mentioned as shown in this chapter.

18
19
20
21
22
For Arduino UNO

23
24
25
26
27
Simulations can be tested on Proteus Software by downloading Arduino libraries.

Figure 2-2 keypad with Arduino mega

Figure 2-3 LCD with Arduino UNO

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29
CHAPTER 3 METHOD AND MATERIAL

In this chapter we have briefly discussed the approach towards the construction, setup,

working and techniques we applied to paint an automobile without waiting for days to dry

up, which was our target. We will discuss all the parts we used, along with their

measurements, materials, structure and the reason behind their selection. There are number of

options which could be used as the substitute but we choose the most consistent and the most

reliable materials, to make this the best way to paint and bake the automobile and to make

the whole process wireless.

3.1 Conveyor Belt

3.1.1 Material of the conveyor belt:

The material of the conveyor was the big target for us, not only to bear the weight of

object, but to resist heat of the furnace too. Our objective was to find the best heat

resistant material which could be used as the conveyor belt. We had many options for

the belt, which includes rubber tube which is used in tires, hard plastic which is used

in utensils, aluminium sheet and leather. The best among them was leather textile

fabric. Leather was chosen because leather can bear high temperatures and is easily

available product too.

3.1.2 Material of Base:

The conveyor structure should be strong enough to carry the entire load, the motors

and all the rest of the components. We had options like, steel, iron, plastic and wood

to use as the base material of the conveyor’s structure. Among all these materials,

30
 wood is the best one as iron and steel were although strong enough but they’ll get

heated at a quicker rate. We used wood as the base material of conveyor and the sides

of the structure is made of acrylic sheet along with the top too.

3.1.3 Measurement of Conveyor:

As the prototype of conveyor consists of robotic arm, sensors, and furnace so it

should be of standard size. After all the measurements and the parts placement it was

decided that the conveyor should be 3 feet long. 3 feet is the best size for the

conveyor, as it has to stop at different spots.

3.1.4 Assembling of Conveyor:

After constructing the base of conveyor in the proper size, we find the perfect

material for the conveyor belt. Now to join the different parts of conveyor we used

screws at the joints. For the movement of conveyor we used two motors, each of 12

volts. The purpose of conveyor is to convey the object that is the car from one

position of the belt to another one.

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3.2

Figure 3-4 conveyor belt

Sensors

3.2.1 Number of Sensors:

As the objective of our project was to place an object on the conveyor belt to be

painted by the robotic arm. There was need for sensors, which will detect the object

when it comes near the mechanical arm. IR sensors are used at different positions of

the conveyor. Three VEE00051 IR sensors are used.

 The purpose of first IR sensor is to detect the object and to start the motors of

conveyor.

 The purpose of second IR sensor is to detect the object and to stop those

motors.

 Third IR sensor is placed near the door of the furnace. When the sensor

detects the object near the furnace, the motors of conveyor stops and the door

of the furnace opens.

3.2.2 Purpose of sensors:

To detect object at different spots on the conveyor belt, we used IR sensors. The first

sensor is placed to detect the object and turn the conveyor on. The conveyor belt stops

at two locations, for that purpose two more IR sensors are used. The second sensor,

32
when detects the object, stops the motors of the conveyor. The third sensor is placed

before the furnace. That sensor IR sensor when detects the object, it stops the motors

and then the doors of furnace opens. So in this way three sensors are placed at

different positions for different purposes.

33
3.3 Robotic Arm

3.3.1 Degree of Freedom:

Degrees of freedom, in a mechanics context, are specific, defined modes in which a

mechanical device or system can move. The number of degrees of freedom is equal to

the total number of independent displacements or aspects of motion.ii The robotic arm

we used has three points at which it can move about.

3.3.2 Number of Motors Used:

The robotic arm has three high speed Metal Gear Servo i.e. MG995 as shown in

figure 3.3, which can rotate approximately 60 degrees in each direction.iii. It has an

operating voltage of about 4.8V a 7.2V which is suitable for painting purpose.

