PORTABLE DRAGON FRUIT GRADE SORTER

(POWER SUPPLY AND STRUCTURE DESIGN)

NOOR RAFIZA BINTI RAMLI

May 2008

“I hereby declared that I have read through this report and found that it has comply

the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering

(Power Electronic and Drive)”

Signature : …………………………………

Supervisor’s Name : PN. ALIZA BINTI CHE AMRAN

Date : …………………………………

PORTABLE DRAGON FRUIT GRADE SORTER

(POWER SUPPLY AND STRUCTURE DESIGN)

NOOR RAFIZA BINTI RAMLI

This Report is submitted in Partial Fulfillment of Requirements for The Degree of

Bachelor in Electrical Engineering (Power Electronic and Drive)

Faculty of Electrical Engineering

Universiti Teknikal Malaysia Melaka

May 2008

ii

“I hereby declared that this report is a result of my own work except for the excerpts

that have been cited clearly in the references.”

Signature : ………………………………

Name : NOOR RAFIZA BINTI RAMLI

Date : ……………………………….

iii

Dedicated to my beloved parents …

iv

ACKNOWLEDGMENTS

Assalamualaikum warahmatullahi wabarakatuh,

First and foremost, I would like to thank to Allah the Almighty for blessing me

to complete my Project Sarjana Muda 1 and 2. I would like to enlarge my appreciation to

my supervisor, Pn.Aliza binti Che Amran because of her kindness heart to accept me as

one of the student under her supervision. Special thanks also dedicated to her for all

comments, idea, and a guideline begin from the first day I start doing this project.

I would also like to thank to all my friends that always give support, opinion, and

advices for me to complete this report especially my project team members Nur Azlina

and Mohd Hidayat.

To my family especially my beloved parents; Hj.Ramli and Wan Zainun, I would

like to forward my obliged for their continuous support during my study period, their

patience and benevolence. Lastly, I would like to thank to everyone who has contributed

during my Project Sarjana Muda 1and 2. Your kindness and cooperation in completion

of my paper work is much appreciated.

Thank you very much!!!!!

v

ABSTRACT

This project focuses on building a Power Supply and Structure Design for Portable

Dragon Fruit Grade Sorter. This Portable Dragon Fruit Grade Sorter machine is an

automatic machine that used to sort the dragon fruits according to their standards, grade

and size. Sorting and grading process were done based on various criteria such as

weight, shape and size. This project combines the knowledge of electrical and

engineering drawing. This project is divided into three stages. The first stage is to design

an adaptor to supply the system from 240Vac. Also to propose the best structure or

design for the machine and then try to assemble the machine parts into one system using

SolidWorks software. Hence, by using the Portable Dragon Fruit Grade Sorter

machine, the human errors that always occurred in manual operations can be minimized

and most important of all, number of human labor is reduced thus making the production

more efficient and productive.

vi

ABSTRAK

Projek ini berfokus pada binaan unit sumber bekalan kuasa dan struktur-struktur binaan

mesin untuk Mesin Pengasingan Buah Naga Mengikut Gred Mudah Alih. Mesin ini

adalah mesin kawalan secara automatik yang digunakan untuk proses pengasingan buah

naga merujuk pada piawaian, gred, dan saiz. Proses mengasing dan menggred buah naga

berdasarkan pada beberapa ciri-ciri seperti berat, bentuk dan saiz. Projek ini

menggabungkan pengetahuan asas tentang elektrikal dan lukisan kejuruteraan. Projek ini

terbahagi kepada tiga peringkat. Pada peringkat pertama, merekabentuk pembekal kuasa

yang sesuai untuk membekalkan kuasa voltan serta arus yang cukup daripada 240 volt

AC kepada voltan DC yang berlainan bergantung kepada bahagian unit sistem tersebut.

Di samping itu, turut mengutarakan idea untuk struktur rekabentuk binaan mesin yang

terbaik dan menghimpunkan bahagian-bahagian mesin tersebut di dalam suatu sistem

menggunakan perisian SolidWorks. Dengan itu, dengan menggunakan Mesin

Pengasingan Buah Naga Mengikut Gred Mudah Alih, kesilapan yang sering dilakukan

oleh manusia dapat dikurangkan dan yang paling penting penggunaan tenaga kerja

manusia dapat dikurangkan. Demikian menjadikan pengeluaran buah naga lebih cekap

dan banyak.

