Faculty of Electrical Engineering

UNIVERSITI TEKNOLOGI MALAYSIA
1
DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT
MAL
UNIVERSITI TEKNOLOGI MALAYSIA
Author’s full name :
AYSIA
Date of birth
:
SITI NORFATIHA BINTI ISMAIL
25 APRIL 1990
Title
:
AUTOMATED OZONE INJECTION SYSTEM FOR MUSHROOM INDUSTRY
Academic Session :
2012/2013
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(Contains confidential information under the Official Secret
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ASSOC. PROF. DR. ZOLKAFLE BIN BUNTAT
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“I hereby declare that I have read this thesis and in my opinion this thesis is
sufficient in terms of scope and quality for the award of Bachelor of Electrical
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:……………….………………
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Date
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i
AUTOMATED OZONE INJECTION SYSTEM FOR MUSHROOM INDUSTRY
SITI NORFATIHA BINTI ISMAIL
A thesis submitted in partial fulfillment of the
requirements for the award of the degree of
Bachelor of Electrical Engineering
Faculty of Electrical Engineering
Universiti Teknologi Malaysia
JUNE 2013
ii
I declare that this thesis entitle “Automated Ozone Injection System for Mushroom
Industry” is the result of my own studies except as cited in the references.
Signature
:…………………………………………
Name
: SITI NORFATIHA BINTI ISMAIL
Date
:…………………………………………
iii
This thesis is dedicated to my beloved parents for their endlessly loves, supports and
encouragements…
iv
ACKNOWLEDGEMENT
Alhamdulillah, praised to ALLAH, I managed to successfully complete my
final year project. First of all, I would like to express my deepest gratitude to my
supervisor, PM. Dr. Zolkafle B. Buntat for willing to accept and supervised me
throughout the year. Other than that, I also would like to thank my family for their
supports and advices that always keep me motivated.
My greatest appreciation also goes to Muhammad Fariz Izzwan B. Zaki for
his guidance and ideas in order for me to accomplish this project. Other than that, I
would like to thank all my friends especially Nur Afifah Abd Halim and Siti Soleha
Ab Ghani for always being with me through my upsides down. Lastly, big thanks to
Universiti Teknologi Malaysia especially to Faculty of Electrical Engineering for
giving me a chance to completing my undergraduates study here.
v
ABSTRACT
Recently, the awareness about the benefits offered by mushrooms has
increased among citizens in our country. All types of mushrooms especially oyster
mushroom supplies a lot of nutrient and vitamins needed by our body. It is not only
prepared as food but it also has medicinal values. The demands for mushrooms are
very high in international and local market. Hence, the mushroom industry was
classified as a good potential industry to be commercialized since there were very
high demands of it. The present treatment methods of mushroom substrate were not
really productive since it is time consuming and less in production. Therefore, in this
project, an introduction of automatic ozone injection system to sterilize mushroom
substrates has been proposed. In this project, there are three approaches used. First,
literature reviews were done to get a clear view of the mushroom industry. Second, a
prototype design and an animation to illustrate the operation of the machine were
developed by using Solidworks software. Lastly, by using OMRON CX-One
Programmer, a controller was constructed to automate the machine operation. The
prototype designs consist of three main parts which are the conveyor, the injection
panel and also the substrates mold. The controller was programmed so that the
injection process must be within 30 minutes only since the purpose of inventing the
machine was to reduce time consuming. At the end of the study, it can be concluded
that an automated mushroom substrates treatment machine that can improve the
cultivation of mushroom was successfully established. However, it is recommended
that in the future the hardware of this prototype can be developed to prove the
validity of this system.
