designing and manufacturing a machine for removing rusted objects using ultrasonic waves

We have effectively integrated ultrasonic technology with the notion of recycling materials used in factories by proposing the idea of using ultrasonic to clean the rusty materials in or

OVERVIEW

Introduction

Today, industrial production is making great strides, along with the need for technical means to maintain systems During the maintenance process, one of the most important parts is cleaning equipment and machines that are rusted or have impurities stuck to them

Traditional cleaning technologies (manual cleaning) no longer meet the new requirements, such as cleaning equipment with complex structures, many small nooks and crannies, which can scratch the pestle machinery and equipment due to unwanted mechanical impacts Therefore, the ultrasonic cleaner was born to overcome the above disadvantages

Figure 1 1 Industrial Ultrasonic Washing Machine

Target

Using the Arduino Uno microcontroller to control the power circuit system, calculate the appropriate power for the rusted object to be cleaned.

Research content

Survey of ultrasonic cleaners available on the market

Summary of theory about ultrasonic washing machines, components related to washing machines

Choose a power circuit and pulse generator design option that is consistent with your abilities and theoretical knowledge learned

Select the frequency appropriate to design needs and the impact of frequency on cleaning ability.

Limitation

Research and manufacturing washing machine capacity of 36 liters, using ultrasonic wave generator with frequency 40kHz , power of 240 Watt

Control the blocks using Arduino Uno microcontroller

The control system allows the user to control and monitor the working system on webserver.

Research Topics And Range

Examining the various kinds of rusted materials that are appropriate and can effectively enhance the cleaning power of the machine

Sstudying the composition, principles of operation, and synthesis of theories related to cleaning machines that employ ultrasonic waves

Designing a power circuit that is in line with the machine's capabilities and the theoretical knowledge that has been acquired

Selecting a frequency that fits the design specifications and comprehending how frequency affects cleaning efficacy

The sandpaper cleaning machine has a capacity of 8–10 liters and uses an ultrasonic wave generator operating at a frequency of 40 KHz with a power capacity of 60W

The control system incorporates the use of an Arduino Uno microcontroller, enabling functionalities such as timer display and countdown, temperature display and control, as well as servo motor control along the X-axis

Information gathered from scientific research conducted both domestically and internationally, examining previously published works in various scientific journals and references from documents, articles, and textbooks

Researching methods from experiment and practice

Gathering information from books, scholarly publications, journals, and documents online

Conducting surveys, interviews, observations, and secondary data analysis

1.5.4 Outline Of The Graduation Thesis

Chapter 3: Design Of Mechanical System

Chapter 4: Design Of Electrical And Control System

Chapter 5: Building A User Interface And Interactive Web Interface

Chapter 6: Implementation, Experiment Results/ Findings And Analysis

THEORETICAL BASIS

Ultrasonic Wave Theory Overview

Ultrasound waves are also a mechanical wave and have basic properties through parameters such as frequency, wavelength

The Nature Of Sound Waves

Elastic media (gas, liquid or solid) can be considered as continuous media consisting of closely interconnected particles Normally, each element has a stable equilibrium position

If a force is applied to a certain element A inside this environment, it will leave its stable equilibrium position Due to the interaction created by the connections with neighboring elements, on the one hand the element is pulled to the equilibrium position, on the other hand it is also affected by the impact force so the element will move back and forth around equilibrium position, which means that the element performs movement in the form of vibrations This phenomenon continues to occur with other elements of the environment Mechanical oscillations that are repetitive in nature and propagate in an elastic medium are called elastic waves or mechanical waves In other words, a wave is a physical phenomenon in which energy is transmitted under the vibrational pattern of material elements of the wave medium.

Ultrasonic Wave Properties

Sound waves are vibrations of particles of solids, liquids and gases, which are elastic substances In other words, sound waves are elastic waves propagating in an elastic medium,

5 which means that all elastic objects can propagate sound waves Depending on the frequency range, elastic waves are divided into the following regions:

The infrasonic region has a frequency from 1Hz to 20Hz The acoustic region has a frequency from 20Hz to 20kHz

The ultrasonic region has a frequency from 20kHz to 100MHz

The ultrasonic region has a frequency > 100MHz

Although it has the same nature as an elastic wave, Due to different frequencies, they have different ap

Ultrasonic waves carry greater energy than sound waves (for example, with the same amplitude of vibration, the wave energy at a frequency of 1MHz is 10 6 times greater than the wave energy at a frequency of 1kHz)

In the same wave transmission environment , ultrasonic waves have a short wavelength so they are highly directional, the wave energy travels in a certain direction Taking advantage of this property, one can create focusing systems to concentrate large amounts of energy over a large area, narrow area

In the ultrasonic wave range under certain conditions, wave cavitation occurs in liquids This property is widely used in industry and civil use

Ultrasound Wave Parameters

The following diagram is a representation of a wave, which is a set of compression and expansion that vary in a sinusoidal order, with the peak representing the highest pressure and the bottom representing the lowest pressure

Figure 2 3 Compression And Rarefaction In A Longitudinal Wave

Characteristic quantities of waves include:

The period T=(s) is the time during which the wave performs one compression and one expansion

Frequency f=(Hz) is the number of cycles performed in 1 second

The propagation speed of a sound wave is the distance the sound wave travels after a unit of time

Wavelength 𝜆(à𝑚): is the distance the wave travels after a period of time equal to 1 cycle (𝜆 𝑣 𝑇 = 𝑣/𝑓)

In the figure, we see that wavelength is the distance between two adjacent peaks or troughs

The frequency of a mechanical wave is also the oscillation frequency of the atoms of the medium in which the wave propagates Frequency represents the number of cycles per second The symbol for frequency is f, the unit is Hertz (Hz)

Wavelength 𝜆 is the distance a wave travels in a period of time T Atoms separated by a distance will have the same vibrational state, that is, they will oscillate in the same phase when the wave passes through the medium

The rate at which energy is transferred between two points in the medium by the motion of the wave is called the wave velocity v

2.4.4 Absorption Of Ultrasonic Waves By The Transmitting Medium

During the process of wave propagation in the medium, the wave intensity is gradually attenuated due to absorption by the medium and scattering of the wave Energy loss depends on factors:

- Thermal conductivity, friction coefficient, heterogeneity of the environment

Cleaning Technology

Cleaning is a problem that we all regularly face every day In a more general sense, it is the cleaning of unnecessary and troublesome materials from the locations of equipment and parts that need cleaning

Cleaning can be done in many ways One of the most common traditional manual methods is to soak the device in a solution This method is a combination of chemical action and mechanical action The traditional method is mainly to use a brush to clean parts with simple structures, used for flat, smooth surfaces, not in nooks and crannies or places that are difficult to brush directly

• The washing process is quick, simple, and does not require high technology

• Cannot wash devices with complex structures, narrow gaps, and small nooks and crannies inside the device

• Causes scratches on the surface by using a brush or broom

• Deformation of surface and structure causing breakage of small, thin parts of the device

2.5.2 Using Ultrasonic Cleaning Technology For Cleaning

Nowadays, industrial production is becoming more and more modern, production lines are being created to ensure the production of millions of products of the same type in a year This reality requires very high quality, size uniformity, and repeatability to ensure easy assembly, less time and effort, and lower product costs To achieve that, technological lines are often equipped with many ultrasonic cleaning devices in different stages Make sure to "absolutely" clean the surface of the product before moving on to another processing step on that product Ultrasonic cleaning technology is especially needed in the manufacturing industry of electronic circuit boards with high component density, in equipment for manufacturing metal mechanical parts with nooks and crannies in shape, many holes but , must have high cleanliness, hardness, and accuracy Ultrasonic cleaning technology helps us handle dirt on the surface of the above details before entering the coating and surface polishing process

2.5.3 Ultrasonic Cleaning Technology Cleaning Principle

Ultrasound waves are waves with frequencies greater than 18kHz, at this frequency humans cannot hear it

In ultrasonic cleaners, the wave frequency is usually in the range of 20kHz - 200kHz Ultrasonic waves used in ultrasonic washing machines applied to production lines and cleaning of medical instruments have high frequencies from 10kHz - 50kHz Ultrasonic cleaners using frequencies higher than 50kHz are used to wash optical instruments, biological and industrial filters, and dental cleaning machines in hospitals

Ultrasonic waves in ultrasonic cleaners are mechanical waves and they have full physical properties such as transmission method, reflection, wave interference, etc., in different transmission environments

