Design and Fabrication of Paper Counting Machine

10 IV https://doi.org/10.22214/ijraset.2022.41169 April 2022 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com Design and Fabrication of Paper Counting Machine Ashokkumar R1, Barathan S2, Suresh R3, Sivapriya S4, Kavinkumar N5 1,2,3,5 Department of Mechanical Engineering, Bannari Amman Institute of Technology, Sathyamangalam, Erode, India 4 Department of Electronics and Instrumentation Engineering, Bannari Amman Institute of Technology, Abstract: For counting of papers in academic institutions and industries, there are no feasible machines available. The design is mainly focused on cost effectiveness and for light to medium usages. The machine is constructed by using rollers, battery, DC motor, LED display, Arduino and IR sensor. In this machine initially we need to keep bunch of papers in the paper feeding tray, then the Arduino is reset. The LED displays the number of papers counted. The machine works based on IR sensor & colour detection. The machine is designed for counting the standard A4 size paper. The roller helps in separating each sheet from a bunch of sheets. Keywords: Arduino, Colour detection, IR sensor, Paper counting. I. INTRODUCTION For counting of papers in academic institutions or in industries or wherever the usage of papers & documentation is high, there are no feasible machines or devices available for saving valuable time. The manual counting may result some error and costs time. Maintaining of databases in documentation area is difficult. Some of the available machines are high in cost and suitable mainly for heavy usages. The available machines also involve complex mechanisms. So that it is proposed to design a cost effective simple paper counting machine using simple mechanical & electronics systems. The design is mainly focused on cost effectiveness and for light to medium usages. It is also suitable for multiple usages and applications. The introduced machine should be portable, effective, efficient and it should adopt to innovations to be made in future. A market survey states that major problem faced by reprographies, stationary shops, documentation sectors are counting and collecting of papers. An average of 1 to 50 papers become a easy task whereas more than 50 becomes a challenging one. So, the introduced machine will be more feasible for their problem. II. SELECTION OF COMPONENTS A. Acrylic sheets The medium impact acrylic sheet is selected as a base material of the machine. The vertical plates and bottom plate are made using sheets of thickness 10 mm. The Electronic unit cover, Top cover are made using thickness of 4 mm. The material is easily available in variety of colors, thickness and transparency which is also compact in weight and effective in cost. B. Frame The Frame used is easily available aluminium frame with a square section of 30 X 30 mm. The frame is chosen as it is most feasible for mechanical mountings, light weight and low cost. The frame part joins the bottom and vertical plates, collecting and feeding tray. C. Sheetmetal The Collecting tray and feeding tray of this machine is made using sheetmetal. The glass fibre may be effective in some cases as surface finish is helpful for smooth flow of papers. But, as the machine is cost effective and easily portable, the best choice is sheetmetal. The sheetmetal used has a thickness of 1.5 mm. D. Arduino The Electronic controller used in the machine is Arduino UNO R3 board. The board acts as a controller which controls the DC Motor and IR Sensor. The inputs such as IR signals and outputs such as Motor control and LED Display count are processed in this board. The board is feasible in cost and the electronic connections are easy. E. DC Motor Three DC Motors controls the feeding, flowing and collecting of papers. The motors are connected with the Arduino with the help of drivers. The motors consumes low power and provides enough torque. The motors used are 12 V DC with a speed of 150 RPM. © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 97 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com F. Motor Driver The electronic power voltage fluctuation may burn out the Arduino. So, to overcome this effect and to provide better electronic connection, a motor driver module is used here. In this machine, the module used is L293D chipset. There are two Motor driver modules used here. G. IR Sensor The main objective of the machine which is counting is obtained by the use of Infrared (IR) Sensor. The sensor is very low in cost. It is easily connectable with the Arduino and high efficiency in object detection. H. LED Display The outcome of this machine is recorded by the use of 8 segment LED Display connected with the Arduino. I. Belt Drive As the End part of the flowing process of papers requires more precise separation so that the detection and counting process becomes more efficient. The end part which has two rollers rotating in opposite directions is connected