vi
ABSTRAK
Kesedaran tentang faedah yang ditawarkan oleh cendawan telah meningkat
dalam kalangan rakyat di negara kita di kebelakangan ini. Cendawan terutamanya
dari jenis tiram, membekalkan banyak nutrien dan vitamin yang sangat diperlukan
oleh badan kita. Ia bukan sahaja boleh dijadikan sebagai makanan tetapi ianya juga
boleh dijadikan bahan bagi tujuan perubatan. Permintaan terhadap cendawan adalah
sangat tinggi sama ada dalam pasaran tempatan mahupun antarabangsa. Oleh kerana
permintaan terhadap cendawan adalah tinggi maka industri ini boleh diklasifikasikan
sebagai industri yang berpotensi untuk dikomersialkan. Kaedah rawatan semasa
untuk substrat cendawan tidak benar-benar produktif kerana proses tersebut
memakan masa yang lama dan hasil pengeluarannya juga kurang. Oleh itu, dalam
projek, ini pengenalan terhadap sistem suntikan ozon secara automatik untuk
mensterilkan substrat cendawan telah dicadangkan. Di dalam projek ini, terdapat tiga
pendekatan yang telah digunakan. Pertama, ulasan kesusasteraan telah dilakukan
untuk mendapatkan gambaran yang jelas mengenai industri cendawan dan cendawan
itu sendiri. Kedua, reka bentuk prototaip dan animasi untuk menggambarkan operasi
mesin telah dibuat dengan menggunakan perisian Solidworks. Akhir sekali, dengan
menggunakan perisian OMRON CX-One Programmer, sebuah alat kawalan telah
dibina untuk mengautomasikan operasi mesin. Reka bentuk prototaip terdiri daripada
tiga bahagian utama iaitu penghantar, panel suntikan dan juga acuan substrat untuk
diisi bongkah cendawan semasa proses suntikan. Alat kawalan ini telah
diprogramkan supaya proses suntikan mestilah berlaku hanya dalam masa 30 minit
sahaja kerana tujuan mesin ini dicipta adalah untuk mengurangkan pengambilan
masa bagi proses rawatan substrat. Kesimpulannya, di akhir kajian ini, sebuah mesin
suntikan ozon secara automatik untuk rawatan substrat yang boleh meningkatkan
penanaman cendawan telah berjaya dibangunkan. Walau bagaimanapun, adalah
disyorkan bahawa pada masa hadapan perkakasan prototaip ini dapat dibangunkan
bagi membuktikan keberkesanan sistem ini.
vii
TABLE OF CONTENT
CHAPTER TITLE
1
2
PAGE
DECLARATION
ii
DEDICATION
iii
ACKNOWLEDGEMENT
iv
ABSTRACT
v
ABSTRAK
vi
TABLE OF CONTENT
vii
LIST OF TABLE
ix
LIST OF FIGURE
x
LIST OF ABBREVIATION
xi
LIST OF SYMBOL
xii
INTRODUCTION
1
1.1
Background of the Study
1
1.2
Problem Statement
2
1.3
Objectives
2
1.4
Scopes
3
LITERATURE REVIEW
4
2.1
Introduction
4
2.2
Mushrooms
4
2.3
Edible Mushroom
5
2.4
Pleurotus Ostreatus (Oyster Mushroom)
5
2.5
Mushroom Cultivation
5
2.6
Mushroom Substrate Treatment
7
viii
3
4
Autoclaves Treatment
7
2.6.2
Hot Water Treatment
8
2.6.3
Chemical Sterilization
8
2.6.4
Oil Drum Pasteurization
9
2.6.5
Ozone Treatment
9
RESEARCH METHODOLOGY
10
3.1.
Introduction
10
3.2.
Project Flow
10
3.3.
Solidworks 2012
11
3.4.
OMRON CX-One Programmer
13
3.4.1. PLC Program Flow Chart
13
RESULTS AND DISCUSSIONS
16
4.1
Introduction
16
4.2
Prototype Design
16
4.2.1 Conveyor
17
4.2.2 Injection Panel
18
4.2.3 Substrates Mold
19
4.2.4 Ozone Generator
20
4.2.5 Ozone Tank
21
4.2.6 Monitoring Unit
22
4.2.7 The Machine
23
PLC Controller
24
4.3.1
The Sequence of the Controller Process
25
4.3.2
CX-One Programmer Simulation
26
4.3
4.4
5
2.6.1
Animation
26
CONCLUSION AND RECOMMENDATION
28
5.1.
Conclusion
28
5.2.