When a mechanical wave is created in air or in a liquid, under the effect of pressure, a quantity of matter is compressed to form waves, this wave is moved towards the lower pressure side and propagates transmitted in different directions, but the strongest is still the direct direction of the thrust This wave beam contains countless higher frequency beams, so countless small beams often called bubbles appear in the beam The size of these bubbles develops quite diversely, usually depending on the frequency of the ultrasound wave The higher the ultrasound wave, the smaller the bubble size

These bubbles move one after another in the liquid medium until they hit the surface of an obstacle in the wave path Under the compression force of the waves, the bubbles burst, creating explosions, shooting liquid particles directly into the surface of the object These bombardments separate the layers of dirt and dust covering the surface of the liquid and pull them away from the object when negative pressure appears in the liquid near the surface of the object

2.5.4 Cleaning Process Using Ultrasonic Cleaning Technology

When power is applied to the ultrasonic sensor, this sensor creates mechanical vibrations on its surface with a frequency greater than 20,000 vibrations/second This mechanical wave is transmitted directly into the stainless steel of the ultrasonic cleaning tank and creates high- frequency shocks in the liquid of the ultrasonic cleaning tank Under the impact of high- frequency mechanical shocks, countless small-sized bubbles are created in a short time and propagate in all directions within the liquid, and this movement fully complies with the laws of waves muscle in dragon fluid The bubbles move forward and hit the surface of the object to be washed, creating a mechanical bombardment of dirt on the surface Under the impact of this bombardment force, the dust is separated from the surface and easily dissolves into the cleaning solvent thanks to the effect of chemicals Thus, the smaller the foam, the greater its ability to penetrate, thus having the effect of cleaning the surface of objects with holes or complex zigzag structures, which cannot be achieved with conventional washing technology The following pictures describe the process of cleaning the surface of an object:

The cleaning process is involved in the creation of contact between chemicals and dirt in order for the cleaning solution to dissolve the dirt particles This requires that the solution come into direct touch with the dust particles

In order to accelerate the cleaning process, it is necessary to add new cleaning chemicals on a regular basis (see picture below) When chemicals dissolve dirt, a layer of chemicals near the surface of the object is gradually saturated, so its dissolving effect becomes increasingly thick, so the cleaning process is slowed down or completely lost

Ultrasonic waves boost cleaning effectiveness by preventing the creation of a saturated layer of chemicals and allowing the active layer of chemicals to come into direct contact with the surface to be cleaned They do this by creating and striking the surface with bubble waves

Certain dirt particles are not dissolved; instead, they are loosely adhered to the object's surface by cohesive forces or ion bonding; these particles are easily removed by pushing against the dirt with a force stronger than the dirt's adhesion force to the surface (see figure below)

The cleaning solution must moisten the filth particles to be cleaned in order to achieve high ultrasonic cleaning efficiency

Since different kinds of dirt actually dissolve differently in cleaning solutions, choosing the right cleaning agent, supplying the required ultrasonic energy, and taking temperature into account—which is also critical for accelerating the cleaning process—are all necessary to guarantee the efficacy of ultrasonic cleaning technology

2.5.5 Advantages Of Ultrasonic Cleaning Technology

Unlike other cleaning techniques, the use of bubbles that may reach varying depths and angles allows ultrasonic waves to efficiently clean the surfaces of objects in any shape

• Consistent and thorough cleaning The uniform cleaning effect of ultrasonic waves applies to objects of all sizes and complexities, whether it is a single part or multiple parts being cleaned in one go Ultrasonic technology enables meticulous cleaning of dirt on the entire surface and is not dependent on the operator

• Safety and environmental compliance by reducing the concentration of hazardous chemicals or replacing corrosive cleaning methods

• Energy-efficient, labor-saving, and cost-effective

• Minimizes direct contact between the operator and potentially dangerous cleaning products

• Ultrasonic cleaning devices offer true productivity benefit for specific cleaning applications.

Factors Influencing The Ultrasonic Cleaning Technology's Cleaning Procedure

The figure below illustrates the size of bubble foam in relation to frequency Higher frequency produces smaller bubbles than lower frequency Smaller bubbles can be formed in a smaller distance than larger bubbles

Figure 2 9 Frequency And Bubble Size Relationship

The bigger the bubble foam, the more intense the cavitation that results from the bubble implosion in water; larger bubble foam is usually produced by high-intensity cavitation; since the bubble size is inversely proportional to the ultrasonic frequency, larger bubble foam is usually produced by lower frequencies; the frequency increases with the number of bubbles; and since the bubble size is inversely related to the ultrasonic power input, lower frequency bubbles are more likely to undergo intense implosion than higher frequency bubbles

A number of chemical cleaning agents are specifically formulated for ultrasonic cleaning, making this technology convenient to use The table below lists some common chemicals used in ultrasonic cleaning technique Choosing the appropriate chemical compounds is crucial to the overall success of the ultrasonic cleaning technique These chemical components need to be compatible with the composition of the metal being cleaned and possess effective cleaning capabilities as well as the ability to generate strong bubble agitation

Table 2 1 Several typical metal cleaning solutions

Temperature ºC Metal to Clean Application

40-50ºC Steel Cleaning dirty parts

30 g/l 40-60ºC Steel Cleaning dirty parts

50ºC Steel Cleaning dirty parts

50ºC Rusty Steel Removing scales and rust

Choosing the right chemical compound is especially important for the overall success of the ultrasonic cleaning process This choice of chemical composition must be compatible with the metal base being washed and be capable of removing dirt It must also have the ability to

16 create good bubbles Most chemical cleaners can be used conveniently with ultrasonic technology They have special formulas for use in ultrasonic cleaning techniques

Temperature is considered the most important parameter in creating maximum bubble intensity Temperature changes lead to changes in viscosity, solubility of gas in liquid, degree of diffusion of gas in liquid, and vapor pressure In pure water, the level of bubble formation reaches a maximum at temperatures near 160°F (~ 71 °C) The viscosity of the liquid greatly reduces the intensity of bubble formation Most liquids have viscosity that decreases as temperature increases To effectively create bubbles, the liquid must contain some small amount of dissolved gas Gas dissolved in the liquid will be dissolved in the process of creating fertilizer and it can prevent forced bubble collapse In fact, as the temperature increases, the amount of gas dissolved in the liquid decreases Diffusion of dissolved gases increases as temperature increases

When the temperature in the liquid increases too high, causing the liquid to approach the evaporation process, the process of creating steam bubbles is very likely to occur As the bubbles filled with steam increased, the intensity of the bubbles decreased and some parts of the tank began to evaporate

• The best ultrasonic performance is about 65% of the boiling point of the liquid in use

• Temperatures above 65% of the boiling point will reduce the scrubbing force of the system

• Most ultrasonic cleaners use temperatures between 54 and 82°C

• When using acidic materials, use the lowest possible temperature to reduce damage to the ultrasonic cleaning tank surface

Suitable temperature for objects needing cleaning:

• Most industrial parts are best cleaned at 50-70 °C, especially when cleaning microscope parts

• Electrical and electronic components are best cleaned at 45-55°C

• Gas-affected items may require cleaning at the highest temperatures up to 80°C

• For items made from soft, chemically bonded materials, only need to be cleaned at room temperature

• Laboratory instruments and medical instruments have their own characteristics and should be cleaned ultrasonically at a temperature of 55-65°C

This is determined by temperature conditions, soil type, concentration of cleaning chemicals, shock frequency It takes time for the cleaning process to take place

In one tub, it can take five to 15 minutes; in a high-pressure sprayer of a quality cleaner, it may take a few seconds

2.6.5 Power And Tank Volume Of Ultrasonic

Manufacturers of equipment use different terms to describe ultrasonic power (watt/gallon, watt/liter) Ultrasonic power is defined as the energy transferred to the transducer and is measured in watts per gallon (or liter) of cleaning solution; most cleaning agents require 30-

The number of bubbles and cleaning effectiveness increase with ultrasonic power, but only up to a certain point; exceeding that point wastes energy and runs the risk of damaging the cleaned components

Total power is another definition; it is the energy needed to run the entire ultrasonic tank, including the ultrasonic generator and the heating system (if applicable) It should not be confused with ultrasonic power alone

Peak power, which might be 2, 4, or 8 times greater than average power, is the ultrasonic power produced at the peak of the sound wave