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CONTENT

CHAPTER TITLE PAGE

TITLE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF APPENDICES xiv

I INTRODUCTION

1.1 Introduction 1

1.2 Problem Statement 3

1.3 Project Objectives 3

1.4 Project Scope 4

1.5 Project Methodology 4

1.6 Thesis Outline 7

viii

II LITERATURE REVIEW

2.1 Introduction 9

2.2 Introduction in Fruit Sorting System 10

2.3 Latest Technology in Sorting Fruit Process 12

2.3.1 OMI Pineapple Sorting Machine 12

2.3.2 Compac In Vision 5000 Blemish Sorting 13

2.3.3 AWETA GS: The Cup Grader 14

2.3.4 AWETA GS: computer cucumber sorting 15

machine

2.4 Example Existing Machine Design 16

2.4.1 Rotary Cylinder Sizer 16

2.4.2 Citrus Juice Extractors 16

2.4.3 The Cherry Kg Grader 17

2.5 Introduction to Linear Power Supply 18

2.6 Introduction to Full-wave rectifiers 19

converting ac-dc

2.6.1 The Bridge Rectifier 21

2.6.2 The Positive Half-cycle 22

2.6.3 The Negative Half-cycle 23

2.7 Introduction to Solidworks Design CAD 24

software

III PORTABLE DRAGON FRUIT GRADE SORTER

3.1 Introduction 25

3.2 The Fruit Sorting System 25

3.3 System Concept and Algorithm 27

3.3.1 Station 1: Loading Process 27

3.3.2 Station 2: Sorting Process 28

3.3.3 Station 3: Storing Station 29

3.4 Design Phases for the Machine 29

ix

3.4.1 Formulation 30

3.4.2 Concept design 30

3.4.3 Configuration design 30

3.4.4 Parametric design 31

3.4.5 Detail design 31

3.5 The Linear Power Supply for the portable 31

dragon fruit grade sorter machine

3.5.1 0-30vdc stabilized power supply with 32

current control 0.002-3A

3.5.2 Technical Specifications-characteristics 32

3.5.3 Features 32

3.5.4 Circuit operation 33

3.6 Exalibur Low-noise High-speed precision 36

Operational amplifier

3.6.1 Introduction 36

3.7 Complementary Silicon Power Transistor 39

2N3055 (NPN)