Recommendation
28
ix
REFERENCES
29
APPENDICES A -B
30
x
LIST OF TABLES
TABLE
TITLE
PAGE
2.1
Import statistics of mushroom in 2004
6
2.2
Export statistics of mushroom in 2004
6
xi
LIST OF FIGURES
FIGURE
TITLE
PAGE
2.1
Auto-claves process
8
3.1
Flow of the project
11
3.2
User interface
12
3.3
PLC programming flow chart
14
4.1
The conveyor in multiple views
17
4.2
Injection panel
18
4.3
Series of needles in the panel
18
4.4
Injection panel’s holder in multiple views
19
4.5
The substrates mold in multiple views
20
4.6
Ozone generator
21
4.7
Ozone tank
22
4.8
Monitoring unit
23
4.9
Isometric view of the automated treatment machine
24
4.10
Ladder diagram
25
xii
LIST OF ABBREVIATIONS
UI
-
User Interface
PLC
-
Programmable Logic Control
HMI
-
Human Machine Interface
1
CHAPTER 1
INTRODUCTION
1.1
Background of Study
Recently, the awareness about the benefits of mushrooms has increased
among citizens in our country. Mushrooms are not only used when preparing food
but it also can be used for medical purposes and as a supplement [1]. There are
various types of mushrooms available in the world. However, only edible
mushrooms can be consumed by human- being.
Oyster, Portobello, Shiitake, Black Truffles and Button are common types of
edible mushrooms. Each type of mushroom has its own benefit. For instance, oyster
mushroom was said to be a cure for HIV disease because it contains high compound
of anti-oxidant [2]. However, this matter is still in research. Other than that, it also
can help people to reduce their cholesterol level.
Mushrooms are not only good in taste, but it also contains high nutrient and
also have medicinal values. Since more people started to become aware about its
benefits, mushroom demands increased day by day. However, the production of
mushroom in our country is still low and cannot fulfill consumer’s demand. Besides,
present methods of mushroom substrate treatments are also not really productive and
this factor also leads to limited production of mushrooms. As we know, good
substrates determine the profitability of the industry. Hence, if there is lack of good
substrates produced, the industry will suffer a profit loss.
2
1.2
Problem Statement
There is a very high demand for mushrooms especially for oyster types
among consumers. This is because the people nowadays started to realize the benefits
of mushrooms. However, the production of mushrooms is still limited because of the
substrate disease problem such as substrate was affected by fungi that can harm the
mushroom cultivation. A good substrate was said to be the important key in order to
determine the profitability in mushroom cultivation industry [4].
The mushroom industry is a very potential market to be involved in because it
is cheap to produce but profitable [1]. However, the present treatments of
mushroom’s substrate such as autoclaves method are not really productive because it
is time consuming. Hence, it is the right time to propose the newest method of
mushroom treatment which is the ozone treatment.
Since ozone treatment is a new treatment method, it is not too exposed to the
industry. Hence, to commercialize this method, an automated ozone injection
machine should be introduced so that it can enhance mushroom cultivation by
producing a large scale of good substrates.
1.3
Objectives
The objectives of this project are:
1. To design the prototype of the new ozone treatment by using Solidworks
software.
2. To develop animation in order to express the operating of ozone treatment
system for mushroom substrate sterilization
3. To construct the controller of the machine in order to automated its operation
by using PLC controller
4. To come out with an automated treatment machine to improve the cultivation
of mushroom especially oyster mushroom.
3
1.4
Scopes
There are three main scopes that were focused in this project.
The scopes are:
1. Designing an automated machine which integrates a conveyor that can be
used for ozone injection into mushroom substrates to enhance mushroom
cultivation.
2. Developing a controller system that can automates the treatment machine
operation.
3. Developing the system animation to illustrates the operation of the machine
4
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
In this chapter, overviews and theories about mushrooms, mushroom
cultivation and also the present method of mushroom substrate sterilization were
discussed. Overviews on these topics are essential in order to give clear views about
mushroom itself and why this project is conducted.
2.2
Mushrooms
Mushroom is defined as a group of fungi which is fleshy and has a domed
shape on top of its stalk [5]. It is a fast growing population and it also can be grown
either in wood, soil or in decaying metal such as saw dust [1]. There are many types
of mushroom available in this world but only a few of them are non-toxic and safe
for human being which is called edible mushroom. Mushroom’s contents were said
to consist 90% of water while the other remaining 10% is from drying matter [6]. It
was estimated that there were about 12,000 species of fungi that can be classified as
mushrooms. However, only 2,000 out of the amount were edible and safe for human.
5
2.3
Edible Mushroom
Edible mushroom is a class of mushroom that is safe for human. It is nontoxic and can be used for cooking, for medical purposes and even as a supplement
for having a healthy body. Edible mushrooms can either be harvested wild or
cultivated [7]. There are many types of edible mushroom available, for instance;
Oyster, Portobello, Shiitake, Black Truffles and Button that offers hundreds of
benefits to human.