2.6.6 Considerations When Use A Cleaning Solution And Ultrasonic Cleaning

Selecting the ultrasonic frequency: Most cleaning tanks work at 38–45 kHz, which is sufficient for most cleaning tasks Lower frequencies produce larger cavitation bubbles, which release more energy when they implode, making them more effective for cleaning; however, lower frequencies tend to be more efficient for rough cleaning processes, though they also increase operating noise High-value materials, like jewelry, electronics, or the smooth surfaces of lightweight metals, may require a very high frequency of 130 kHz

Selecting ultrasonic power: The ultrasonic power should rise in proportion to the volume of the cleaning solution More power typically means faster and more thorough cleaning, but too much power can potentially harm electronic components and material surfaces, particularly metals like aluminum The ideal power level is one that strikes a balance between thorough cleaning and protecting the objects being cleaned

Selecting the right cleaning solution: In real life, different kinds of dirt will either dissolve or stay insoluble in cleaning solutions In order to guarantee that ultrasonic cleaning works, it is important to choose a cleaning agent that is appropriate for the kind of dirt that is there

Functions And Categorization Of Transducers

A device known as an ultrasonic transducer is one that can directly convert electrical energy at an ultrasonic frequency into mechanical oscillations at the same frequency On the other hand, it can also convert mechanical oscillations into corresponding electrical oscillations Receiving transducers and transmitting transducers are the two types of transducers that are based on these two functions

After being processed and amplified to the necessary level, an electrical oscillation at ultrasonic frequency is sent to the transmitting transducer, which transforms it into a mechanical oscillation that propagates in the medium to accomplish a particular purpose Transducers can be either electrostrictive or magnetostrictive, depending on the material used in their construction

Electrostrictive transducers are usually low power and operate at high frequency ranges, whereas magnetostrictive transducers are typically used in high-power devices and operate at low frequencies

Receiving transducers are usually electrostrictive transducers with high sensitivity that detect mechanical oscillations from the external environment that act upon their surface

The transducer then converts the mechanical oscillations into electrical oscillations, processes and amplifies the electrical signal to the required level, and uses the electrical signal as input for indicating, measuring, or alerting devices

Based on Curie's 1880 discovery of the piezoelectric effect, piezoelectric transducers produce alternating electric charges by means of mechanical vibrations in materials such as quartz crystals and barium titanate, which are typically unstable and have low mechanical load- bearing capacities American scientists have been producing piezoelectric sensors with high power, durability, and stable frequency response in mechanical and unique environmental conditions since the 1940s

The deformation effect in piezoelectric materials, on the other hand, is frequently much smaller than in magnetostrictive transducers The oscillation amplitude of piezoelectric materials typically ranges from 0.1àm to 7àm Despite this, piezoelectric transducers can operate at frequencies up to 5MHz

In terms of power, magnetostrictive sensors have a significantly higher power than in piezoelectric sensors Piezoelectric sensors can convert between reciprocating energy forms,

19 such as electrical, mechanical, and acoustic energies Because of their compact size, piezoelectric transducers are well-suited for the production of ultrasonic cleaning machines

In the instance of the direct piezoelectric effect, force applied to the material results in opposite charges being generated on both surfaces; this can be observed by attaching electrodes to the surfaces of a quartz plate coated in silver and measuring the deflection of an electrometer needle The piezoelectric effect happens when a force is applied to a piezoelectric material, causing it to deform and generate an electrical signal

The electrometer's needle deflects to the left (figure a) when a tensile force is applied, causing the thin plate to expand; on the other hand, when a compressive force is applied, causing the thin plate to contract; on the other hand, the needle deflects to the right (figure b), indicating a change in the direction of the charges on the two surfaces of the plate

Figure 2 10 Direct Piezoelectric Effect (A) Tension Force (B) Compressive Force

This phenomenon illustrates the direct piezoelectric effect, which is the fundamental principle behind the use of piezoelectric materials in a wide range of applications, including actuators, sensors, and ultrasonic devices It occurs when mechanical deformation results in the generation of opposite charges on the surfaces of a piezoelectric material

The following equation establishes the link between the charge Q and the force F:

Q is the charge in Coulombs

F is the magnitude of the applied force in kilograms

This equation shows us that when a mechanical force acts on a thin plate's surface, causing mechanical oscillations, an alternating electrical signal with the same frequency as the mechanical oscillation will appear on the thin plate's two electrodes

Materials that exhibit these properties are referred to as piezoelectric materials, and piezoelectric sensors for ultrasonic wave detection are built on this principle

This phenomenon, known as the inverse piezoelectric effect, where the mechanical deformation of the material is induced by the applied electric field, illustrates how piezoelectric materials can convert electrical energy into mechanical strain When two electrodes of a piezoelectric plate are connected to a DC power source as shown in Figure , it is observed that the thickness of the piezoelectric plate expands On the other hand, when the polarity of the power source is reversed, the thickness of the piezoelectric plate contracts The following equation establishes the relationship between L and the applied voltage V:

L is the variation in the geometric dimension of the piezoelectric plate

K is the piezoelectric constant, which has a value of 6.9 × 10 -8

V is the magnitude of the applied polarizing voltage from the power source

The relationship states that when a piezoelectric plate is subjected to an alternating electrical signal at frequency f, the thin plate's thickness changes continuously at the same frequency, resulting in the generation of a mechanical oscillation in the surrounding environment

This idea serves as the foundation for the construction of ultrasonic transducers Experiments have shown that the oscillation amplitude is maximized when the voltage source V's oscillation frequency and the piezoelectric plate's natural oscillation frequency, which is determined by the material and thickness of the plate and can be expressed by the following equation:

𝑓𝑜 is the natural oscillation frequency of the piezoelectric plate k is the natural oscillation coefficient (kHzãmm) l is the thickness of the piezoelectric plate (mm)

An Ultrasonic Transducer's Composition And Form:

Figure 2 12 How An Ultrasonic Transducer Is Constructed

The physical phenomenon known as magnetostriction occurs when a magnetic material is exposed to a magnetic field and changes in size and shape as a result Specifically, when a magnetic material is exposed to a magnetic field, the interaction between the material's magnetic structure and the magnetic field modifies the spacing between its atoms or molecules, causing the material to either expand or contract

This indicates that when an alternating current signal with a frequency of f is applied to the coil, the length of the magnetic core will continuously vary with the same frequency, resulting in the creation of a mechanical oscillation in the surrounding environment

This is the principle behind the construction of magnetostrictive ultrasonic transducers The length of the magnetic core expands when the two ends of the coil are connected to a DC power source as shown in the figure

On the other hand, when the direction of the power supply is reversed, the length of the magnetic core contracts.

Survey The Types Of Ultrasonic Cleaners Available On The Market

(Rama Ultrasonic Cleaner) is a surface cleaning device using ultrasonic wave technology, used for cleaning grease on motorbike engines, grease-stained machinery, washing dust and rust Clay sticks to metal, washes glass, washes jewelry, watches, printer heads, washes CNC products & many other applications

Highly efficient and high-capacity ultrasonic generator used in industry for great cleaning performance, visible to the naked eye

Complete structure (tank tank, shell, lid, basket ) from high quality SUS 304 stainless steel Separate independent ultrasonic generator with adjustable ultrasonic power

- Internal dimensions (length x width x height): designed according to user needs

- External dimensions (length x width x height) width x height): designed according to user needs

- Heating power supply: AC 380V, 20AMP, 3 phase

- Power for generator Ultrasonic: AC 220V/240V, 20AMP, 1 phase

Introduction Of Web Server

A website is a collection of many web pages - a type of hypertext (HTML or XHTML file) that presents information on the Internet at a certain address for viewers to access and view The first website a viewer visits from a domain name is often called the home page, and viewers can view other pages through hyperlinks The advantage of the website is that information is easy to update and change, users can view information immediately, anywhere, save printing costs and are not limited to the area or scope of use

A website is usually divided into 2 parts:

- User interface (front-end): User interface (usually html code) web page format displayed on a personal computer or smartphone of users and encrypted by web browser software such as Google Chrome, Internet Explorer

- The presentation of a website must ensure the following elements: aesthetics, clear layout, easy to understand, easy to use, friendly and convenient for users

- Web server (back-end): Program that handles user requests from the user interface (back- end)

- Static website: is a website without a database but only websites with little-changed content, often suitable for websites that require complex content and high graphics

- Dynamic website: is a website with a database, information on the website is often updated or changed continuously

2.9.2.1 Server-Side Web Programming Language

Currently, there are quite a few server-side web programming languages (web server) such as: NET, PHP (Hypertext PreProcessor), Python Django, HTML and Javascript, However, in terms of popularity, PHP and Javascript is superior Both are the easiest to learn and most popular web programming languages in the world