3.3.3 Structure of Robot:

The structure of robotic arm is purely metallic. The body of mechanical arm is made

of metal along with a protective coating. The parts of robot are joined together by the

help of screws.

3.3.4 Material of Robot:

On the front top there is a metal claw on which the paint nozzle is fixed. The three

metal gear servo motors are present at three different locations on the arm. The whole

stand of the arm is made of metal while the base if of acrylic sheet.

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3.4 Furnace

3.4.1Material of Furnace:

Our target for the furnace was to find any material that that can bear up to hundreds

of degrees of temperature. The survey showed what a number of materials are

available in the market that can be used to construct furnace. We used metal sheets

for the top and side layers of the furnace. And the doors of the furnace are constructed

by acrylic sheet covered with the hard board.

3.4.2 Structure of Furnace:

The furnace is a cuboids shaped metal body fixed on the conveyor. The structure of

the frame is constructed in such a way, that the doors can fit easily with the frame and

the mechanism of furnace door opening and closing can be performed easily.

3.4.3 Motors of Furnace:

The motors which are used for the furnace door are 4 pole stepper motor, found

normally in CD ROMS. The main motor is the stepper motor but its driving

requirements are complicated.

3.4.4 Measurement of Furnace:

The length height and width of the furnace is 9, 10 and 6 inches respectively. It is

designed by a metallic body which can resist high temperature.

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3.4.5 Temperature of Furnace:

The temperature range of the heating element is 120- 150 degree. This temperature is

perfect for the paint of the car’s structure to dry it up. We require a small range of

temperature, up to 40 degrees.

3.4.6 Heating Element:

For the heating purpose, the metal wire is used. Metal wire normally used

domestically for heating water, water heaters, kettles or boilers are hollow metallic

coiled wires. These wires use Nichrome because of its high resistance and it forms a

layer of chromium oxide when first time it is heated

3.4.7 Sensors:

A sensor is used in the furnace. The purpose of sensor is to sense the current

temperature of the furnace, and to send that temperature to the LCD. Temperature

sensor DHT11 is used for temperature sensing. Capacitive humidity sensor is used by

this sensor to measure the surrounding air.

3.4.8 Relay Module

Arduino relay module is used for the heating element of the furnace. The high voltage of the

heating element is controlled by the module. The relay which is a switch basically is

electrically operated by the electromagnet, which needs 5 volts to be activated.

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 Figure 3-5 furnace structure

3.5 Keypad and Panel Box

3.5.1 Model of Keypad:

To enter the desired temperature a 4x4 27899 keypad is used. The matrix keypad

which is normally seen on microwaves, calculators, gas stations, is used by the user to

set the temperature required for the paint drying purpose. This temperature should be

in the temperature range of the heating element. The temperature should not exceed

the range; otherwise it will take more time to dry or may cause damage to the object.

3.5.2 Model of LCD:

The chosen temperature will be displayed on the LCD. For the display of the

characters a 16x4 LCD is used. The model number of LCD is 016N004b. the

displayed temperature will be achieved by the heating element. As soon the desired

temperature is achieved, the coil stops working.

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3.5.3 NRF

NRF24L01 is used for the wireless communication between the transceiver and the

receiver. It uses 2.4GHz band with range up to 100 meter if it is used in open space.

NRF is an embedded system which is used to communicate between two devices

wirelessly.

3.5.4Purpose of Panel Box:

The transmission of the desired temperature from the user via keypad to the LCD will

be done through a wireless channel. The purpose of this panel box is to set the

furnace temperature to start the functioning of heating element.

3.6 Controller

Two Arduino overall are used in this whole project.

1. For the furnace ATmega328 is used. It is Arduino UNO which has total 14

analogue/digital and 6 pins are analogue input pins.

2. For rest of the process, microcontroller ATmega1280 is used. The Arduino

mega is the board which is based on this microcontroller. It has 16 PWM pins

which are digital input/output pins and 16 analogue pins.

With the first Arduino, the heating element, the temperature sensors, the LCD and

the NRF is connected. While with the Arduino Mega the three IR sensors, the robotic

arm, the keypad and the motors of conveyor are connected.

