Slide-2

Our project's main goal is to reduce the time spent in testing the product and reduce the
error correction process. In this project we will be detecting the product height. We can
use the sensor to measure the product height as it is traveling on the conveyor belt.
Sensor can sense the product's height and if it thinks the product 's height is less than
the requirements needed then it will be automatically detected. And, then, the
detected product will be isolated from the conveyor belt by using the conveyor arm.
Here, we use the rollers and the rubber belt for making the moving conveyor belt
motion. And this machine is motor-operated. The proximity sensor we use is a sensor
that detects the defective product having a height lower than its minimum
requirement. So we use valves to isolate the defective component from the conveyor
belt and we use a pneumatic cylinder system on that. With this entire device, the
product is locked in this situation, we can automatically check its scale, shape and
function so that no research department or extra human resources are required to test
the product.

Slide-3,4

Maintenance of quality is one of the essential aspects of making a product. There must
be high class equipment and qualified employees are needed to maintain the standard.
Yet in doing so, commodity cost must go high and can lead to company loss. In any
manufacturing department, quality department is set to overcome such problems and
doing improving tasks. This department's job is to check the product consistency and
quality after it's being made. The product is manufactured and packed in the same line
during automated manufacturing process. Based on the type of product the product
may be of several forms.

While manufacturing of the product or after manufacturing it, if the product doesn’t
meet the specification requirement then it is further considered as the faulty product.
Fault can be anything like its’ weight, size, shape, tolerances, dimensions, operation etc.
It depends on which type of product we are considering.
 Fault detection is the phase in which the faulty component is detected and removed
from the collection so that further it can either be used as raw material or be sent back
for improvement to production process line. Fault detection can be performed by
multiple of techniques using many methods such as batch testing, one-by-one testing or
product checking on the output. Both of these approaches require human resources and
are time consuming. This will lead to financial load to the organization.

Slide-5,6

Material Handling requires that products be moved for production or storage purposes
from one location to another. According to the American Material Handling Society,
material handling is an art and science involving the movement, packaging and storage
of subsystems of any form. Therefore, the material handling function includes all forms
of vertical, horizontal or combined movement of both and all product varieties of fluid,
semi-fluid, and individual items, as well as the movement necessary for packaging and
storage.

Reference [1] suggests the faulty lock detection and separation system .The main objective
of our project is to eliminate the time consumed in testing the product and to eliminate the
process of correcting the mistake. For this project we use Arduino controller, IR sensor,
Ultrasonic sensor, PIR sensor and servo motor to test the product. We use ultrasonic sensor
so that the product can stop exactly below the IR sensor for testing. The PIR sensor senses
the movement of the product. The servo motor is used to run the conveyer belt. Using this
entire instrument, the product in this case lock, we can test its size, shape and working
automatically so the there is no need of any testing department or any extra human
resourced to test the product.

Slide-7,8

A sample block diagram describes the project, in this we have use an IR sensor to detect
the height of the product. On the frame, the entire model structure is mounted by using
different metal plates. And on this, the conveyor belt mechanism is mounted for
movement of the product from one side to another side. And also separation system is
also mounted on the same frame.
 There are different components which are used in making of the project model like 12V
motor, Rollers for conveyor belt mechanism, Rubber belt for better material movement,
Shaft for connecting the rollers, Servo Motor for whole system engagement, Pneumatic
actuator for separating mechanism, Pneumatic Valves for operating the air into the
Pneumatic actuator for separating mechanism, Separator arm for make product opt out
from the conveyor belt, and the main structure on which the whole system is
assembled.

As per figure, the general conveyor belt mechanism is shown. We are using same
mechanism in our project model. In this model we will use two rollers and one rubber
belt and shaft for connecting the rollers. By assembling these together, the conveyor
belt mechanism is ready to use. This mechanism is operated by 12V motor. We can
change the speed of the material movement on the belt as per requirement.
Then Pneumatic system is applied for the defected parts separation.

This actuator is working with the Pneumatic Valve. As valve gives command to this
actuator, with the help of air, the tip of the actuator moves out and press the defected
product and after that it will goes inside. We can attached one separator arm at the tip
of the actuator for separating the product to the specified location. Then we have to
select the proper pipe fittings for the pneumatic system such as pipes, joints etc. we are
using 1mm pipe thickness for our project model. And five way two positioned solenoid
valve is used for operating the pneumatic system. And depending upon the size of the
pipe and size of the valve, we need to choose the fittings accordingly. The dc motor is
used as per the requirements.

Slide-9,10

Then main part of the separator system which enables the pneumatic system is IR
sensor. It is used to detect the height of the product as per the specification criteria
requirement. An infrared sensor is an electrical system that absorbs to detect certain
external elements. An IR sensor can measure an object's heat and can also sense the
motion. Such types of sensors often monitor infrared radiation instead of emitting it
 which is considered a passive IR sensor. The emitter is simply an IR LED (Light Emitting
Diode) and the receiver is simply a responsive IR photodiode with the same wavelength
as the IR LED. Change in relation to the extent of the emitted IR light as IR light lands on
the photodiode, the resistances and these output voltages.

Slide-12,13

The fault detection and separation system starts after the product manufactured in the
production line. This system can be used after the production line. In the inspection area
we can kept this system to inspect the products. Now first of all start with the main
structure frame. This frame is made by the metal plates or channels. This frame must be
carry heavy load because on this structure whole assembly is fitted.
Two rollers are installed on the structure and these two rollers are attached with the
rubber belt as it moves, we can place the manufactured parts on this belt and it moves
from one place to another place. Now in-between, we use pneumatic system in the
structure. In that, the pneumatic valve we can add below or near to the structure and
pneumatic actuator is used almost center of the conveyor system.
We can add one box which collects the defected parts. The defected parts are being
separated from the conveyor belt by the pneumatic actuator. By attached all these
different parts together, we will have one Fault detection and separation system model.

Now as per the actual model we can see in the above figure, the working of this model
starts with the motor. The electric circuit is connected with the DC motor as well as
pneumatic system hence it will be working together. Now, with the help of conveyor belt
mechanism, we put the product which we want to inspect. Then it will pass through the
IR sensor. Now this sensor sense the height of the moving product. We made a
simulation in this sensor that it sense the height and we add the specification criteria for
acceptance of the product height. If the product is being sensed as an acceptance height
then pneumatic system will not enabled. And product moves on continuously on the
conveyor belt to another side without getting separated.
Now if the sensor sense that the product height is lesser than the required specification
criteria than it will directly enable the contact to the pneumatic system.
Now pneumatic system comes into the work as it starts from the pneumatic valve. By this
valve, the electric supply change the position of the solenoid inside the valve and the air
goes to the pneumatic actuator to move the pneumatic cylinder rod comes out. This
pneumatic cylinder rod pushes the detected product to the outside form the conveyor
belt. This cylinder pushes the product into the separator collecting box or bin which is
located exactly opposite side from the pneumatic actuator location. Hence this defected
part is opt out from the conveyor belt and collected on the separator box. Then the
pneumatic valve change the direction of the solenoid and hence the pneumatic actuator
cylinder rod comes in to the actuator shell as its original position.