PHP: Hypertext PreProcessor, often abbreviated to PHP, is a scripting programming language or a type of code mainly used to develop applications written for servers, open source, for general purposes Because it is optimized for web applications, fast, compact, and easy to learn, PHP has quickly become the most popular web programming language in the world

Javascript: Javascript is one of the most popular and widely used scripting languages in the world, used to build interactive web applications Today, Javascript can also build mobile applications The advantages of Javascript are similar to PHP but are somewhat more popular due to the convenience it brings when being able to program both the server side (web server) and the user interface side

2.9.2.2 Front-End Web Programming Language

To be able to program the web on the user interface side, it is usually necessary to use three main languages: HTML, CSS, Javascript

HTML: HTML stands for Hyper Text Markup Language, which means hypertext markup language, used to create static interfaces for websites The basic HTML website structure consists of the main tag, the tag Inside the tag there is a tag and a

tag, other child tags will be inside these two tags, most tags have an opening tag and a closing tag The closing tags are the same like opening tags but with an additional / (e.g

Text between tags will be formatted by the browser according to the name of each tag to show the content type

CSS (Cascading Style Sheets): Is a form of code similar to HTML, operating on HTML code to format the website, making the website more vivid and aesthetic, CSS is inserted between the style> , this tag is placed in the tag of HTML code to change the properties of tags in HTML such as: font, color, text size of paragraphs

Javascript: Is a piece of code on the user interface that runs on the web browser and is used to automatically transmit and receive data and then access HTML tags to display the data Javascript is inserted between the tag, which is usually placed in the

SQL is a computer language that helps store and retrieve data stored in a relational database SQL stands for Structured Query Language which is a structured query language

All RDBMS (relational database management systems) such as MySQL, Oracle, MS Access, Sybase, Informix, Postgres and SQL Server use SQL as the standard database language

SQL is a language standardized by ANSI (American National Standards Institute) This is also a commonly used language in relational database management systems and supports use in large technology companies

- In addition to being a popular computer language, SQL is also a useful computer language Therefore, people often use SQL for the following purposes:

+ Create new databases, tables and views

+ To insert records into a database

+ To delete records from a database

+ To retrieve data from a database

One of the reasons why SQL is so popular is that it allows users to perform a variety of functions:

- Allows users to access data in database management systems relationship

- Allows users to describe data

- Allows users to define data in the database and manipulate the data

- Allows embedding in other languages using SQL modules, libraries and precompiler

- Allows users to create and drop databases and tables

- Allows users to create views, stored procedures, and functions in the facility data

- Allows users to set permissions on tables, procedures and views

3.6.3.3 Advantages and disadvantages of SQL

- Add, edit, read and delete data easily

- SQL makes programming work easier

- Used and supported by many large companies

- SQL has a complex interface that makes it difficult for some users to access

- Programmers using SQL do not have full control over the database

- Most SQL database programs have their own proprietary extensions

Introduction Of Bootstrap

Bootstrap is a framework that includes sample HTML, CSS and JavaScript for developing responsive websites, a free collection of open source code and tools used to create a complete website template with responsive properties Pre-defined interface such as size, color, height, width

Bootstrap allows the website design process to take place faster and easier based on available basic elements such as typography, forms, buttons, tables

2.10.2 Bootstrap Components And Their Functionalities

Bootstrap includes 3 main files that help manage website functions and user interface:

Bootstrap.CCS: is a CSS Framework that has the function of managing and arranging the layout of Web pages If HTML is responsible for managing structure and content, CSS will handle the layout of the Website CSS to create a unified interface across many websites without limitations, in addition, CSS functions are not only limited to text styles but also use formats such as tables and image layouts

Bootstrap.JS: this is the core part because it contains JavaScript files, it is responsible for the interaction of the website To save time writing JavaScript syntax many developers will use jQuery This is an open source, cross-platform JavaScript library that helps you add more functionality to your website

Glyphicons: In the website interface, the indispensable part is Icons They are often associated with certain data and actions in the user interface Glyphicons will meet the above needs and it has unlocked the Halflings Glyphicons set for you to use for free

2.10.3 The Structure And Features Of Bootstrap

Bootstrap contains compiled and compressed JavaScript, CSS and fonts files In addition, Bootstrap is designed as modules, so it is easy to integrate with most open source code such as WordPress, Joomla, Magento, In particular, Bootstrap brings many outstanding functions Bootstrap allows users to access a "huge" library of elements used to create the interface of a complete website such as fonts, typography, forms, tables, grids

Bootstrap allows customization of a website's framework before downloading and using it at the framework's website Reuse repetitive elements on the website Bootstrap is integrated with jQuery You just need to accurately declare the features in your web programming process Define glyphicons to minimize the use of images as icons and increase page loading speed

2.10.4 Advantages And Disadvantages Of Bootstrap

- Easy to learn, easy to use, easy to customize

- The product is heavy, the optimal speed is not high

- Bootstrap does not encourage creativity.

Introduction To AJAX Technology

AJAX is the abbreviation for Asynchronous JavaScript and XML This is a technology that helps us create dynamic websites that do not reload the page at all, so it is very smooth and beautiful So Asynchronous, JavaScript, XML in the word AJAX are: Asynchronous: or in short, Async - asynchronous Asynchronous means that a program can execute functions out of sequence The most obvious benefit of asynchrony is that the program can handle multiple tasks at once Javascript: is a famous programming language Among its many functions is the ability to manage a website's dynamic content and support user interaction

XML: is a form of markup language like HTML, its full word is eXtensible Markup Language

If HTML is used to display data, XML is designed to contain data

We need to note that AJAX is not a single technology, nor is it a programming language As mentioned above, AJAX is a set of web development techniques This system set includes: HTML/XHTML as the main language and CSS for styling

- The Document Object Model (DOM) to dynamically display data and create interactivity

- XML for internal data exchange and XSLT for processing it Many programmers have Replace with JSON because it's closer to JavaScript

- XMLHttpRequest object for asynchronous communication

- Finally, JavaScript is the programming language to connect all of the above technologies Operation diagram:

Figure 2 15 Operation Diagram of AJAX

- First, the browser creates a Javascript call to activate XMLHttpRequest

- Then, in the background, the browser makes an HTTP request to the server

- At that time, the server will receive, retrieve and send data back to the browser

- The browser receives data from the server and immediately displays it on the page without reloading the entire page

2.11.3 Advantages And Disadvantages Of AJAX

- It helps make web design more diverse and increases the interactivity of the website

- It uses existing technologies so it is easy to learn and use

- Thanks to its popularity, it has encouraged the development of templates that will help programmers avoid previous mistakes

- Supported in popular browsers today

- You cannot bookmark it as favorites on your browser or send the link to your friends, because all the processes are done in the background and are not displayed on the address

- Cannot display content on search pages because current search pages still do not support searching because it is very difficult to find and almost impossible to find

- Cannot use back button because back is also itself

- With some browsers, due to security needs, the JavaScript function will be turned off so ajax cannot run, or in some hosts, it does not support deep server configuration, so it often gets the

DESIGN OF MECHANICAL SYSTEM

Introduction

The meticulous selection of mechanisms and transmission plans serves as the cornerstone for precise calculations, thorough comparisons, and the subsequent selection of suitable machine components and intricacies This meticulous process ensures that the technical specifications of the group are met in constructing a comprehensive mechanical machine configuration

Within this chapter, we delve deeply into the calculation methodologies and formulas embedded within the detailed design documents of the machine These are complemented by the utilization of calculation websites and the careful selection of necessary equipment for the system Through rigorous adherence to input criteria, calculation procedures, and part selection, the group has successfully concluded the mechanical aspect of the project

The mechanical system not only satisfies the initial requirements but also operates seamlessly, continuously, and devoid of disruptive vibrations This minimizes delays and guarantees the precision of measurement results, thereby solidifying the efficacy of the entire system.

Machine Structure Requirements

- It is imperative to prioritize safety protocols during machine operation

- The actuator maintains stability throughout operation

- The machine moves back and forth along the X axis using either the "Screw Drive" mechanism, with a movement range from 10 mm to 500 mm

- The machine operates up and down along the X axis according to the selected mechanism

"Pneumatic" Motion range from 0 mm to 200 mm

- The water level and boiling temperature always ensure the workpiece washing process.