2.4
Pleurotus Ostreatus (Oyster Mushroom)
Pleurotus Ostreatus or commonly known as Oyster mushroom is a famous
type of mushroom even in our country. This type of edible mushroom is very popular
among humans because it is tasty and also nutritious since it contains most of the
nutrients needed by human body such as vitamin, protein and also mineral [8].
Hence, oyster mushroom is a suitable food which can serve as a nutritious daily diet
for all types of age.
Other than that, oyster mushroom can help people who suffer from anemia to
recover since it can improve hematopoietic factors in human body. Besides that, it
also can help in reducing cholesterol level since it contains low caloric value and also
less in fat. As a result, oyster mushrooms are chosen the most by consumers because
it brings a lot of benefits for their health.
2.5
Mushroom Cultivation
Mushrooms especially edible mushrooms can be wildly harvested or
cultivated. Mushroom cultivation industry was said to be a profitable industry [4].
6
This is because there are high demands of mushroom from customers from both local
and international market.
Internationally, China is the largest producer of
mushrooms which contributes almost 85% of the total world production while in
Malaysia, Selangor was identified as the largest producer of mushrooms. Table 2.1
and Table 2.2 below show the statistics of import and export of mushrooms in 2004.
However, the value was expected to increase from year to year.
Table 2.1
Import statistics of mushroom in 2004 [17]
Table 2.2
Export statistics of mushroom in 2004 [17]
In addition, the cost to produce mushroom is also very low since man power
needed to cultivate mushroom is cheaper compared to others [4, 1]. Other than that,
nowadays there are a lot of initiatives taken by the government to enhance mushroom
cultivation in our country such as courses for mushroom cultivation for new
entrepreneur and also researches about mushroom cultivation that has been jointventured by some universities
7
2.6
Mushroom Substrate Treatment
Mushroom substrate treatments are essential in order to ensure that the
mushroom product is in high quality. Sterilization is one of them. Sterilization is
defined as any process of eliminating transmissible agents [13]. Hence, treatment
was done so that it can kill bacteria such as fungus that will contaminate and affect
the substrate during the cultivation process.
2.6.1
Autoclaves Treatment
Autoclaves treatment is one of the methods of sterilization for mushroom
substrate preparation. It kills bacteria by giving them a high pressure of saturated
steam at the temperature of 121˚C [9]. During the treatment process, substrates will
be placed in polypropylene bags and autoclaved in a device that is similar to a rice
cooker for several hours in order to ensure that all the bacteria that contaminated the
substrates will be killed.
However, there was a study reported that this type of sterilization method was
a cost consuming method even though it can produce high yields [6]. It is because it
used high electricity during the process. Other than that, this method was also time
consuming since the time was calculated starting from the heating process until the
cooling down process [14]. It took six to ten hours to complete the sanitizing process
while for cooling down process it took nearly 10 hours. Figure 2.1 shows the process
of autoclaving.
8
Figure 2.1
2.6.2
Auto-claves process [15]
Hot Water Treatment
Hot water treatment is a treatment using hot boiling water in order to remove
bacteria in substrates. During the treatment, substrates will be soaked into hot boiling
water to produce sanitation against bacterial disease that can affect the growth or the
cultivation process of mushrooms. Even though this method is cheaper in cost than
the auto-claves method but it is really time-consuming since it also has a cooling
down process. Furthermore, the productions of mushroom are also less with this
method since this method is more suitable for small scale industry.
2.6.3
Chemical Sterilization
Chemical sterilization was done by soaking the substrates into a chemical
solution for instance ethylene oxide to reduce the contaminating agents. However,
this method of sterilization was not really recommended because it is feared that the
chemical agents will reduce the nutrient contains in the substrate.
9
2.6.4
Oil Drum Pasteurization
Oil drum pasteurization was done by using heated water and grate. The grate
was placed into a notch in the drum. Then, water was filled into a drum
approximately 15cm below the grate. After that, the prepared substrates bags were
placed into the grate in stack layer. Then, when all the prepared bags have been
placed, the lid rim will be sealed. In the meantime, the water was started to boil until
four to six hours when the vapor starts to rise. The pasteurization time depends on
the substrates materials and also the size of the bag [16]. However, this method is not
suitable for commercializing since the production of substrate is less.