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CHAPTER 4

IMPLEMENTATION AND RESULTS

4.1 Connections and Wiring

4.1.1 Block Diagram

ROBOTIC ARM

Figure 4-6 block diagram of entire system

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4.1.2 Connections of Robotic Arm:

The robotic arm is built in a way that it can bear the weight of the painting nozzle. There are

three servo motors joined at the three joints. The servo motor MG995 is used for the arm’s

movement, which has three pins. The red wire is the Vcc one, brown one is the ground wire

and the orange one is the PWM wire. Three power supplies of 5 volts are used to power each

motor.

Figure 4-7 servo with Arduino mega

In the same manner as shown in Figure 4-8 three servos of robotic arm are controlled through

Arduino.

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 Figure 4-9 DHT11 WITH ARDUINO

4.1.3 Connection of Furnace

The furnace has following three components attached;

i. Motor driver: the motor driver is used for the doors of the furnace. The four pole

stepper motor is connected to the motor driver. The 12 volt adapter is used for power

and the motor is connected to the motor pins of motor driver.

ii. Temperature sensor: the temperature sensor, DHT11 is used for measuring the

accurate temperature of the furnace. It has three output pins. The Vcc, ground and

data pin. Vcc and ground are connected via Arduino and the data pin is connected to

the analog pin of Arduino.

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 iii. Heating coil: the nichrome coil has two output pin terminals. One is connected to

relay and other is connected to the ground of 220 v ac. While the 220 v is connected

in relay at normally open pin.

The connection of Arduino Uno to DHT11 can be seen in Figure 4-10 and heating coil is

shown in Figure 4 -11

Figure 4-11 Nichrome coil inside furnace

4.1.4 Connection of Conveyor

For the conveyor belt, a DC motor of 24V is used on one side only to run the belt. The motor

has two wires, one is connected to the relay and one is connected to the ground. As the

conveyor has to turn off at many stations so the relay is used which is powered by a 12 volts

adapter and the ground of motor and relay are common. As the relay needs 5 volts input, so

the voltage regulator LM7805 is used to convert 12 volts input into 5 volts. One pin of motor

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is connected to relay at normally close pin and other is connected to the ground of 12V while

the 12V is connected in relay at normally open pin.

4.1.5 Connection of NRF

Figure 4-12 NRF Arduino UNO

Two NRF are used for the wireless communication between the user controlled keypad and

the display screen LCD. One NRF is connected to the Arduino UNO along with LCD and the

other NRF is connected to the Arduino Mega. 3.3 volt input is used to power each NRF. The

rest of the pins of NRF are connected to the digital pins of Arduino with a common ground.

In Figure 4 -12 it is shown how nrf connected to UNO and in Figure 4 -13 how nrf

connected to Mega.

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 Figure 4-13 NRF WITH MEGA

Figure 4-14 Arduino and keypad

4.1.6 Connection of Panel Box

The LCD is connected to the Arduino UNO along with the heating coil, and the temperature

sensor. Whereas the keypad is connected to the Arduino Mega along with the IR sensors and

the robotic arm.

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 Figure 4-7 shows keypad connected to Arduino mega and Figure 4 -15 shows the

connection of LCD to Arduino UNO.

Figure 4-15 Arduino and LCD

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4.2 Power Supply

Power supply is used for robotic arm. Three power supplies each of 12 volts is used for the

three motors of the robotic arm. Diodes, LM7805 and capacitors are used with a three

ampere, 24 volts transformer for designing the power supply such as the circuit shown in
Figure 4-9

Figure 4-9 power supply

4.3 Working and Mechanism

4.3.1 Working of Conveyor:

The conveyor belt is powered by the help of adapter, which converts 220V to 12V.

The relay module plays the most important part here. The purpose of switching is

performed byte switches. The start and stop of the conveyor cannot be done without

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 relay module. Whenever the object gets detected, the mechanism of switching is done

by the relay module.