Analysis And Choice Of Components

S3.3.1 Guidance Mechanism For The X Axis

3.1.1 Choose Type Of Ball Screw

The development of modern science has produced many types of screw shafts to best meet the needs of use in all areas of life As well as customer needs There are 3 popular types of lead screws today:

The ball screw mechanism is a transmission system composed of a helical groove with bearings running inside It converts rotational motion into linear motion Specifically, when

33 the ball screw rotates, the bearings change direction and move into the recirculation tube They then exit the recirculation tube and enter the space between the ball screw and the nut

A complete ball screw mechanism consists of two main parts: the ball screw and the ball screw nut Regarding the ball screw, there are currently two main types: ball screws produced by thread rolling (also known as thread rolling) and ball screws produced by thread grinding

Due to its unique structure, the ball screw mechanism has many advantages, such as high transmission accuracy, minimal losses due to friction, high rigidity and axial direction, no clearance in the joint, and the ability to generate initial tension forces

Figure 3 1 Lead Screw And Nut

The CNC machine's ball screw is a component consisting of a shaft and an accompanying nut When combined with other components such as bearings, thrust bearings, and chuck, it forms a complete lathe machine

A high-quality ball screw for a lathe machine ensures optimal transmission for the CNC machine It enables stable and continuous operation over extended periods Particularly, this component facilitates smooth and flexible movements with minimal friction, resulting in almost noiseless operation This quality also leads to significant savings in maintenance and component replacement costs

Figure 3 2 CNC Machine Lead Screw

Lead screw for lifting and lowering:

The lift screw in CNC machines is installed between the motor and the Z-axis It is used to raise and lower the Z-axis, converting the rotary motion of the motor into linear motion along the Z-axis The lift screw is typically much longer than its diameter This type of screw is designed in two basic shapes: trapezoidal and square threads

Generally, lift screws are specialized for lifting and lowering operations in various industries such as water plant valve gates, hydroelectric projects, lifting platforms, woodworking machinery, metallurgy, chemicals, textiles, and medical equipment These products feature compact designs and slow lifting speeds to achieve high precision

Figure 3 3 Lead Screw For Lifting And Lowering

Based on working capability and required efficiency, the team opted for the ball screw due to its minimal and consistent friction, which remains nearly unaffected by speed variations Hence, the ball screw emerges as the most fitting option

3.1.2 The Drive Mechanism Combines The Roller Screw And The Rail

Figure 3 4 Integral-Structure Actuator with the combination of guide and ball screw the integral-structure actuator brings many of the following benefits:

- Offered in various sizes on the market (Streamlining design and installation processes)

- Compatible with any installation orientation

- Minimized load fluctuations enabling precise operations

- Compact design for space efficiency

Technical requirements for weighing systems:

To achieve optimal space efficiency and expedite the design process without compromising on rigidity and operational smoothness, our team made the strategic decision to implement a transmission mechanism that seamlessly integrates a vitme and sliding rail This choice led us

36 to adopt slide rail leads for both the X and Y axes Given the substantial load-bearing requirements of the Y axis, we recognized the imperative of incorporating two square rail sliders to reinforce rigidity

Following the concept of simplicity in our design approach, we focused on selecting components that are straightforward to repair and handle, while also guaranteeing durability along the X-axis

A key aspect of our design strategy involves carefully constructing a sturdy base for rail movement and a solid block to support the lead screw The main goal for the base is to maintain consistent stability, with its top surface meticulously machined to ensure a precise level of smoothness and flatness necessary for installing two lead screws

Table 3 1 Input Specifications Of Roller Screw

Load m = 4 kg (minus factor of safety k = 1.5)

Maximum acceleration of the system a = g/2 = 5 m/𝑠 2

Velocity of motor Nmax = 6000 (rpm)

No-load position accuracy ± 0,03/1000mm

Since the system should choose a step roller screw (l) greater than or equal to 3.3 (mm/r), our team decided to choose a step roller screw equal to 5 (mm/r)

Table 3 2 Working Condition Of Step Roller Screw

• Maximum axial force when turning to the right:

• Maximum axial force when going left:

F1max; F2max: Maximum axial force during machining and before machining

N1max; N2max: Maximum rotation speed during machining and without machining (because when machining or not, the weight of the machine remains almost constant, hence the same rotation speed) We choose a speed of 2000 rpm t1; t2: The time the machine operates in idle and loaded modes We realize up to 90% of the machine operates under load and only 10% of the time the machine operates without load So:

Calculation of static load: max o max a o s a s

In there: f s : Static safety factor (for industrial production machines: 1.2 ÷ 2; for machine tools: 1.5 ÷ 3), inferred to choose f s = 2

F amax : Maximum axial force (Famax = 74N)

Load factor: f w are checked based on the following table:

Table 3 3 Load Factor Of Step Roller Screw

Select lead screw length L: 500 (mm)

Choose iron as material had [𝝈 𝑲 ] = 16,7 Mpa

Working height of thread: h 1 = (0,3 ÷ 0,35) D b = 0,3.1 = 0.3 (mm) (3.19) Outer roller screw diameter:

With d = 12 (mm) and d1 = 10 (mm) Our team decided to choose BF12 bearing for the lead screw head and BK12 bearing for the lead screw tail

Utilizing the provided input parameters, the motor's essential parameters are calculated to meet the initial requirements

Choose roller screw with step h = 5mm

Coefficient of sliding friction between steel and cast iron 𝜇 =0,12

The mass of the displacement head part m = 4 kg

Maximum rotational speed of the motor 3000 r/m

In order to select the appropriate engine, it is essential to begin by comparing the strengths and weaknesses of various types of engines

Table 3 5 Type Of Servo Motor

Stepper Motor DC Servo Motor AC Servo Motor

Control method Used in open loop controller

Used in closed loop controller

Used in closed loop controller

No feedback signal, error prone

There is feedback about, less error

There is feedback about, less error

No need Encoder Need Encoder and

Need Encoder and Gearbox to control accuracy

Moment At low speed there is large torque At high speed there is small torque

There is a huge moment Beneficial when driving at high torque

Size Motor Small Size Big size Bigger than stepper motor but smaller than

DC Servo in the same power

Causes more noise and vibration

Noise Very Noise Fewer noise Limit noise

Price Less expensive than servo motor

After creating a table comparing different types of engines combined with the project's requirements we decided to choose AC Servo Motor Because there is a compact motor, high moving speed ensures thread accuracy, high torque, low noise and few errors

Table 3 6 Input Parameter Of AC Servo Motor

Maximum speed of the slide vL = 0,3 (m/s)

The mass of the displacement head part m = 4 (kg)

Internal friction coefficient of the nut 𝜇 0 = 0.3

Lead screw diameter DB = 12 (mm)

Lead screw length LB = 500 (mm)

Lead screw step PB = 5 (mm)

Lead screw material Iron ( ρ = 7,9.10 3 [kg/m 3 ])

Let's say the safety factor 𝑺 𝒇 is 1.5, we have load moment 𝑻 ′ 𝑳 :

Based on the parameters just found above as follows: 𝑁 𝑀 = 3600 (𝑁 𝑚), 𝑇 ′ 𝐿 0.024 (𝑁 𝑚), 𝐽 𝐿 = 1 10 −5 (𝑘𝑔 𝑚 2 ) 𝑎𝑛𝑑 𝜃 = 1,44 0 My team decide to choose the SGMAV-01ADA21 AC Servo

Figure 3 7 SGMAV-01ADA21 AC Servo

Table 3 7 Specifications Of SGMAV-01ADA21 AC Servo

Current 0.91 (A) highest rotation speed 6000 (rpm)

With the use of SGMAV-01ADA21 AC Servo, our team decided to choose SERVO DRIVE YASKAWA SGDV-R90A01A to suit the requirements of the motor

Figure 3 8 Servo Driver Yaskawa SGDV-R90A01A

Table 3 8 Specifications Of Servo Driver Yaskawa SGDV-R90A01A

3.3.2 Guidance Mechanism for the Z Axis

To ensure full immersion of the object in the washing tank, considering the basket weighs approximately 300g, we can choose the type of cylinder TD-16-175-SE-1

Table 3 9 Specification Of Cylinder TD-16-175-SE-1

Pressure range (kgf/cm² (kPa)) 1 ~ 8.5 (100 ~ 850)

Max service pressure(kgf/cm² (kPa)) 9 (900)

We have chosen a 2.0HP Arwa AW-2040 air compressor to provide compressed air for our model to run smoothly without running out of air midway

