Battery less and Wireless Conveyor Belt System

Project Title

Battery less and Wireless Conveyor Belt System

Project Area of Specialization Mechatronics EngineeringProject Summary Industry 4.0 needs wireless fully automated, minimum labour, and power-saving Conveyor BElt System with low maintenance cost. We are determined to provide what is need of today's production era. Wire-less and Battery-less Conveyor Belt is self-efficient system providing the full control and Visual monitoring over each part. Energy Harvesting modules (Electromagnetic and Peizoelectric) energizing the low-powered modules containing Zigbee Communication Module and monitoring sensors. Project Objectives

The main objective we are striving for is to provide maximum facilities for Packaging and Loading in following areas;

• Workshops
• Warehouses 
• Transport and Logistics Industries
• Manufacturing Industries

The objectives we will attain are mentioned below. Each feature boosts up the productions and also provides the aid for labours.

• Power saving and energy-efficient
• Battery-Less system for sensors and communication module
• Wire-Less and Analytical Monitoring system
• Advance Visual and Analytical Monitoring 
• Full filling safety parameters for maintenance and labour

Project Implementation Method

Conveyor Belt is a machine used for raw and logistic transport in vast fields. Batteryless and Wireless Conveyer Belt Monitoring System can easily be installed on any Conveyor Belt machine for listed benefits. Only Installing system and software will provide a complete monitoring system. Easy to identify the problem and see the recommended solution. The following parts make our project easy to implement;

1. Mechanical Hardware

• Designing and Calibrating the Piezoelectric transducer and Electromagnetic Rotor for the required output 
• 3D Printing and collecting the required part

2. Electronics Circuitry

• Green power circuitry for energizing low power ZigBee comm module and sensors. Driver for DC Motor and assembling Zigbee Communication Module along with UartBee within single layer PCB routing is quite challenging.
• Single Layer PCB is preferred over double-sided or Multilayered PCB
• PCB Manufacturing and collecting good quality verified components

3. Project Imran

• Modifying NXP IDEs and profile for custom ZigBee automation Environment for Wireless communication network.
• Assembling Zigbee modules along with UartBee and making a proper connection for low power 'Green Power Circuitry' with sensors and driver for Visual and Analytical Monitoring.
• Collecting and testing the modules and different sensors Step by Step can help us form efficient system.

Benefits of the Project

 The benefits of the Smart Conveyor Belt are limitless. Production totally depends on Conveyor Belts. Following things must not be ignored;

• Belt health and wear
• Raw weigh and speed
• Motor and Belt speed comparison
• Efficiency(Power consumed  and regenerated)
• labour assigned
• maintenance

Our project will benefit the above-mentioned bullets. We can monitor belt health, which helps us in maintenance and labour cost.

Technical Details of Final Deliverable

We have divided our project into three categories, Briefly explained below;

1. Mechanical Hardware Design and Installation

• Designing the modules in compact space capable of harvesting maximum energy from both Piezoelectric and Electromagnetic Energy harvesting Modules.
• Calibrating and opting the sample giving best results.
• Positioning recommended sensors and Green Power Circuitry

2. Electronics Circuitry Design and Installation

• Converting Varying Pulsating AC into constant stable DC
• First performing rectification and stabilizing voltage can be used for Backup Charging
• LOUV (Lock-Out under voltage) protection circuit
• Green power circuitry for energizing low power ZigBee comm module and sensors.

3. Project Imran (Zigbee Communication Protocol for Monitoring)

• Building Environment for Wireless communication between ZigBee modules.
• Modifying NXP IDEs and profile for custom ZigBee automation network
• Smart Efficient code for minimum power consumption and power saving (Idle mode)
• Visual and Analytical Monitoring over each part
• Flash Programmer and Zigbee Debugging handles .bin file for UartBee USB Dongle

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70289
Magnet Roller Case(3D Printed)	Miscellaneous	2	950	1900
Striking Gear(3D Printed)	Miscellaneous	1	1450	1450
Hybrid Guide(3D Printed)	Miscellaneous	2	2100	4200
Zigbee JN5168 NXP	Equipment	2	6752	13503
UartBee USB Dongle	Equipment	2	3215	6430
CC2531 USB Ziffer	Equipment	1	2560	2560
PEH Transducer	Equipment	2	1607	3214
EMEH Rotors	Equipment	3	500	1500
DC Motor	Equipment	1	1500	1500
Ferromagnets	Equipment	12	886	10632
Idler metal case(Machined)	Equipment	1	2300	2300
PCB(Manufactured)	Equipment	1	8500	8500
Low Impedance capacitors	Equipment	2	2500	5000
Rasberry pi 4	Equipment	1	0	0
Garmin Speed Sensor	Equipment	1	3300	3300
Diymall Voltage Sensor	Equipment	2	800	1600
Necessary Power Electronics Components	Equipment	1	2700	2700