4.3.2 Working of Robotic Arm

When the object is detected by the second sensor, the conveyor stops. At this stage,

the robotic arm has to paint the object. The arm has three motors; they can move 60

degree in each direction. Firstly, the middle motor works. It moves five times from

left to right to paint. Then the motor at top that is the third motor moves similarly five

times up and five times down to complete painting the object.

4.3.3 Working of furnace

When the object gets detected by the third sensor, the conveyor stops for the second

time. Now the door of the furnace opens. When the door opens completely, the motor

starts again, and the object moves into the furnace and the door closes again. Now the

user will set the suitable temperature of the furnace. That temperature will be

achieved by the heating coil. As that temperature is attained, the heating coil stops

working. The back door of the furnace opens and the object leaves the furnace. In this

way the paint of the object gets dried up in the furnace.

4.3.4 Working of Panel Box

To dry the paint of the object, it is necessary to give a perfectly suitable temperature at which

the paint can dry. It is up to the users, what temperature they may give. To give the input

temperature a 4x4 keypad is present in this system. As the temperature will be, it will be

shown on the LCD and at the same time the heating of coil starts. The temperature of the coil
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increases and reaches the given temperature. Two NRFs are present at the transmitter side

and at the receiver side. The NRF connected to the Arduino UNO will send the signal to the

second NRF of Arduino Mega. In this way we can control the temperature through a wireless

channel.

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CHAPTER 5 CONCLUSION AND

FUTURE WORK

5.1 Conclusion

The objective of this task was to develop and implement a working prototype of an

automated wirelessly controlled automobile paint baking system. By the grace of Allah, we

are successful.

The main aim of undertaking any project is to learn something new and achieve something.

These achievements are not only related to technical aspects, but to behavioural and cultural

aspects as well.

When we first picked up this project we did not had much of the idea of wireless interfacing

but we had many goals in our mind that we wanted to achieve and most of all we wanted to

achieve something big, meaningful and yet useful. As we started to learn about how wide is

the field of wireless communication and how much it is useful to so many applications, it

became quite clear enough to us that yes it may not be an easy language to learn, but it is

indeed a language which was fun to learn.

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As we get near towards to finishing our report, the conclusion to it is definitely positive. We

all wanted to learn a few parts from something new, instead we learnt more than our own

expectations.

With each result from testing of Arduino for the first time to the end of completing an entire

circuit and body of the project, the results worked out fine. The conveyor works very smooth

and the object detection at different instants was also done finely. The painting and the

furnace parts took the longest time, as there were number of things which had to be

compiled and we want perfection in every single step.

Similarly the task to set the temperature via wireless channel was a big difficult task for us to

achieve but by the help of such modules we communicated the signals without any

distortions.

That being said this project is easily applicable to any small or big car painting shop. If it’s a

big room or an office then place two of them rather than one. Not only because they are

automated but also they are powerful and timesaving.

We would like to conclude our achievements and lessons as follows:-

1) There was a very good practice of completing the task within the allotted time as this

prepares us for the practical life.

2) We learnt how to work as a team and how a team functions.

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 3) It boosted our self-confidence both within ourselves and in our project mates.

4) It improved our imagination and designing abilities.

5) The project enabled us to gain technical knowledge of devices and components which

were previously unknown to us.

5.2 Future Advancements

In future the work will be done on painting mechanism through robotic arm. Using

MATLAB or any software image processing will be achieved to paint accurately. Axes and

cursors will be set for proper directional paint of car.

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 References

[1]http://m.durr.com/fileadmin/user_upload/duerr/de/pdf/praesentationen/

120427_Du_PFS_Eco_Paintshop_EN_low.pdf

[2] https://whatis.techtarget.com/definition/degrees-of-freedom

[3]http://www.electronicoscaldas.com/datasheet/MG995_Tower-Pro.pdf

[4]https://raymondhandling.com/dictionary/belt-conveyor/

[5]https://www.conveyorbelting.net/conveyor-belt-materials/

[6]https://www.thomasnet.com/about/conveyor-systems-18890608.html

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