This research presents a cost-effective, solar-powered double infrared (IR) sensor-based counting and conveying system to reduce production cost and improve efficiency and accuracy in industrial product processing. The proposed system is mainly based on a microcontroller with double infrared (IR) sensors to automate manual counting, providing precise real-time counted data displayed on an LCD. A conveyor belt, whose speed is controlled via a MOSFET-based motor driver, enables handling of various products, developing operational flexibility. Powered entirely by collecting energy from high-efficiency solar cells and supported by a rechargeable Li-ion battery, the machinery setup operates with minimal running costs, making it extremely suitable for rural and off-grid environments. The versatility of the design architecture supports the scalable automation of analog production processes, reducing labor dependency, operational expenses, and energy consumption, which results in a huge amount of fuel saved. Field tests demonstrated consistent counting accuracy and smooth conveying operation under varying speeds. A combination of renewable energy with microcontroller and sensor-based automation, our system empowers users to modernize their workflows, increase productivity, and provide huge economic benefit. The system gives solutions to challenges faced by small- and medium-scale producers by providing them an almost free-running automation system to automate their production in multiple stages.

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Autonomous Solar-Powered Microcontroller-Based Counting and Conveying Platform for Sustainable and Scalable Product Processing

  • Tanvir Ahmed,
  • Fariha Rahman,
  • Limon Bhuiyan,
  • Aliva Sadnim Mahmud,
  • Md. Amimul Ihsan

摘要

This research presents a cost-effective, solar-powered double infrared (IR) sensor-based counting and conveying system to reduce production cost and improve efficiency and accuracy in industrial product processing. The proposed system is mainly based on a microcontroller with double infrared (IR) sensors to automate manual counting, providing precise real-time counted data displayed on an LCD. A conveyor belt, whose speed is controlled via a MOSFET-based motor driver, enables handling of various products, developing operational flexibility. Powered entirely by collecting energy from high-efficiency solar cells and supported by a rechargeable Li-ion battery, the machinery setup operates with minimal running costs, making it extremely suitable for rural and off-grid environments. The versatility of the design architecture supports the scalable automation of analog production processes, reducing labor dependency, operational expenses, and energy consumption, which results in a huge amount of fuel saved. Field tests demonstrated consistent counting accuracy and smooth conveying operation under varying speeds. A combination of renewable energy with microcontroller and sensor-based automation, our system empowers users to modernize their workflows, increase productivity, and provide huge economic benefit. The system gives solutions to challenges faced by small- and medium-scale producers by providing them an almost free-running automation system to automate their production in multiple stages.