IV RESULTS AND ANALYSIS OF DESIGN ASPECT

4.1 Introduction 40

4.2 Design Specification 40

4.3 Design Concept and Design Comparison 41

4.3.1 First Concept 42

4.3.2 Second Concept 43

4.3.3 The Result Analyzing and Concept Evaluate 46

4.4 Analysis for the 12VDC power supply 47

4.5 Problem Occur From the Stabilized Power Supply 48

4.6 The Hardware Configuration of stabilized Power supply 51

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V CONCLUSION

5.1 Conclusion 52

5.2 Recommendation 52

REFERENCES 54

APPENDIX A - G 56 - 83

xi

LIST OF TABLES

NUM. TITLE PAGE

1.1 Difference types of dragon fruit weights and sizes 2

3.1 Fruit Grade Truth Table 28

xii

LIST OF FIGURES

NUM. TITLE PAGE

1.1 Hylocereus undatus 1

1.2 Hylocereus polyrhizus 1

1.3 Project methodology 5

2.1 Fruit sorting machine vision 10

2.2 User control console 11

2.3 CCD Camera and Weight Sensor 12

2.4 Channelizer 12

2.5 Apple weighting (Single Line Sorter) 14

2.6 Baggers interfaced to Compac 4 lane 14

2.7 Apple 8 lane pre-grade line with InVision 5000 Blemish grading

System 14

2.8 Fruit grading line 15

2.9 The cup grader 15

2.10 Cucumber sorting tray 15

2.11 Rotary cylinder sizer 16

2.12 Citrus Juice Extractors 17

2.13 The Cherry KG Grader 17

2.14 Diagram of Simple Series Power Supply 18

2.15 Basic diagram of rectifier conversion 19

2.16 Full-wave rectifier circuit using two-diodes 20

2.17 The Diode Bridge Rectifier 22

2.18 The Positive Half-cycle 22

2.19 The Negative Half-cycle 23

xiii 2.20 Full-wave bridge rectifier (a) alternative presentation

(b) Voltages and current 23

2.21 The Solidworks software user interface 24

3.1 Whole system 26

3.2 Loading Station 27

3.3 Five phases of design, emphasizing the crucial nature of design

problem formulation 29

3.4 Schematic diagram 34

3.5 Symbol for TLE2141 37

3.6 TLE2141 op-amp 37

3.7 Block Diagram of TLE2141 38

3.8 Power Transistor 2N3055 (NPN)

4.1 Design for first concept 42

4.2 Flowchart of the sorting process 42

4.3 Design for second concept 43

4.4 Front view of the design 44

4.5 Back view of the design 44

4.6 Top view of the design 45

4.7 Components part 45

4.8 Circuit for 12vdc motor 48

4.9 Waveform of 12VDC motor 48

4.10 Revised circuit for TLE2141 operational amplifier 50

4.11 Modified circuit for 0-30vdc stabilized power supply 50

4.12 The electronics components placed on the printed circuit board 51

4.13 Overall view of the stabilized power supply 51

xiv

LIST OF APPENDICES

NUM. TITLE PAGE

A Gantt chart 56

B Instruction to use the Solidworks software 58

C Component List 66

D Circuit for 0-30vdc stabilized power supply 68

E Operational Amplifier (TLE2141) 70

F Operational Amplifier (TL081) 74

G Power Transistor 2N3055 82

1

CHAPTER I

INTRODUCTION

1.1 Introduction

Malaysia is blessed with good tropical climate. Besides fruits, many crops

can be grown here like rubber, oil palm, paddy and cocoa. One of the most recent

newcomers in the Malaysian fruit industry is dragon fruits (Hylocereus polyrhizus).

After many trials and errors, dragon cultivation has made its way in the Malaysian

fruit industry. The local name for dragon fruit is „buah naga‟ or „buah mata naga‟.

The dragon fruit growing areas are in the states of Johor, Perak, Negeri Sembilan,

Pahang, Pulau Pinang and Sabah [4]. The fruit comes in three types, all with leathery,

slightly leafy skin which is white flesh with pink skin (Hylocereus undatus), red

flesh with pink skin (Hylocereus polyrhizus) and white flesh with yellow skin

(Selenicereus megalanthus) [5] . But only two types of variety can be grow in

Malaysia which is the red and white flesh. Figure below show the two variety types

of dragon fruit:

Figure 1.1: Hylocereus undatus Figure 1.2: Hylocereus polyrhizus

2

Dragon fruits have different weights and sizes. Table 1.1 shows the different

weight and grade of the dragon fruit:

Table 1.1: Difference types of dragon fruit weights and sizes.

GRADE WEIGHT

AA 601gm and above

A 451gm – 450gm

B 356gm – 450gm

C 350gm – 250gm

D 250gm and below

For this project its combines the knowledge of electrical and engineering

drawing in designing the Portable Dragon Fruit Grade Sorter. This project is to

design an automatic machine that used to sort the dragon fruits according to their

standards, grade and size. Sorting and grading process were done based on various

criteria such as weight, shape and size. This project is divided into three stages. The

first stage is to propose the best design for the Portable Dragon Fruit Grade Sorter

Machine in low cost but still effective. For the second stage, to design and assemble

the machine parts into one system using the SolidWorks software. For the last stage,

to design and develop an adaptor to supply the system from 240Vac to the desired

input value for the actuator, motor and sensors.

For the power supply design, a linear high quality power supply with a

continuously variable stabilized output adjustable at any value between 0 and

30VDC is build. The circuit also incorporates an electronic output current limiter that

effectively controls the output current from a few miliamperes (2mA) to the

maximum output of three amperes that the circuit can deliver. [9]

3

1.2 Problem Statement

In Malaysia, the fruit grade sorting is based on shape, weight, or size. Fruit

sorting is still in the initial stage and most of the sorting process still done manually.

Currently, the manual sorting is more popular and cheaper where the process is done

by a number of labors. Automatic fruit grading and sorting has not been implemented

widely for this type of fruit. The process is time consuming and error prone as human

labor efficiency and consistency will decrease with time. To overcome this problem,

the Portable Dragon Fruit Grade Sorter is proposed. Grading is done on several of

criteria like weight, shape, size and etc [6]. This machine is designed to overcome the

human error and reduce labor work in a short time and the design will not be fully

automated, but can sort the fruits in a short time with less number of labor works.

The main advantages of the present machine is it will facilitate automatic grading

and sorting of dragon fruit in a non destructive method. The purposed machine is

cheaper compared to other existing machines where robotic arms are used and cost

around RM500, 000 per unit depending on its performance.

1.3 Objectives

The objectives of the project that need to be accomplished are:

1) To propose the best design for the Portable Dragon Fruit Grade Sorter

Machine in low cost but still effective.

2) To design and assemble the machine parts into one system using the

SolidWorks software.

