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Automated Puzzle Piece Counting Machine: Enhancing Quality Control

This presentation outlines a senior project aimed at developing an automated machine for counting puzzle pieces, improving quality control in a labor-intensive process. The current hand-counting method is inefficient, prompting our team to implement a system combining pneumatics and electronics. Key components include a microphone for detecting noise from fallen pieces, circuitry to process the signals, and an LCD for user interface. We also discuss our software that monitors voltage changes to accurately count pieces, addressing noise and filtering issues, along with a detailed budget and schedule.

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Automated Puzzle Piece Counting Machine: Enhancing Quality Control

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  1. Puzzled Design Presentation 2 Senior Projects 2011 Eric Babski ~ Ben Gagne ~ Erik Artus

  2. Agenda • Problem Statement • Solution • System Diagram • Sub-system Descriptions • Microphone • Circuitry • LCD • Software • Schedule • Budget

  3. Problem Statement • Our team was given the challenge to design a machine that improves the method of counting puzzle pieces for quality control. • The current method requires a human counting by hand piece by piece. • This is too time consuming, labor intensive and impractical.

  4. Problem Solution We plan to use a combination of a pneumatics system and electronics to count pieces as they are loaded into the machine. • Air System • Microphone/Amplification • User Interface

  5. System Diagram Pieces In-Feed Hopper Microphone Circuitry Air Inlet *tink LCD Display Air Outlet Start Button Stop/Reset Catch Drawer

  6. Microphone Requirements • Must run off 3 volts. • Frequency range within that of a dropped piece. • Sample at 1000 Hz.

  7. Microphone Details • WM-52B • Specifications: • Runs on 2.5VDC • Frequency: 20-16k HZ • Impedance: Less than 2.2k

  8. Testing • We used LabView to test the output of our microphone. • Dropped 3 pieces. 1 2 3

  9. Results Our LabView test results show… • Gain • We found that the voltage spikes we were getting were in the 500mV range. • Noise • There is a lot of noise produced at the output of the microphone. • Filtering • Time Delay Secondary Spikes Outside Noise

  10. Op-Amp • Needed to run single-ended. • Between 0-3 volts at the supply. • Readily available. INA 126P G = 5+(80k/RG)

  11. Circuitry Gain Calculation G = 5+(80k/RG) 6 = 5+(80k/RG) RG = 80K

  12. LCD • Requirement: • Need at least 12 Characters • Inexpensive • Specifications: • High quality STN 16x2 character LCD • 3.3V power supply • Yellow LED Backlight • Cost $14

  13. Software • Program • The microphone that we are using is basically a capacitor. When audible noise surrounds the microphone, the voltage absorbed by the capacitor changes. • Our software will be monitoring the voltage in the capacitor, and will use that information to keep a running count of how many puzzle pieces have triggered a spike.

  14. State Machine

  15. Budget

  16. Questions?

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