Figure 3 10 Arwa AW-2040 2.0HP Air Compressor

Table 3 10 Specifications Of Arwa AW-2040 2.0HP Air Compressor

Air flow rate 200 liters per minute

Because we want to wash the largest amount of materials possible, we designed the sink to be large enough to hold enough materials

Figure 3 11 Design A Sink With Solidworks

We use solidworks software to calculate the bearing capacity of materials

Model name: Chiu_luc Current Configuration: Default

Reference Treated As Volumetric Properties

Mass:0.450505 kg Volume:0.000166854 m^3 Density:2,700 kg/m^3 Weight:4.41495 N

Mass:0.124547 kg Volume:4.61286e-05 m^3 Density:2,700 kg/m^3 Weight:1.22056 N

Mass:0.021492 kg Volume:7.96e-06 m^3 Density:2,700 kg/m^3 Weight:0.210622 N

Mass:0.0998884 kg Volume:3.69957e-05 m^3 Density:2,700 kg/m^3 Weight:0.978906 N

Mass:0.503325 kg Volume:0.000186417 m^3 Density:2,700 kg/m^3 Weight:4.93259 N

Mass:0.433901 kg Volume:0.000160704 m^3 Density:2,700 kg/m^3 Weight:4.25223 N

Mass:0.433901 kg Volume:0.000160704 m^3 Density:2,700 kg/m^3 Weight:4.25223 N

Mass:1.05066 kg Volume:0.000389134 m^3 Density:2,700 kg/m^3 Weight:10.2965 N

Table 3 12 Properties Table Of Whole Automatic Arm

Default failure criterion: Max von Mises Stress

Selection set Units Sum X Sum Y Sum Z Resultant

Selection set Units Sum X Sum Y Sum Z Resultant

Selection set Units Sum X Sum Y Sum Z Resultant

Selection set Units Sum X Sum Y Sum Z Resultant

Stress1 VON: von Mises Stress 31.548N/m^2

Displacement1 URES: Resultant Displacement 0.000e+00mm

DESIGN OF ELECTRICAL AND CONTROL SYSTEM

Introduction

For the system to be able to perform the set functions, an electrical and control system is needed to collect signals from the external environment and interact with humans For equipment, the sensor system is extremely important The sensor provides input signals such as real-time water level and temperature values The interactive interface provides input signals through user interaction and verification on screen or remotely over the internet All input signals and data are sent to the central computer to process and output the information, the output signals are through the actuator which is the motor

The washing machine also needs to have a safety system to protect the electrical system from damage when an incident occurs and ensure the safety of the system when a sudden incident occurs The structure of the electrical and control system is described as shown below

The electrical and control system is divided into two parts The first part is the control circuit that collects signals from the sensor and controls the movement of the arm mechanism through the motor actuator The second part is the central computer that processes information input from users Details of the parts of the diagram will be presented by the group in this chapter.

Control System

Power Block: From 220v power, through the AC/DC converter, provides 24v, 12v, 5v power for devices such as Servos, water pumps, pneumatic pumps, pneumatic valves, microcontrollers and sensor devices, relay

Signal Block: Specifically, temperature sensors and water level sensors Its main task is to measure data and send the parameters to the central processing unit as required

Mechanical System Block: Includes the X-axis drive transmission system, the material supply system, water pumps, pneumatic pumps, pneumatic valves Its main task is to operate the machine according to the instructions from the central processing block

Central Processing Block: Specifically, the Arduino Uno is responsible for processing input signals such as sensor feedback, reading data such as temperature sensors, receiving control signals from the Python GUI, processing the information, and displaying the necessary values on the GUI interface and send data from temperature and water level sensors to Esp8266 to send data to webserver display data (IOT)

The control circuit is responsible for controlling the motor, reading the signal from the encoder to control the position of the arm mechanism, reading the ultrasonic sensor signal to determine the water level, reading the temperature sensor to determine the temperature, Uart communicates through the serial port to receive and transmit data to the computer, and Uart communicates with the ESP to receive and transmit data to the Webserver

The control system diagram is shown in the figure below

To control the motor stably at the desired speed and position, the team uses a driver for the motor Drivers communicate with the control circuit using the UART

The control circuit receives data from the computer The controller will calculate the velocity values The control circuit will send the position value to the driver The driver receives the data and will control the motor to the pre-programmed position The control diagram is shown in Figure below

Figure 4 3 Servo motor control diagram

4.2.2 Communication Between Control Circuit And Computer

When users need the desired temperature and water level The computer will send that data to the control circuit via Uart The control circuit will determine the current temperature and water level and control to the temperature and water level that the user has set Through the computer, users can control the device as desired With the requirement to control and monitor from a remote location, the group proposed options such as: bluetooth, rf, wifi The group chose the control option via wifi The wifi network has high security, very good anti- interference ability, saves time without using wires, making the electrical system more neat Using wifi helps the control circuit connect to a server, so users can monitor the temperature and water level via the internet in a very remote geographical location

To be able to communicate with the computer via wifi, the control circuit needs to use ESP This module will catch wifi waves broadcast from wifi routers in the house repository to connect to ESP software on the computer This ESP plays a role intermediary, receives data from the computer through software, then transmits this data to the Webserver At the same time, it also receives data from the control circuit using uart, then transmits it to the computer

Details of this part will be presented in detail by the team in the next chapter The connection and communication diagram between the computer and control circuit is as shown in Figure 4.4

Figure 4 4 The connection and communication diagram

The flowchart diagram delineates the operational sequence of the machine First with the input of desired temperature and water level parameters, the machine initiates its operation Upon reaching the specified temperature and water level thresholds, the Ultrasonic component activates, facilitating the lowering of the object by the robot arm into the detergent

Subsequently, the arm relocates the object to the cleaning water bath, following which it returns the object to its initial position, thereby concluding the process

Throughout the operational phase, the values detected by the temperature and water level sensors are continually transmitted to both the Python GUI and Webserver interfaces This continuous transmission serves to enable users to monitor the process seamlessly.

Electrical System

4.3.1 Overview of the electrical system

Figure 4 6 Wiring diagram in electrical system

The diagram will start from the 220VAC power supply - this is the main power supply for the entire system This 220VAC source will be connected to the converter to create 24VDC power and 5VDC power for devices using these voltages In which, the 24VDC power supply will create current to operate the pneumatic valve, while the 5VDC source will be used to run smaller peripheral devices such as ESP8266, Arduino Uno, Besides the total 220VAC power supply is reducing pressure to create sources with smaller voltages, devices that directly use 220VAC voltage can be mentioned as water pumps, air compressors, ultrasonic pulse source systems, servo drivers, heating resistor bars,…

To ensure electrical safety for the system and protect electrical equipment from damage, the team arranges voltage stabilizer circuits at the input of electrical equipment When there is a problem, the circuit will automatically disconnect This ensures system safety Details are presented by the team in the electrical drawings in the appendix The machine has an emergency stop button for users to turn off the system in case of unexpected problems

In this project, we aim to use Arduino Uno as main board, which is a microcontroller board based on the ATmega328P (datasheet) It has 14 digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz ceramic resonator (CSTCE16M0V53-R0), a USB connection, a power jack, an ICSP header and a reset button It contains everything needed to support the microcontroller; simply connect it to a computer with a USB cable or power it with a AC-to-DC adapter or battery to get started

Table 4 1 Specifications of Arduino Uno

Based on the ESP8266 Wi-Fi transceiver module and the CH340 USB converter chip, this compact (Open Source) development and prototyping board is ideal for IoT applications

Digital I/O Pins 14 (of which 6 provide PWM output)

DC Current per I/O Pin 20 mA

DC Current for 3.3V Pin 50 mA

Flash Memory 32 KB (ATmega328P) of which 0.5 KB used by bootloader

The Wi-Fi module is compatible with the 802.11 b/g/n standard at 2.4 GHz, has an integrated TCP/IP stack, 19.5 dBm output power, data interface (UART / HSPI / I2C / I2S / Ir Remote Control GPIO / PWM) and PCB antenna It also has a micro USB connector and reset button

Wi-Fi mode: Station / SoftAP / SoftAP+station

Output power: 19.5dBm in 802.11b mode

Data interface: UART / HSPI / I2C / I2S / Ir

Supports protection mode: WPA / WPA2

Power supply: from 4.5 VDC to 9 VDC (VIN) or via micro USB connector

Consumption: with continuous Wi-Fi transmission about 70 mA (200 mA MAX) - in standby < 200àA

