Design badminton equipment feather planting machine for manufacturing badminton ball

Hanoi University of Science and Technology School of Mechanical Engineering Center for Training of Excellent Students **********  ********** Final Thesis Topic: Design badminton equipment feather planting machine for manufacturing badminton ball Instructor: Ph.D Trương Hoành Sơn Students: Nguyễn Huy Bắc Trương Thành Công Class: Mechatronics Advanced Training Program course 56 Hanoi, June, 2016 Ph.D Truong Hoanh Son Students: Nguyen Huy Bac-Truong Thanh Cong Hanoi University of Science and Technology School of Mechanical Engineering Center for Training of Excellent Students SOCIALIST REPUBLIC OF VIETNAM Independence-Freedom-Happiness FINAL THESIS Students: Class: Nguyễn Huy Bắc Trương Thành Công Mechatronics - Advanced Training Program – Course 56 I PROJECT Design badminton equipment feather planting machine for manufacturing badminton ball II CONTENTS Chapter – Introduction Chapter – Mechanical structure Chapter – Design driving system Chapter – Design control system Appendix A: Codes for MCU ATmega8 III Day of assigning thesis: November 20th, 2015 IV Day of completing thesis: May 30th, 2016 Hanoi, June , 2016 DEAN OF DEPARTMENT INSTRUCTOR HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY SCHOOL OF MECHANICAL ENGINEERING CENTER FOR TRAINING OF EXCELLENT STUDENTS - FINAL THESIS REMARK Nguyễn Huy Bắc Trương Thành Công Mechatronics - Advanced Training Program - Course 56 Students: Class: PROJECT Design badminton equipment feather planting machine for manufacturing badminton ball CONTENTS Chapter – Introduction Chapter – Mechanical structure Chapter – Design driving system Chapter – Design control system Appendix A: Codes for MCU ATmega8 REMARK Remark of Instructor ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… Evaluation Hanoi , June, 2016 INSTRUCTOR Remark of Reviewer ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… ……………………………………………………………………………………… Evaluation Hanoi , June, 2016 REVIEWER ABSTRACT Every days, there are a lots of shuttlecock are consumed in Viet Nam Almost of them are manufactured in Viet Nam and because of the poor of the production technology so we spend a lot of money for each ball is produced In the world, there are some manufacturer sell the chain of badminton machine but the price of them is very high (normally above 6000$ USD) In the production process, these steps as drilling and putting leather are very important in hole process but almost is realized on separate machine that cause the waste Actually, there are several shuttlecock manufacturing facility in Viet Nam But almost of them use the machines which are composed of all mechanical elements In this project we use the microcontroller to build a machine because of microcontroller brings high performance in space, time, economic value and very convenient for using to suit to the development of society In this project we will design and make a shuttlecock manufacturing machine which has almost automatically work This machine will need only one worker to realize these process as drilling hole, putting leather and the productivity of this machine will be increased Therefore, we will save money, time and labour After months of study and research reference material with a sense of personal effort, we succeeded in designing and making the shuttlecock manufacturing machine; Building the control system of this machine using Atmega16.Since in the process of working, with young on the level of professional knowledge, practical experience and time constraints of the project so we cannot avoid mistakes Therefore, we are looking forward to more help of the teacher, and the contribution of friends Acknowledgements This thesis is constant effort to learn new things, and almost importantly to excel at what we know Throughout year, this work was never to see the light without a great help from people around us and people in our mind We would like to thank Ph.D Trương Hoành Sơn for his great effort and help, also, we would like to thank Dr Nguyễn Trọng Thanh for his great effort and great tips every day Not forget many thank to teachers in practical center, our parents, our friends they made great help to our project TABLE OF CONTENTS Table List Table Name of table Page 3.1 Comparison between step, servo and DC motor 19 4.1 Setting current of DMA860H 49 4.2 Setting pulse/rev of DMA860H 50 4.3 Setting current of M6600 51 4.4 Setting pulse of M6600 52 Table of Figures Number Name of Picture