through a belt driven pulleys. The belt is Rubber made. J. Rollers There are three different sized rollers in this machine which acts as a mechanism for separation and smooth flow of papers. The Rollers are Connected with the motors through Shafts and bearings. The rollers are made up of ABS Plastic as it is very light weight and has smooth surface finish which does not do damages for the paper. K. Bearings The bearings ensure the smooth rotation of the shafts in this machine. This also mounts the shafts and motors with the vertical plates of the machine. Two different sized bearings are used with Inner diameter of 10, 6 mm and outer diameter of 30,19 mm respectively. III. MECHANISMS AND METHODOLOGY The machine works on the basic objective which is obtained by the use of two processes explained below. A. Counting Mechanism The Papers are initially fed on the feeding tray. Then the Machine is Reset and the Papers are flown through the tray and each single sheet is separated and the IR sensor detects the flow and the flow is counted and it is displayed in the LED display. Fig. 1 Methodology of Counting process of Paper Counting Machine © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 98 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com B. Collecting Mechanism The other process is collecting of papers. Initially the paper is fed in the feeding tray and the required number of papers are set with the help of Arduino and the papers will get separated and counted with the above counting procedure. When the set number of papers are collected, the machine will stop. Fig. 2 Methodology of Collecting process of Paper Counting Machine C. Working Methodology The machine consists of mechanical components such as Motors, Rollers, Acrylic sheets, Sheetmetal, Shafts, bearings, nuts, bolts, frames, clamps, screws. And the electronic components are Infrared sensor, Arduino board, breadboard, L293D chipsets, wires, battery and LED display. Initially the paper bundle is fed in the feeding tray of the machine, then after resetting the Arduino the motors starts and the first roller which is a tyre like in both the ends starts pulling the papers and the separation of papers starts here. For more efficiency there is a roller in middle part which is also pulls the paper to the end part. The first and middle roller and controlled by individual motors connected with Arduino with single motor driver. The end part has two rollers because of more requirement of precise separation of paper which is controlled by a single motor and a motor driver. The two rollers rotate in opposite direction which is obtained by using a belt pulley drive. Then the paper is flown and the Infrared sensor detects and the count is displayed in the LED display. The process is repeated. Fig. 3 Electrical connections of Paper Counting Machine © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 99 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com IV. DESIGN The electronics are connected with the use of breadboard and the electronic mountings are covered by an acrylic transparent cover. The top body of the machine is also covered by transparent acrylic sheet to protect the papers and machine from dusts. The base plate and vertical plates are joined with the use of aluminium frames. The trays are also connected with the plates using aluminium frames. The motors are mounted on the vertical plate with the use of motor clamps. The shafts holds the Rollers and the shafts are mounted with the motors and vertical members through bearings. The IR sensor is mounted in the End part of the machine. Fig. 4 Rendered Model of Paper Counting Machine Fig. 5 Front view of Paper Counting Machine Fig. 6 Side view of Paper Counting Machine © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 100 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com Fig. 7 Top view of Paper Counting Machine Fig. 8(a) Annotations of Paper Counting Machine Fig. 8(b) Annotations of Paper Counting Machine © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 101 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com S.no 1 TABLE I DESIGN SPECIFICATIONS Component Material Specification Base plate Acrylic sheet 600 * 250 mm 2 3 4 Vertical plate End Roller Shaft Acrylic sheet ABS Plastic Aluminium 600 * 250 mm OD = 59.5 mm OD = 10 mm 5 6 7 Middle Roller Roller tyre Frame ABS Plastic Rubber Aluminium OD = 48 mm OD = 69 mm 30 * 30 mm c/s 8 9 Collecting tray Bearing Sheetmetal Chrome stainless steel 1.5 mm thick ID = 10 mm OD = 30 mm 10 11 Shaft Bearing Aluminium Chrome stainless steel OD = 6 mm ID = 6 mm OD = 19 mm 12 Motor clamp Aluminium 3 Nos 13 Motor Support Aluminium 3 Nos 14 Motor - 12 V DC, 150 RPM 15 Motor shaft - - 16 17 Pulley Belt Aluminium Rubber 2 Nos Length = 168.69 mm 18 Arduino - Arduino UNO R3, 5 V 19 Motor Driver Module - L293D 20 21 22 LED Display Breadboard IR Card Acrylic sheet LED 12864 830 tie points - 23 24 25 IR Sensor Top cover Electronics cover Acrylic sheet