3.3.

1 Motor Sizing and Selection

1. Measuring Chamber Sliding Valve Drive Mechanism

(a) Determination of the Drive Mechanism

Three actuators are required to open and close the three sliding gate valves that allow the grains onto
the weigh scales in the measurement chambers. Accuracy of these actuators is important to prevent
release of excess grains onto the weigh scales. Table 3.4 shows a comparison of various drive
mechanisms.

Table 3.4: characteristics of different actuators.

CHARACTERISTIC LINEAR MOTOR RACK AND PINION BALL SCREWS

Efficiency 87 97 89
Operation Quiet Quiet Noisy
Energy consumption Moderate Moderate High
Heat emission Moderate Low High
Acceleration rate Moderate High Low

Linear actuator motor was chosen due to accuracy and quiet operation.

(b) Dimensions and Mass The sliding valves hold all the grains in the reservoirs, hence prevents spilling
of grains past the measurement chamber unless measurement is taking place. The linear actuators
should be able to withstand all the weight of grains while releasing them bit by bit onto the weigh
scales, thus maximum weight of grains in each reservoir is calculated using the volume Vreservoir and
average density of grains µ as shown in Equation 3.24.

M = Vreservoir × ρ = 0.00694 × 720 = 7.2kg (3.24)

where M is the mass of the load. The radius of each measuring chamber is 75mm, thus the linear
actuator must have a stroke length of at least 75mm.

(c) Determination of the Linear Motor Performance and Specifications

To determine the load capacity, FL, of the required linear actuator [9], parameters such as the maximum
load (weight of grains), the coefficient of friction (µ) and the force due to gravity are required.

FL = (Ff + Fg + M) (3.25)

FL = (M × µ) + (M × g) + M = 0.23(72) + 9.8(72) + 72 (3.26)

FL=795N
where M is equal to 72N, which is based on the maximum weight each reservoir can accommodate. The
Symbol µ is the friction coefficient for mild steel and g is the acceleration due to gravity. In Kenya, there
are only two available varieties of linear actuators. One has an operating voltage of 12V DC, stroke
length of 100 mm, static load of 900N and a speed of 6mm/s. While the other has an operating voltage
of 12V DC, stroke length of 200mm, static load of 300N and a speed of 30mm/s. The first option was
chosen since it is cheaper and meets the design specifications: operating voltage of 12V DC, 100mm
stroke length, static load of 900N and a speed of 6mm/s.

(d) Weighing Scale Valve Drive Mechanism

i. Determination of the Drive Mechanism

This actuator is used to control the opening and closing of the weigh scale valves, which are on the
lower side of the measurement chambers. It rotates in small, discrete steps up to 90 degrees, rather
than continuously thus ensuring all the measured grains are poured into the funnel. All the three valves
of each chamber are connected together by a single shaft. At any instance only one type of grain is
released when the shaft rotates. All these requirements for the drive mechanism are met by the stepper
motor and hence selected to drive the valves.

ii. Dimensions and Mass

The maximum mass that the weighing scale can carry is 1kg, summing to 3kgs.

iii. Determination of the Stepper Motor Performance and Specifications

The maximum opening angle for the weighing scale control valve for this machine is 90◦ . The load
torque acting on the stepper motor equals to:

T = (F × r) = (30 × 0.075) = 2.25Nm (3.27)

Where T is the holding torque, F is the maximum axial force on the motor, 30N and r is the
perpendicular distance from the point of action of the force and the fulcrum, r in this case is the radius
of the weigh scale plate. The holding torque is 2.25N/m.

The NEMA 23 was selected and has the following specifications; 24.0 kg-cm, 1.8 step angle, 8.6V, 2.0A.

(e) Agitator Drive Mechanism

i. Determination of the Drive Mechanism

The drive mechanism must be able to provide direct rotation.

ii. Determination of the specifications

The maximum load acting on the motor is the total mass of the agitator (2 grams) and the grains and
hence;
F = (Mg + Ma)g (3.28)

F = 30N

where F is the sum of mass of grains and the mass of the agitator.

The torque required, T is:

T = (F × r)

T= 3.712Nm (3.29)

where r is the radius of the agitator.

Output power is therefore

P = (T × w)

P = 19.436W (3.30)

where w is the rotational speed of the motor in m/s. Hence the agitator uses a motor with a torque of
3.712Nm and power of 20W.