Page Fig 1.1 Structure of a standard badminton ball 13 Fig 1.2 Drawing of cork base 114 Fig 1.3 Feather 14 Fig2.1 Block for holding and pushing the cork base 16 Fig 2.2 Drilling mechanism 17 Fig 2.3 Feather planting mechanism 17 Fig 2.4 The mechanism create in-out motion 18 Fig 2.5 Pushing support 18 Fig 3.1 The dynamic diagram of the machine 19 Fig 3.2 Some step revolutions 21 Fig 3.3 Structure of a step motor 22 Fig 3.4 Operation principle of step motor 23 Fig 3.5 Torque and speed relationship of step motor 24 Fig 3.6 Pulse rate and inertial load relationship of step motor 25 Fig 3.7 Single step response 26 Fig 3.8 Torque and angle characteristics of step motor 27 Fig 3.9 Relation between frequency of pulse and the rotated angle of 28 step motor Fig 3.10 Parameter of the first step motor 31 Fig 3.11 Parameter of the second step motor 33 Fig 3.12 Bevel gears 34 Fig 3.13 Bevel gear Terminology 34 Fig 3.14 Bevel gear force 34 Fig 3.15 Size factor of bevel gear 35 Fig3.16 Geometry Factor for Contact Stress 36 Fig 3.17 Structure and specific parameter of Malt mechanism 36 Fig 3.18 Ratchet structure 38 Fig3.19 Culit Structure 39 Fig3.20 Some types of ratchet 39 Fig 3.21 Force act on cylinder 41 Fig 4.1 Pin configurations PDIP 44 Fig 4.2 I/O Pin Equivalent Schematic 46 Fig 4.3 Block diagram of electric control system 47 Fig 4.4 Schematic of supply source 48 Fig 4.5 Oscillator circuit 48 Fig 4.6 24V- power supply 48 Fig 4.7 DMA860H 49 Fig 4.8 M6600 51 10 When set a voltage to this valve: the air is supplied for way B, way A is connected to exhaust way ● Pressure limiting valve Fig 4.12: Pressure limiting valve and its symbol - - - - Features: • Range: 0.9>>9.9 Kgf/cm3 • Maximum 9.9 Kgf/cm3 Purpose: • Limit the pressure in the system to below some safe value The valve opens and vents to the atmosphere, or back to the pump, if the pressure rises above the set safe value Pin configuration • P: air supply • T: output way Principle operation The pressure limiting valve has an orifice which is normally closed When the inlet pressure over comes the force exerted by the spring, the valve opens and vents to the atmosphere or back to the pump ● Throttle valve 54 • • Fig 4.13 Throttle valve and its symbol Purpose: to control the amount of air that reaches the cylinders Operation principle Fig 4.14: Operation principle of throttle valve The disc is a flexible material liner, similar to a diaphragm The stem of the throttle valve has a free-moving connection to a moving closure bar called a compressor, which is located directly above the liner As the hand wheel is turned, the compressor lowers the liner to squeeze the liner against the bottom support to close the valve The pressure of the media can help in starting or topping the flow ● Photo-micro sensor EE-SPY 301 55 Fig 4.15: Structure of photo-micro sensor EE-SPY 301 Features: • Sensing distance: 3.6 mm • Sensing object: 1x0.5 mm minimum • Light source: GaAs infrared led with a wavelength of 940 nm • Supply voltage: 5>>24V-DC • Material: polycarbonate ● Module relay 5V - channels - - Coil rate voltage: 3-48VDC Insulation resistance: ≥ 100Ω Fig 4.16: Module relay 5V - channels 56 Fig 4.17: Schematic of Module relay 5V - channels ● Pneumatic diaphragm A P B T EA P EB A B EA P EB Fig 4.18: Pneumatic diaphragm 57 ● Control circuit Fig 4.19: Pneumatic control system 58 4.3 Programing START READ DATA FROM SENSOR (EE-SPY 301) NO PORTC.0=1? YES ACTIVE RELAY (CLAMP FEATHER) STEPPER ROTATE 1/2 REVOLUTION STOP RELAY (PLANT FEATHER) STEPPER ROTATE 1/2 REVOLUTION NO STOP RELAY STEPPER ROTATE 16 REVOLUTIONS ? YES STEPPER ROTATE REVOLUTION ACTIVE RELAY (PUSH PRODUCT) Fig 4.20: Program algorithm 59 END CHAPTER V: IMPLEMENTATION AND TEST RUN The project is divided into phases of work -Phase one: In this period we make the block of holding and pushing the cork base We decide to use the air cylinder and cam structure to push the cork base We also use the limiting pressure valve and throttle valve to adjust the velocity of the cylinder -Phase two: After successful in making the pushing block, we continue to phase two We assembly the shaft with the disk and four clot of holding the cork base We also stick the ratchet and the second disk of malt structure with the disk And one motor is connected with the malt structure to rotate the disk -Phase three: We continue doing the milling part and inserting leather part Two part is separate but they operate synchronous, so we use one motor and two direct gear to drive that two sections at