Acrylic sheet - 26 Feeding tray Sheetmetal 1.5 mm thick V. STATIC STUDY The important mechanical parts which forms the Machine’s structure were to be studied so that the conclusion can be made whether the dimensions, material, design, DFMA etc., are safe and in limit so that the machine will work fine and no errors takes place. The importance of static study is to design a machine safer to avoid vibrations, thermal effects, stresses and strains etc., The said parameters are studied and analysed using Solidworks software by performing static study. The mechanical specifications and parameters for the materials are shown in below table. © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 102 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com S.no 1 2 3 4 5 6 7 8 9 TABLE III MATERIAL SPECIFICATIONS Parameter Acrylic sheet Aluminium Name Acrylic 1060 Alloy (Medium-high impact) Type Linear Elastic Linear Elastic Isotropic Isotropic Yield strength 4.5e7 N/m2 2.75742e7 N/m2 Tensile strength Elastic modulus Poisson’s ratio Density Shear modulus Thermal expansion 7.3e7 N/m2 6.89356e7 N/m2 3e9 N/m2 6.9e10 N/m2 0.35 1,200 kg/m3 8.9e8 N/m2 0.33 2,700 kg/m3 2.7e10 N/m2 5.2e-5 /Kelvin 2.4e-5 /Kelvin A. Base Plate Fig. 9 Stress study of Base plate The part is made up of Acrylic sheet material. The total mass of the part is identified as 1.79771 kg. No thermal effects takes place in this part. The Von mises stress is found to be a minimum of 2.722e1 N/m2 and a maximum of 2.574e6 N/m2. As the stress is found to be in limit and in safe zone, the design is safe. Fig. 10 Displacement study of Base plate © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 103 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com The URES Resultant displacement is found to be a minimum of 0 and a maximum of 1.114e0 mm. As the displacement is found to be in limit and in safe zone, the design is safe. Fig. 11 Strain study of Base plate The Equivalent strain is found to be a minimum of 1.221e-7 and a maximum of 5.207e-4. As the strain is found to be in limit and in safe zone, the design is safe. B. Vertical Plate Fig. 12 Stress study of Vertical plate The part is made up of Acrylic sheet material. The total mass of the part is identified as 1.76527 kg. No thermal effects takes place in this part. The Von mises stress is found to be a minimum of 0 and a maximum of 3.407e-4 N/m2. As the stress is found to be in limit and in safe zone, the design is safe. Fig. 13 Displacement study of Vertical plate The URES Resultant displacement is found to be a minimum of 0 and a maximum of 3.407e-4 mm. As the displacement is found to be in limit and in safe zone, the design is safe. © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 104 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com Fig. 14 Strain study of Vertical plate The Equivalent strain is found to be a minimum of 1.157e-7 and a maximum of 1.517e-5. As the strain is found to be in limit and in safe zone, the design is safe. C. Frame Fig. 15 Stress study of Frame The part is made up of Aluminium material. The total mass of the part is identified as 0.027 kg. No thermal effects takes place in this part. The Von mises stress is found to be a minimum of 9.393e1 N/m2 and a maximum of 8.4645 N/m2. As the stress is found to be in limit and in safe zone, the design is safe. Fig. 16 Displacement study of Frame The URES Resultant displacement is found to be a minimum of 0 and a maximum of 2.641e-3 mm. As the displacement is found to be in limit and in safe zone, the design is safe. © IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 105 International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538 Volume 10 Issue IV Apr 2022- Available at www.ijraset.com Fig. 17 Strain study of Frame The Equivalent strain is found to be a minimum of 3.051e-9 and a maximum of 9.424e-6. As the strain is found to be in limit and in safe zone, the design is safe. VI. RESULTS AND DISCUSSION The machine is designed and fabricated with simple mechanical and electronic systems at very low cost. This machine is portable and affordable. The machine is mainly suitable for low to medium usages in offices, accounts section, stationery shops, Reprographies etc., This machine is also maintenance free. It also occupies less space only. Setting the allowance between the roller and the tray is the difficult task, as it leads to improper separation of papers. VII. CONCLUSIONS The output expected in this machine is to reduce the human power and the time taken to count the papers in industries and in educational institutes and it is achieved. Further improvements like increasing the capacity of papers in the tray can be made by incorporating additional rollers. This machine can be used for further applications like counting cards by incorporating additional features. The machine can be also further automated by using additional electronic and mechanical systems. 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