2.6.5
Ozone Treatment
Ozone is defined as a powerful reactive of triplet oxygen molecules which is
bonded together [11]. It is very oxidative and powerful in sterilizing. Hence, it is
widely used in food producing industry since it is eco-friendly.
Ozone treatment is best used in order to avoid anti-fungal disease that can
either be applied for plants such as mushrooms or also to water as treatment agents.
In mushroom cultivation industry, by using ozone, bacteria that affect the mushroom
cultivation can be killed in a very short period of time depending on the
concentration of the ozone itself [3]. The concentrated the ozone, the less time
needed to kill the bacteria.
Ozone treatment is a new technology in mushroom industries for sterilization
of mushroom substrate. However, this method was not yet to be commercialized.
This treatment method is very environmental friendly. Besides, the production of
mushroom will be higher compared to other methods of treatments. Furthermore, due
to the oxidation process with the organic matter, the nutrient in the mushroom
substrates also will be raised by using this new method [14]. The best thing is, by
using this method; the sterilization process will be efficient in time and also in cost.
10
CHAPTER 3
RESEARCH METHODOLOGY
3.1
Introduction
There are three methods and approaches that were used in order to complete
this project. First, literature reviews from books and journals about mushroom
cultivation and present mushroom treatment were done in order to get a clear view
about the mushroom industry itself.
Secondly, by using Solidworks software both designing of the automated
treatment machine and also the animation to illustrate the operation of the machine
was developed. Lastly, a PLC programmer which is OMRON CX-One was used to
construct a controller that automates the machine operation.
3.2
Project Flow
A flow chart in Figure 3.1 illustrates the flow of the project.
11
Start
Literature reviews
Designing process
Animation developing
Controller designing
Complete project
End
Figure 3.1
3.3
Flow of the project
Solidworks 2012
Solidworks 2012 is the latest version of Solidworks software. It is a powerful
software that can be used for designing a prototype of any computer aided design
(CAD). Other than that, this software also can be used in order to develop animation.
Hence, Solidworks is the best software to be chosen for completing this project
because it contains both designing and animation developer.
12
In addition, this software is also more user friendly compared to other similar
softwares. There are some advantages of using this software which are;
1. Solidworks has a function of auto-checks and also autocorrects that
can automates the reviewing and correction process.
2. Solidworks has its own online forum so that designers and engineers
all over the world can compare their works and also ask for advice
regarding their designs from the community in the forum.
3. Solidworks has a Microsoft structural storage format and this makes
it more user-friendly as we know that everyone knows how to use
Windows.
4. Solidworks is a compatible software because it can work with
various data format.
5. Solidworks are easily accessible software at any time and flexible.
Figure 3.2 below illustrates the function of toolbars that are available in
Solidworks software and also its user interface (UI).
Figure 3.2
User interface (UI)
13
3.4
OMRON CX-One Programmer
CX-One programmer by OMRON is one of the best software for
programming activities. It enables the user to build, configure and build networks
especially for PLCs, HMIs, motion control system and sensors. The result of this
software was reduced in complexity. Hence, an automation program can be easily
programmed.
Other than that, the graphical interface for this software is also user friendly.
The simple integration reduces training need and user can learn to use the software
by self-learning. The general appearance of this software which is the menus and the
function is simple and quite similar with other softwares.
In addition, this software also has a good documentation so that it eases the
user to search and open the file. Furthermore, this software has easy project
management. The file management operates in the background of automatically
saving in one common directory. As a result, a backup of a project is easy to make.
3.4.1
PLC Program Flow Chart
Before simulating the PLC program in CX-One programmer, a flow chart
must first be made. The flow chart is essential in order to have a clear picture about
the flow of the automation machine. Then, the flow chart will be transformed into the
ladder diagram in CX-One programmer that will be discussed in the next chapter.
Figure 3.3 describes the flow chart for the PLC programming.