the same time For the milling part, when the machine is operating, this part will move out (in) to the holding cork to milling the cork base so we decide to use the crosshead and slider After that we making the fix stay and stick to the motor • For the inserting part, we use the cylinder to clamp the leather The cylinder is stick to the fix stay In this part we have adjust clamping structure many time to avoid the clamping hurt the leather One optical sensor is stick below the clamping The ratchet is connect to the slider to shift the cork an angle 22.5 degree • - Phase four: We design the control circuit We using the proteus software to draw the schematic circuit and Code vision software to program for the AT Mega controller After completely the control circuit, we try to run the motor And then we use the motor to adjust all mechanical part Finally, we connect all mechanical part to control circuit and test the holding process of machine Below is some picture about our product after finishing 60 61 Figure 5.1: Some picture about final product 62 CHAPTER VI: CONCLUSION 5.1 Result The thesis accomplish most of the proposed problems: • • • • • • Understanding the power transmission of some mechanism system like bevel gear, malt structure, Cam mechanism Calculate and choose the stepping motor for each drive mechanism Calculate and design the pneumatic cylinder Successful in build the Badminton Equipment feather planting machine for manufacturing Badminton shuttlecock Build the control system of machine using Atmega Know how to solve the difficult mechanical problems encountering 5.2 Limitation This is the first time we design the real product so we have a lack of experience Besides some part of this machine we made by ourselves so there are some mistakes during making process The limitation can be summary as follow:  Because we use the stepping motor so when the machine is operating it generates some noise and the stepping motor has high energy consuming  The inserting leather part are made by ourselves so it’s quite unstable leading to the slow operating of machine and therefore the productivity is slightly lower than expected 5.3 Conclusion When received this thesis, we have determined it is important to assess the full knowledge that we had learned, with main purpose: Design and make the Badminton Equipment feather planting machine for manufacturing Badminton shuttlecock This subject is very suitable for Mechatronics student because it requires us to utilize all knowledge about mechanic, electronics as well as programming After months of study and research reference material with a sense of personal effort, special thanks the instruction of Ph.D Truong Hoanh Son, Dr Nguyen Trong Thanh and from our friends we have completed the work assigned up to date During the process of working, because of lacking of professional knowledge, practical experience and time constraints of the project so we cannot avoid mistakes In near future we will complete some aspect we encountered and try to make some innovation in Badminton shuttlecock 63 manufacturing machine … After doing this project, we see the powerful of Badminton manufacturing machine and the useful application of microprocessor It plays a importance role to control automatically the holding process of making the badminton shuttlecock The microprocessor brings high performance in space, time, economic value and very convenient for using to suit to the development of society In addition the microprocessor can be programmed for many other industrial automation process control REFERRENCES 64 [1] Nguyễn Trọng Hiệp, Chi Tiết Nguyên Lí Máy tập (và tập 2), xuất lần thứ 7, Nhà xuất Giáo dục,2006 [2]Trịnh Chất-Lê Văn Uyển, Tính toán thiết kế hệ dẫn động khí tập (và tập 2), xuất lần thứ 6,Nhà xuất Giáo dục, 2006 [3] Joseph E.Shigley,Theory of machine and mechanism [4] ThS Nguyễn Phúc Thảo, Hệ thống khí nén thủy lực [5] Oriented motor catalogue, Selection calculation for motor [6] PGS.TS Đào Văn Hiệp,Kỹ thuật robot.NXB Khoa học Kỹ thuật,2006 [7] Richard Barnett, Larry O’Cull and Sarah Cox, Embedded C Programming and the Atmel AVR second edition, Thomson Delmar Learning, 2007 [8] James Wagner, State Machine for Microprocessors, January 2010 [9] Robert L Norton, Machine Design An Integrated Approach, Third Edition, Pearson Prentice Hall, 2006 [10] http://www.hocavr.com 65 APPENDIX A: CODES FOR MCU ATMEGA Chip type : ATmega8 Program type : Application AVR Core clock frequency: 16.000000 MHz Memory model : Small External RAM Size :0 Data stack size : 256 ******************************************* #include #include //Declare your global variables here int i=0,j=0,count=0; void main(void) { //Input/Output ports initialization //Port B initialization DDRB=0x03; PORTB=0x00; //Port C initialization DDC=0x06; PORTC=0x01; While(1) { //read data from sensor while(PINC.0==0) {} delay_ms(1500); //Active relay 66 PORTC.1=1; //Rotates stepper For (i=0;i[...]