(f) Mixing Chamber Sliding Valve Drive Mechanism

i. Determination of the Drive Mechanism

This actuator allows the sliding valve to move linearly until all the grains have been released into the
customer’s container. Rack and pinion was selected since it is affordable and produces relatively high
speed due to reduced backlash.

ii. Determination of the performance and specifications The holding torque, T,

T = (F × r)

T= 15 Nm (3.31)

hence the holding torque is 15 N/m. where F is the force acting on the motor, which is 30 N and r is the
perpendicular distance from the point of action of the force and the fulcrum, r in this case is the radius
of the weigh scale plate.

3.3.3 Circuit Design

(a) Control circuit

Motor drivers

The H-bridge L298N motor driver will be used. Some of the advantages of H-bridge drivers over other
drivers are that it allows for speed control using pulse width modulation and allows for change of
direction of rotation of the motor by reversing the polarity of the voltage applied to a DC motor. The
L298N can handle up to 3A at 35 V, making it suitable for motors. The L298N also contains two H-bridge
circuits making it capable of driving two motors. It has an internal 5 V voltage regulator that can be used
to supply the logic circuit (78M05). The L298N is attached to a heat sink for dissipating heat.The motor
power supply needs to be 1.4V higher than the actual motor requirements , due to internal voltage drop
in the transistors. Since the DC motors are rated 6 V, they actually require 6.4 V. A voltage of 12V will be
supplied from the source. For the logic supply voltage, 5 V will be supplied from the voltage regulator.
Below are the pins that will be used.

i. IN1 – Input 1 for Motor A

ii. IN2 – Input 2 for Motor A

iii. IN3 – Input 3 for Motor B

iv. IN4 – Input 4 for Motor B

v. EN1 – Enable line for Motor A

vi. EN2 – Enable Line for Motor B

vii. VCC – 12V

viii. Vs – 5V

The ENA1 and ENA2 are connected to PWM on the arduino to allow for speed control when PWM signal
is applied. The shorter the signal the lower the speed. IN1 and IN2 are used for changing the direction of
rotation of motor A.

Load cell sensors

These are used in weighing of the grains from each reservoir. Accuracy and resolution is paramount as
various load cells have different accuracy and capacity. The required load cell capacity for this machine
is 1kg. In Kenya, there are only two varieties of load cells available. The Load Sensor body scale has very
low accuracy as compared to the Load cell weight sensor. The latter, was chosen due to its high accuracy
[4]. The circuit for the load cell is shown in Figure 3.8. It was designed using Proteus software. Since
there is no standard Proteus library for this load cell, five resistors (one variable) and an amplifier were
used for the circuit simulation.

(Circuit ya load cell na computations)

(b) Power Circuit

240V from the mains will be stepped down to 14.4V to ensure protection from over voltage. This value
14.4V was chosen so as to give an allowance for stepper motor voltage requirement (12V). To design the
number of turns for the transformer, the formula below is used.

Vs /Vp = Ns/ Np (3.32)

Where Secondary voltage Vs = 14.4 V , Primary Voltage Vp = 240 V. Number of turns in secondary = Ns ,
Number of turns in Primary = Np. Substituting, turns ratio Ns :Np = 6:100.

The LM317k linear voltage regulator is used to step down the voltage from 14.4V to 12V required for
our components. Linear voltage regulators are Inexpensive and don’t create electrical noise.

Vout = Vref (1 + R2 R1 ) (3.33)

Feedback resistor R1 is set to 240 Ω to draw a minimum of 5mA from the regulator and help maintain
stability. A sink resistor R2 is connected from the adjust pin to ground, creating a potential divider.
Inside the LM317 is a power switch, a voltage reference set to produce Vref of 1.25 V , and an
operational amplifier. The op-amp tries to keep the voltage at the output equal to the voltage at the
adjust pin minus the reference. Capacitors C1 and C2 are decoupling capacitors for smoothing the signal.
Output voltage from the regulator vout = 12 V . Substituting, R2 = 2064 Ω ≈2 kΩ.

REDESIGNS IN ELECTRICAL

Stepper motor

The Hitachi 4A 5 V was used instead of the NEMA 23. This is because it provided a higher torque(6Nm)
than the NEMA 23 (2.25Nm).

Linear Actuator Drivers

An 8- Channel Relay was used to drive the linear actuators instead of the L298N drivers. This is because
the L298N supplies a maximum of 2A while the linear actuators require four.