14
Start
Loaded molded tray with mushroom substrates
No
Check whether
the mushroom
substrates is fully
loaded in the tray
Yes
Injection panels are ready for injection process
-green lights turn on
Injection panel holder going down and covered the
tray
-process within 30 seconds
Ozone injection process is started
-process within 30 minutes
-red light turn on
15
Injection panel holder going up
-process within 30 seconds
Sufficient
ozone
injected
No
Yes
Conveyor conveys the treated substrates to roller
tray
End
Figure 3.3
PLC programming flow chart
Inject again
16
CHAPTER 4
RESULTS AND DISCUSSIONS
4.1
Introduction
Results of the automated ozone injection machine project will be discussed in
this chapter. There were several processes needed to be done in completing this
project. Hence, this chapter will cover all the processes which are prototype
designing, controller developing and also animation developing.
4.2
Prototype Design
In this section, it will discuss about the results obtained for the prototype
design. The prototype of the automated injection machine consists of three main
components which are the conveyor, the injection panel and the substrates mold.
Apart from that, there are some other components which are the ozone generator to
generate ozone, an ozone tank to store generated ozone before injection process is
perform and also a monitoring unit to monitor the flow of the machine’s operation.
All the designed components have their own dimensions. However, in the future, the
dimension can be changed if there are any changes in the design. All the designs of
the component were obtained by using SolidWorks software.
17
4.2.1
Conveyor
The design of the conveyor consists of four stands for stability purpose. Then,
it will be moved by using two motors attached at both ends of the conveyor. A roller
tray was connected at one end of the conveyor. The roller tray functions as a
temporary holder of the treated substrates before it was lifted by the workers.
The dimensions of components in the conveyor were as follows.
However, the dimensions can be edited if there are any changes to be made. Figure
4.1 below illustrates the conveyor in multiple views which are from front, left, top
and trimetric view.
Motor
Stands
(a)
Conveyor
Tray
(c)
Figure 4.1
(b)
(d)
The conveyor from (a) front (b) left (c) top and (d) trimetric views
18
4.2.2
Injection Panel
The injection panel contains series of needles to inject the mushroom
substrate with ozone for sterilization purpose. Each injection panel consists of 81
needles. Since an automated treatment machine was designed to have four panels of
injection, it means that the machine contains of 324 needles. Hence, for each
treatment session ,a large scale of substrate can be injected. Figure 4.2 and Figure 4.2
show the injection tools in a clearer view.
(a)
Figure 4.2
Injection panel in (a) trimetric and (b) top views
Figure 4.3
Series of needles in the panel
(b)
19
The injection panel was hold by a holder. The holder of the injection panel
adapted the concept of pneumatic. The holder can move up and down during the
injection process. This feature helps to make the treatment process smoother. Figure
4.4 below illustrates the holder in multiple views with its dimensions.
(a)
(b)
Figure 4.4
(c)
(d)
Injection panel’s holder in multiple views; (a) front (b) top (c) left and
(d) trimetric views
4.2.3
Substrates Mold
The base or the substrates mold was designed with containing series of
“cups”. The mushroom substrates were placed in the cups of the mold during the
injection session. The function of the cups is to prevent the wastage of ozone. The
cups will act as a covered mug during the injection process. As a result, the injected
ozone will be totally absorbed by the substrates without any waste. Figure 4.5 below
shows the substrates mold clearly with its dimension in various views.
20
(a)
(b)
Series of “cups”
(c)
Figure 4.5
(d)
The substrates mold from (a) front (b) diametric (c) top and (d)
trimetric views
4.2.4
Ozone Generator
This machine was attached with an ozone generator that generates the ozone
for the treatment process. The generator was build inside a generator board for safety
purpose. It is because ozone generator is one of the high voltage equipment. Figure
4.6 shows the ozone generator board in multiple views.
21
Figure 4.6
4.2.5
(a)
(b)
(c)
(d)
Ozone generator in (a) front (b) left (c) right and (d) trimetric views
Ozone Tank
An ozone tank is shown in the Figure 4.7. The purpose of this tank is to store
the ozone that has been generated from the generator. During the injection process,
the ozone used was obtained from the tank.
22
(a)
(c)
Figure 4.7
4.2.6
(b)
(d)
Ozone tank from (a) front (b) left (c) top and (d) trimetric views
Monitoring Unit
The operation of this treatment machine was fully automated. Therefore, a
monitoring unit was needed to monitor the automation of the machine. The
monitoring unit consists of LEDs light, a panel monitor and also push button to start
and stop the treatment process. Figure 4.8 illustrates how the monitoring unit looks
like.