Ultrasonic sensor HC-SR05 is a sensor used to determine internal distance small range by emitting ultrasonic waves Sensor with pretty accurate accuracy high (with minimum recognition distance of 3mm) and high stability during use application, and easily connect to MCUs (Arduino, DSP, AVR, PIC, ARM )

This sensor uses the principle of ultrasonic wave reflection, including 2 modules, 1 module emits ultrasonic waves and a module receives reflected ultrasonic waves Firstly The sensor will emit an ultrasonic wave If there are obstacles on the way, waves The ultrasound will reflect back and affect the receiving module By measuring time from From transmitting to receiving, we will calculate the distance from the sensor to the obstacle

Distance = (time*Speed of sound)/2

Table 4 2 Specifications of Ultrasonic Distance Sensor

Trigger Input Signal 10uS TTL pulse

Echo Output Signal TTL lever signal and the range in proportion

The thermocouple, which is a closed circuit thermal sensing device made up of two different metal wires joined at both ends, is most commonly used in a variety of industries It measures temperature by creating an electric current in response to a temperature difference between the two ends The thermocouple comes in a number of types, each denoted by a letter (K, J,

Table 4 3 Advantages And Disadvantages Of K Type Thermalcouple

The capacity to record very high temperatures for an extended period of time

Throughout the whole range, the inaccuracy is roughly 1%

Able to withstand abrupt rise or fall in temperature

Its output is expressed in millivolts (mV), and because of its modest size, noise can

Able to measure high temperatures constantly easily interfere with long-distance transmissions

Affordable price There will be some delay when using

Table 4 4 Specifications of Thermocouple K Type

Temperature Sensor Type Thermocouple K Type

Wire Metal coated sensor wire

The heat sensor thermocouple type K MAX6675 is used in temperature measurement systems in the industrial environment to ensure the accuracy and durability of the system It amplifies the measured value from the K-type thermocouple for high accuracy, stable during operation, and transfers sensor values to microcontroller using sensor SPI communication standard Specifications:

Table 4 5 Specifications of MAX6675 Converter Module

Resolution ADC 12bit, 0.25 degree K/unit

Figure 4 11 Settings for The MAX6675

Figure 4 13 Connecting MAX6675 to Arduino

How to utilize a K-type thermalcouple with MAX6675

Processing will be quite challenging because the K-type TC's output signal is such a tiny voltage In this case, I am using the MAX6675 ADC converter circuit and communicating with the computer via SPI interface

Figure 4 14 Connect The Microcontroller And MAX6675

Figure 4 15 SPI Protocol of MAX6675

Each data transfer consists of 16 bits, where bit 15 and 3 bits 0 1 2 are device information, unused 12 bits left Again bits 3 to 14 contain the value to read the temperature When the CS pin has a low signal, each SCK clock pin goes high, the signal SO pin will write and shift from bit 15 to bit 0 When the CS pin goes high again, line transmit interrupt and terminate a data read cycle

The temperature value will be equal to the reading of / 4 when the string value is all bits equal to 0, as per the manufacturer's datasheet All bits equal to 1 correspond to 1024 degrees Celsius, and 12 bits of data correspond to 2^12 = 4096.heat

In controlling the water temperature, we used a zero point detection circuit and a triac trigger circuit via Arduino Uno to adjust the PID to increase or decrease the water temperature to suit the desired

There will be times when the voltage is zero because the 220V sinusoidal voltage has a frequency of 50Hz, T = 0.02s At this point, we will adjust power control by stopping briefly in the previous half-cycle when supplying the control pulse to the triac The voltage will change from a negative value to a positive value or vice versa again after every half cycle of

The power supply will be limited to a fixed temperature after the target temperature value is obtained This time interval will be determined by the set of PID; the longer the delay time, the smaller the power supply, and vice versa

Figure 4 16 Zero Point Detection Circuit On Proteus

A semiconductor consisting of a light emitter and an optical sensor integrated into a single block is called an opto-isolator, or Opto PC817/EL817 SOP4 Photoconductive sensors are photo transistors, and the luminizer is a luminescent doide used to emit excitation light

Developing A Temperature Control Algorithm

4.4.1 Overview Of The Temperature Control Unit

The heating process is a common process widely used in industries such as food, manufacturing and agriculture Proper heating during product manufacturing ensures quality and prolongs shelf life PID control is known as a simple and powerful control applied to control this heating process According to statistics, more than 97% of industrial controllers are the same type as PID controllers

Proper adjustment of control parameters will ensure optimal performance over the specified operating range Some prominent methods are the first and second ZieglerNichols methods, continuous PID, and digital PID (discrete PID)

The temperature control unit can also regulate humidity, pressure, and flow rate through input signals of 4-20mA or 0-10 VDC, 0-5 VDC It integrates additional features like temperature alarms, direct value setting through a display screen, self-adjustment mode, and adaptive mode Furthermore, with PID control mode, the temperature control unit adjusts the system temperature to match the set temperature as quickly and accurately as possible

Figure 4 33 Diagram Of Closed-Loop PID Control

The set temperature and the actual temperature feedback are the two input signals for temperature control applications The control output signal for the triac is the angle value Since modeling the system is challenging, the transfer function of the object is a first-order lag element—is determined by an identification method, and the PID parameters are then designed

Proportional Integral Derivative, or PID, is a feedback control mechanism that consists of three control components: proportional, integral, and derivative It is the most common type of controller and is utilized in automation, electronics, electrical systems, and industrial control systems

We used formulas to find the PID transfer function including: Ziegler-Nichols 1, Cohen-Coon, Haalman, Module Optimization Method

Figure 4 34 Diagram When Using Some Methods

Using a PID controller, this circuit is intended to regulate the temperature of a heating resistor (220V/1kW) The temperature control circuit modulates the voltage applied to the heating resistor in order to control the on/off state of the TRIAC

The circuit carries out the following functions: it determines the AC voltage's zero-crossing point, applies the PID controller, and modifies the TRIAC gate's firing angle to regulate the heating resistor's temperature

The transfer function of the system:

 PID control signals for discrete systems:

• u(k) is the current time control signal

• e(k) is the error at the present time

• e(k-1) is the previous error 1 sample

• e(k-2) is the previous error 2 samples

4.4.4.2 Build The Simulation Transfer Function

Figure 4 36 System Simulation Block Diagram

We determine the approximate transfer function of the thermal furnace as:

The approximate output signal is the function: c(t) = f(t - T1) (4.34) Within:

Therefore, when applying the delay theorem, we get:

It can be deduced that the transfer function of the thermal furnace is:

The transfer function of the heat furnace is determined by experimental methods Maximum heat supply to the furnace (input power P = 100%), furnace temperature gradually increases After a while, the furnace temperature reaches saturation value Thermal characteristics over time can be shown as Figure below Because the exact properties of the thermal furnace are quite complicated, we can approximate it with an approximate response as shown in Figure below

Figure 4 39 The Temperature Graph Of The Object Over Time

From the graph, we deduce that K = 53, the time delay T1 = 50s, and the time constant T2 150s

4.4.4.3 Apply Methods To Find PID

After all methods, the PI method is the method that produces the lowest overshoot and least fluctuation, so we chose this method

Figure 4 40 Comparing The Methods With Each Other

• Conclusion: From the analysis, the team has chosen the parameters Kp = 0.0176 and

Figure 4 42 Running PID In Reality With Setpoint 50 o C

Figure 4 43 Running PID In Reality With Setpoint 60 o C

Subsequently, we incorporated the PID controller into the code and ran the heating system, yielding results as shown in the adjacent figure

BUILDING A USER INTERFACE AND INTERACTIVE WEB

Introduction

With requirements for operability, interoperability and User-friendliness, the machine needs to have a control interface to coordinate with the mechanical mechanisms and peripheral devices to operate synchronously and merge with each other, thereby being able to operate well A remote monitoring console and web interface will be provided giving users good interaction as well as a friendly feeling when using, meeting user-friendly criteria.