... the international standards There exists a huge demand for badminton ball in Viet Nam 1.2 Structure of a badminton ball A badminton ball consist of 2 main parts: A cork base (made of cellular rubber) • feather • Fig 1.1: Structure of a standard badminton ball 1.3 Process of making the badminton ball • • • • • Feather selection Feather inspection Feather insertion Pouring glue on cork base Curing period... countersink 2.3 Planting feather mechanism Fig 2.3: Feather planting mechanism A base has the same deformation with feather shaft is created and move up and down based on the motion of an air cylinder 2.4 Other parts 16 Fig 2.4: The mechanism create in-out motion Fig 2.5: Pushing support To synchronous drilling motion and planting motion, we need a mechanism that can drill and plant feather at the same... INTRODUCTION 1.1 History Badminton is played almost throughout the world by both men and women and also by the Children This game is also very popular in our country and is being patronized by the Government and Non-Government agencies and clubs etc With the increase in popularity of the badminton, the demand for good quality badminton ball is also increasing The life of each badminton ball is generally short... in the game Hence, the consumption pattern is quite frequent The badminton ball is one of the simplest items of sports goods manufacture with lesser investment of capital and can be produced in tiny and small-scale sector There exists a very good market potential for badminton ball in Viet Nam and abroad However, most of the badminton ball manufactured are used internally with the exports being very... processors, electric discharge processors, CNC machines, sewing machines, etc -Semiconductor fabrication equipment: Wafer processing devices, wafer conveyors, IC bonders, dicing machines, IC inspection devices, etc -Automation and labor-saving devices: ATMs, ticket machines, postal sorters, laboratory systems, bill counters, vending machines, etc -Medical equipment: Analytical instruments, blood pumps,... stepping motor for this machine 3.2.1 Stepping motor ■ Introduction Stepping motors are digitally controlled motors used for precise positioning They enable simple, accurate control of rotation angle and rotation speed, so they are suitable for wide variety of applications Oriental Motor has brought hybrid stepping motors into its product line to provide better levels of precision and performance when... Curing period 12 • • • • Sewing Pouring glue on string Final curing Testing Feather insertion – After being selected, feather will be planted on cork base This process can be divided to 2 small stage: • Drilling 16 holes on cork base • Planting feather on these holes 1.4 Define the problem From this analysis, we can see that the machine will has 2 main function is drill 16 holes on the cork base as the... contains ten pieces of badminton ball) Production Volume (per annum) 12000 rolls Turnover (per annum) 12000 x 375 = 4500000 Motive Power 1 HP Pollution Control There is no pollution hazard from this type of industry either in air or in water Hence, there is no need of taking any pollution control measures Energy Conservation The scope for energy conservation in the shuttle cock manufacturing industry... base out of holding part 17 CHAPTER III: DRIVING SYSTEM DESIGN 3.1 The dynamic diagram of the machine Slider Crank mechanism Mantit mechanism S TEP M O TO R Ratchet mechanism STEP MOTOR Pulley Fig 3.1: The dynamic diagram of the machine 3.2 Select the motor DC motor Stepping motor Servo motor Advantages -high speed, motor turning continuously -Use for devices which need a RPM speed such as shaft of the... the moment of load inertial d Select motor e Check the data of motor ■ For the 1st motor (motor to drive drilling and feather planting blocks):  Specifications and Operating conditions of the drive mechanism – – Feed Ball 200mm 27 – – – – – – – Desired resolution Load Coefficient of ball and slider Gear and belt coefficient D bear Weight of the gear Time  Determine the operating pattern θs = Required