23
Figure 4.8
4.2.7
(a)
(b)
(c)
(d)
Monitoring unit in (a) front (b) top (c) right and (d) isometric views
The Machine
Figure 4.9 demonstrates the whole system of the machine which integrated all
the components described in the section above in isometric view.
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Ozone tank
Ozone generator
PLC monitoring unit
Substrate “cups”
Injection panel
Figure 4.9
4.3
Isometric view of the automated treatment machine
PLC Controller
In this project, in order to automate the operation of the machine, a PLC
controller was used. PLC controller suited the system well since the machine was
bulky. Before developing the controller, a ladder diagram must first be constructed.
By using the constructed ladder diagram, then only the system can be run in
OMRON CX-One Programmer to check the validity of the automation process.
Figure 4.10 denotes the ladder diagram that has been used in this project.
.
25
Figure 4.10
Ladder diagram
4.3.1 The Sequence of the Controller Process
The sequence of the controller process can be interpreted based on the ladder
diagram shown in the section above. To start up the machine, the operator must push
the green button available on the monitoring unit. Once the button was pushed, the
machine will be ON and the mass sensor will start sensing if the mushrooms
substrates were loaded in the mold. The content of the ozone in the tank must be
26
more than 50% for the process to be continued. Then, when the two conditions have
been fulfilled, the first green light will light on. At the same time, the injection panels
will move down until it is able to censor the injection sensor on the holder.
After that, the process of ozone injection will start and this process was set to
be within 30 minutes. During this process, the red LED light will light on. After 30
minutes, the second green light on the monitoring unit will light on. This indicates
that the process has been successfully carried out. In the meantime, the injection
panel will move upward until it censors the stop sensor. Then, the conveyor and the
rollers will start to move to convey the treated substrates. The rollers will stop when
it sense the stop sensor at the end of the tray.
For every step, there must be an emergency button for safety purpose. If any
failure happens during the process, the emergency button will be activated. Once
activated, the buzzer starts to chime and the emergency LED light also will start to
light on. This situation can only be stopped once the reset button was pushed.
4.3.2
CX-One Programmer Simulation
The simulation of this program was demonstrated by the video placed in the
CD that was attached together with this thesis.
4.4
Animation
In order to express the operation of the ozone treatment system for mushroom
sterilization, an animation had been developed. The animation was developed by
using SolidWorks software with the aid of Adobe Premier Pro video software. The
animation video also was available in the attached CD.
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CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1
Conclusion
At the end of the study, it can be concluded that a prototype of the new
automated ozone treatment machine was managed to be designed by using
SolidWorks software. During the designing process, there are several features and
specification that need to be taken into account. Next, by using the same software, an
animation was successfully developed in order to express the ozone treatment
machine’s operation. Then, by using OMRON CX-One programmer, a controller
also was successfully constructed for automation purpose. In a nutshell, it can be
concluded that this project was successful in order to come out with an automated
mushroom substrates treatment machine that can improve the cultivation of
mushroom especially oyster mushroom.
5.2
Recommendation
There are some improvements that can be conducted in the future to improve
this project. As recommendations, hardware of the prototype is suggested to be
developed in the future so that it can prove the validity of the system established.
Other than that, a payback research should be conducted so that it can prove that the
new treatment machine is economical than other present substrate treatments
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Y.Munirah, M. Rozlini , Y. Siti Mariam(2012). Design and Rules
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[2]
http://www.fitday.com/fitness-articles/nutrition/healthy-eating/8-types-ofmushrooms-and-their-health-benefits.html
[3]
Universiti Teknologi Malaysia (2012). Ozone Treatment System for Spawn
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[4]
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[5]
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[6]
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29
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W. Hui, L. Zhonghai, G. Jijun (2010). Effects of Ozone Combined with High
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[12]
http://www.industrysearch.com.au/Benefits-of-using-SolidWorks/f/9604
[13]
Dr. Yashmin Sultana (2007). Sterilization Methods and Principles. Dept. of
Pharmaceutics Faculty of Pharmacy New Delhi
[14]
http://itejb-witech.blogspot.com/2013/05/ozone-treatment-system-forspawn.html
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HyungJong Kwon, Byung Sik Kim (2004). Cultivation Modes: Bag
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http://z-farm.blogspot.com/2007/11/mushroom.htm
30
APPENDIX A
Automated Machine in Front View
31
APPENDIX B
Automated Machine from Right and Left Views
(a) Left view
(b) Right view