User Interface

5.2.1 Introduction To Python Programming Language

Python is not only a popular programming language in the fields of software development and computer science, but is also widely used in the Internet of Things (IoT) field With its flexibility and versatility, Python has become one of the top choices for building IoT applications

One of the advantages of Python in the IoT field is its compatibility with many different types of devices and sensors Python's readability and familiar syntax help create IoT applications that can be deployed and controlled efficiently

In addition, Python also provides many libraries and frameworks to support IoT development, allowing developers to take advantage of features such as networking, processing data from devices, and creating applications complex IoT applications With its popularity and versatility, Python is certainly a powerful tool in building and deploying diverse and effective IoT solutions

Therefore, our team is choosing Python to design User Interface

5.2.2 Introducing An Overview Of The User Interface

The user interface will be built with the following main functions:

Figure 5 1 User Interface Block Diagram

Our team developed a control interface in Python to easily monitor and control sensors and operational processes as shown in the figure below

In this section, establish connection between computer and washing machine via Pyserial communication To establish a connection, users need to enter the correct COM port and Baudrate If not found, press the "Refresh" button to reload the available ports, then press the

"Connect" button and press “Disconnect” button when close the connection

Figure 5 3 Connect To Com Port

In this section, Set the temperature and water level for both tanks and press "Submit" to set the machine's temperature and water level values

Figure 5 4 Control Temperature And Water Level Via Web

• Jog left, Jog right : Used to control the working arm to the desired position When in normal running mode, the machine will control it automatically

• Run: Used to control automated processes

• On, Off Ultrasound: Used to manually turn on and off the ultrasonic transmitter for cleaning

• Current temperature and water level in each tank values will be updated and displayed in real time

In this section, Current temperature and water level in each tank values will be updated and displayed in real time on the line graph to allow users to easily track the temperature, water level

Figure 5 5 Results Are Exported As Graphs

Web Interface

Internet of Things (IoT) is a network of connections between smart devices over the internet These devices can be everyday objects or smart sensors, collecting data from their surroundings and sending it for remote processing or control IoT is widely applied in areas such as smart homes, healthcare, industry, and smart cities to enhance utility and performance

In the field of IoT development, web technologies such as PHP, MySQL, HTML, CSS, and JavaScript play an important role in creating user interfaces and managing data from IoT devices In which these technologies can be combined to create flexible and efficient IoT applications:

PHP and MySQL: PHP is often used to process data sent from IoT devices to the server This data is then stored, processed and queried in a MySQL database so that it can be displayed and analyzed on a web interface

HTML, CSS and JavaScript: HTML creates the structure of a website, CSS governs the visual appearance, and JavaScript provides dynamic interactive features These technologies create user interfaces that interact with and display information from IoT devices

Connection and Communication: Data from IoT devices is transmitted to the webserver via protocols such as HTTP or MQTT This information is then processed and displayed on a web interface so users can conveniently monitor and control IoT devices from anywhere

Integrating Webserver and IoT: Combining web technology and IoT opens up many opportunities in creating smart IoT applications This integration not only simplifies control of smart devices, but also creates a flexible and enjoyable interactive environment for users the combination of web and IoT technologies not only creates flexibility and convenience but also opens up great potential for future smart application development

Figure 5 6 Controller Design Diagram Via Web

Here are the steps to design a verification website, specifically:

- Web server design: responsible for receiving requests from clients (user interfaces, ESP8266 to process, then responding and giving results to the clients

- Setup for ESP8266: acts as a web client, responsible for retrieving data and displaying it on the Web Server, and at the same time receiving data from the server

- Setup for Arduino: plays the role of connecting Uart with ESP8266, receiving commands from raspberry and transmitting control signals to control the robot

5.3.3 Overview Of Monitoring On The Webserver

Checking and monitoring machines in factories has historically been quite difficult for operators Normally, they will have to check through software, but when in a remote location, they will not be able to monitor the machine's operation

Understanding that the cleaning machine integrated website to monitor and check machine operations was created to support people in monitoring the machine quickly, accurately and most conveniently for users at all times place Users can be located in different locations in the factory and can check right on the computer web

Remote monitoring function will be available for possible users Fully check information as well as control water level and temperature

Operating principle, users need to log in to the account provided first and then will be navigated to the monitoring page The monitoring page provides complete information about the current temperature and water level of the two tanks Besides, users can export data from the web to the computer to Excel

Database is an indispensable part of any webserver, the team researched and decided to create

2 tables: users and sensor_reading to manage users as well as sensor values from temperature and water level sensors

With database features, user and sensor data are managed effectively

Sensor data sent from the main board to the ESP8266 via Uart is saved in the tables created above

With the login feature, users are forced to log in first to use it If you have not registered a user account, you will be prompted to register before using

With this feature, the temperature and water level will be displayed for users to easily observe and manage

With this feature, users can export temperature and water level data to an Excel file for processing

Figure 5 11 Export Data To Excel

After clicking the Export button, the data will automatically be saved to the excel file

Figure 5 12 Data Is Exported To Excel

IMPLEMENTATION, EXPERIMENT RESULTS/ FINDINGS AND

Implementation

Figure 6 2 Completed System Top View

Figure 6 3 Servo System And Automatic Arm

Figure 6 4 Making PCB Printed Circuits

Figure 6 5 Compeleted Zero Detection Circuit

Set Objective Requirements

1 It must have great durability

2 The rusty materials needs to remain clean on its surface

3 The rusty materials ought to remain useable on its surface

4 It must have a great power

6.2.2 Correlation Between Needs And Metrics

Metric No Need No Metric Important rate Units

Table 6 2 Correlation Between Needs And Metrics

We use two real tests, referred to as static tests, which estimate static metrics including dimension, total mass, stiffness, and other no-electricity criteria, to test the machine's functioning range and dependability

Table 6 3 Compare Between Design Value And Actual Value

METRICS DESIGN VALUE ACTUAL VALUE

• Verify the machine's operational capacity

• Think about vibration in machines

- After adjusting the electrical connection and testing the machine, make sure it is safe, turn off the power source, and submerge the device securely in 36 liters of water

- When using, keep the washing machine's construction in mind

• The machine runs steadily and vibration-free all the way around the machine body

• Although it makes a little noise, the machine is good for large spaces like factories and businesses

• The servo unit moves with gentle stability

Cleaning solution test by temperature:

The group establishes its own standards for evaluate the machine's efficacy: its cleaning ability and the degree to which the surface is still useful despite its roughness Outcomes of variables influencing the cleaning process:

Table 6 4 Temperature Affects The Outcome

• Conclusion: The data show that, that objects tend to be less clean at lower temperatures, whereas they become cleaner at higher water temperatures Our team conducted tests on

109 cleaning efficacy at various temperatures, and overall, temperature does have an impact on rust removal Results indicate that temperatures above 80 degrees generally yield better cleaning effectiveness

Test of cleaning solution by Solven:

Table 6 5 Solven Affects The Outcome

• Conclusion: The data show that, although the temperature is the same, using dishwashing liquid is more effective

Test of cleaning solution by Time:

The team also observed that time affects the machine's cleaning capability Specifically, after multiple trials, it was found that the items reached maximum cleanliness that the machine could achieve after 20 minutes.

Analysis

What completed and need improvements?

• The team has successfully created an ultrasonic washing machine

• The machine is capable of cleaning slightly rusted objects

• The model is controlled via interface and can be monitored remotely via WebServer

• Can be easily upgraded in the future to increase efficiency

After doing experiments and test, we have finalized some pending problems to be improved:

• The machine's low cleaning effectiveness is due to its insufficient ultrasonic emission power

• Limited budget constraints hinder the accurate measurement of water levels using ultrasonic waves, as oscillations cause inaccuracies in setting water levels

• Prolonged operation leads to unstable malfunctions due to low-quality components such as the ultrasonic transmitter circuit

• Experimentation across various conditions and items hasn't been possible yet

• Revised tank design (adding a spring mechanism to the ultrasonic sink to increase cleaning efficiency)

CONCLUSION AND RECOMMENDATIONS

Lessons Learned

It is extremely important to thoroughly evaluate performance and limitations before implementation In this case, the sound wave generation does not achieve the desired performance, reducing the cleaning efficiency of the machine

Using poor quality components can cause unwanted problems and reduce the reliability of the final product Choosing high-quality components and periodic quality testing are important to ensure product performance and durability

Cleaning rusty objects can use more effective methods using specialized industrial cleaning chemicals

The project has provided an overview of knowledge on web models, myPHPAdmin, based on which a successful control website has been built capable of handling multiple concurrent processes with extremely large data streams

Revised tank design (adding a spring mechanism to the ultrasonic sink to increase cleaning efficiency)

Future Development

To perfect an optimal washing machine, functioning well and stable in various environmental conditions for commercialization, the team needs to further research and improve several issues such as:

- Improving the hardware design for durability and aesthetics involves enhancing both structural integrity and visual appeal

- Improving the temperature control algorithm to operate more stably and enhancing the responsiveness of the response speed

- Developing software for stable operation, ensuring the machine operates flexibly and is easy to maintain Creating a foundation for future research and development

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