3) To design and develop an adaptor to supply the system from 240Vac to

the desired input value for the actuator, motor and sensors.

4

Literature review

Determine the objectives of the project.

Identifying problem and study the system.

Research about the project throughout resources

like internet and books.

Discussion among team members, supervisor and from

experienced person

1.4 Scope

In this project, the scope is based on three main parts. The first scope for this

project starts with conducting research on information for example fruit grading and

sorting, to get the basic idea to design the sorting machine. The second scope is, after

find the best structure design for this project try to assemble the machine parts into

one system using SolidWorks software. Then for the last scope, it follows with

designing a power supply for the motor, actuator and sensors then simulate the

circuit using Proteus‟s Lite software. The power supply is then built and be part of

the sorter machine.

1.5 Project Methodology

In order to complete this project, a necessary project planning should be

arranged. For this project, there are several steps should be taken to achieve the

project‟s scope and objectives. Basically, Project Methodology defines the planning

process flow and principles that are essentials guide to produce a well planning

project. Besides, selected approach or methodology will be described the activities

that may do in every stage. The requirements that are requisite in this system will be

explained in project requirements and followed with project schedule and milestones.

The flow chart that describes the methodology for this project is shown in the

flow chart below:

Start

5

End

Engineering Drawing Design

Simulate the circuit using Proteus software

Construct the circuit

Find the best structure design

Assemble the machine parts into one system

using SolidWorks software

Build the structure design using suitable

material

Yes

Figure 1.3: Project methodology

1) Literature review

The first stage for completing the final year project is determining the

objectives of the project and identifying the problems for this project and

study the system. Besides, doing the research and finds information that

related to the project through out resources such as internet, books and etc.

By doing this literature review, the high understanding of the project can be

achieved

Troubleshooting

Power supply design

Circuit operate correctly?

6

2) Discussion

After gather all the information and identifying the problem, discussion

among team members and supervisor is important. In this stage, supervisor

will give the explanation and guideline throughout the project.

3) Engineering Drawing Design using SolidWorks.

The next step is find the best design for the main structure of the machine and

then tries to sketch the design machine. The designs parts including sorting

system design, power supply, computer system and etc. Learn about

SolidWorks software and assemble the machine parts into one system.

4) Power supply design

Find the suitable circuit design for adaptor to supply the system from 240Vac

and simulated the design using Proteus‟s Lite software. After the simulation

is complete, the circuit for the power supply will be constructing along with

the troubleshooting process.

5) Build the machine structure

The design parts for the structure are complete and the machine structure

needs to be done. Doing some research among team members and supervisor

for choosing the best material for the structure.

6) Build the adaptor supply hardware.

By completing the simulation on Proteus‟s Lite, all the data and analysis had

been retrieved. The circuit is build using printed board.

7) Analyzed the results of simulation and hardware.

After complete the hardware, the output will be observed and analyzed so that

a comparison can be make to see any differences between the simulation and

actual output.

7

1.6 Thesis Outline

Chapter 1 is basically the introduction part of the project chosen. In this

chapter, the project background and problems statements will be discussed clearly.

Besides, elaboration on the project objectives and project scope will be explained in

details so that a better view of the project can be obtained. The project methodology

is the most important part that describes the flow of the project, also be mentioned

and elaborated in details in this chapter.

In chapter 2, the literature review of the project will be discussed. The

literature review is the method for collecting information regarding the machine, and

the result based on the information will be analysis and examine for the purpose to

know the benefit or the scarcity of the machine. In this section, it will be discuss

about the theory and concepts that is accordingly to the project in details. Also, it will

inform about the perspective and method that have been using in this project. The

information for this project according: 1) Introduction in fruit sorting and grading

system. 2) The latest technology in fruit sorting and grading process. 3) Example

existing design from the fruit sorting machine application.

In chapter 3, the methodology is the method and tools that used to achieve the

objective and the goal of the project. In this chapter, a few methods have been chosen

to get the good solution for all the problems in sorting the dragon fruit. This chapter

explains and elaborates about the methods, material and tools used to create this

project and reasons of choosing such methods and tools. Problems arises in the

methods used are also discussed.

In chapter 4, it will discuss about the design specification, design concept and

design comparison of the sketch design. The design specification is one of the

method need for designing a new product. In this chapter also will be discussed about

the 0-30VDc stabilized power supply experiments results and data collection. The

simulation and experimental results of the project will be analysis and discuss.

8

In chapter 5, the conclusion and necessary recommendation will be

highlighted. The recommendation that recommend by the author will be useful for

the final year project next semester.