CHAPTER-3

METHODOLOGY AND DESIGN

3.1 INTRODUCTION:

The project technology and components were elaborately discussed and

plan made for implementation. Detailed study of requirements and functioning
of various existing systems, components and its sub parts was undertaken for
defining project methodology.

Available technical literature and interaction with engineers working on

these systems and components were carried out for finalization of efficient
design at minimum cost and least time frame.

3.2 PROBLEM DEFINITION:

Households of today are becoming smarter and more automated. Home

automation delivers convenience and creates more time for people. Domestic
robots are entering homes and people’s daily lives, but it is yet a relatively new
and immature market. However, growth is predicted and the adoption of
domestic robots is evolving. This work can be very useful in improving life
style of mankind.
 Our aim is to design the Automatic vacuum cleaner that will help to make
household work convenient and much easier. It operates in autonomous mode as
well as in manual mode along with additional features like scheduling for
specific time and dirt container with auto- dirt disposal mechanism. The
flexibility, time saving and efficiency make the robot a clean choice for cleaning
the floor.

3.3 PROJECT METHODOLOGY:

The methodology of the project implementation is to design and develop

the smart vacuum cleaner, based on node MCU and machine learning using
open cv technique to assess its functional efficiency. The validity of project
concept is required to be demonstrated by using hardware components, required
software and integrating it all to fabricate a functioning model.

The wheels and wipers are the output of the real time system proposed
above. The Wheel is connected to DC geared motor which is driven by DC
Motor Driver. The DC Motor is being rotated as per the code fed in NODEMCU
8266 and a result of which the wheels are moving in the sensed direction.

The sprinklers and wipers are also attached to the proposed model in which
when the wheels are moving in any particular direction of the floor, the floor
under the vacuum cleaner model also gets cleaned up with the help of wipers
and sprinklers are used to pour water at the time of cleaning the floor by wipers.
3.4 PROJECT TECHNOLOGY:

Apart from basic engineering knowledge, certain technologies cover

Arduino, NODEMCU, IOT, artificial intelligence, control system, sensors,
machine learning, which is used for the project implementation.

3.4.1 SENSORS AND IoT:

Sensor is a device, which detects or measures a physical property and

records, indicates, or otherwise responds to it. It is used to detect and
respond to electrical or optical signals. It converts the physical parameter like
temperature, pressure, humidity, speed etc, into a signal which can be measured
electrically. Sensors which we used in this project is Ultrasonic Sensor.

Once the data gets to the cloud, software processes it and then might decide
to perform an action, such as sending an alert or automatically adjusting the
sensors/devices without the need for the user.

3.5 PROJECT IMPLEMENTATION:

The project has combination of software and hardware components. The

hardware used is and NODEMCU board which interfaced with sensors like
Ultrasonic sensor, Dc Motor and LCD wheel. Arduino program for hardware
integration is developed to process and transmit sensor signals for the display.
The communication device used is a NODEMCU which has in-built wifi
module in it.

3.6 PROJECT HARDWARE:

Various components used and working principles of the project hardware

are described in succeeding paragraphs.

3.6.1 DC MOTOR:

A DC motor is any of a class of rotary electrical machines that converts

direct current electrical energy into mechanical energy. The most common types
rely on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor.

DC motors were the first form of motor widely used, as they could be
powered from existing direct-current lighting power distribution systems. A DC
motor's speed can be controlled over a wide range, using either a variable
supply voltage or by changing the strength of current in its field windings.
Small DC motors are used in tools, toys, and appliances. The universal motor
can operate on direct current but is a lightweight brushed motor used for
portable power tools and appliances. Larger DC motors are currently used in
propulsion of electric vehicles, elevator and hoists, and in drives for steel rolling
mills. The advent of power electronics has made replacement of DC motors
with ac motor possible in many applications.

Fig-3.1 DC Gear Motor

DC motor is used in this project for the movement of wheel. High torque
DC motor is used for the convenient movement of the wheel. As the weight of
the automatic vacuum cleaner is approximately 5-6 kg we need a series dc
motor which generate high torque. DC motor is also used for controlling the
speed of wheel of automatic vacuum cleaner.

DC motor is used to convert direct electrical energy into mechanical energy.

DC motor work on the principal that "whenever a current carrying conductor is
placed in a magnetic field, it experiences a mechanical force”. The direction of
the mechanical force induced in a dc motor is given by Fleming’s Left-hand
Rule and its magnitude is given by F=BIL Newton.
 DC motor is connected with NodeMcu Esp8266 with the help of dc motor
driver, which is further connected to the battery. DC motor can rotate in both
clockwise and anticlockwise movement of the wheel.as the load driven by DC
motor is more so armature current needed by it will also be more as a result high
torque dc motor is required so that it can bear a heavy load.

3.6.2 DC MOTOR DRIVER:

A dc motor driver is a device that serves to conduct in some predetermined

manner the performance of a dc motor. A dc motor driver can be use to control
the starting and stopping or in forward or reverse rotation of a wheel, regulating
the speed of the wheel, limiting the torque and protecting against overloads and
faults either a manual or automatic.

Common features of dc motor driver are:

 Precise Closed Loop Position Control

 Fast Acceleration Rates

 Precise Speed Control Dc Motors May Be Made From Several Motor

Types, The most common being:

 Brushed Dc Motors

 Brushless Dc Motors
 Fig-3.2 L298n Motor Driver Module

The L298N is an integrated monolithic circuit in a 15- lead Multi-watt and

PowerSO20 packages. It is a high voltage, high current dual full-bridge driver
de-signed to accept standard TTL logic level sand drive inductive loads such as
relays, solenoids, DC and stepping motors. Two enable inputs are provided to
enable or disable the device independently of the in-put signals. The emitter of
the lower transistors of each bridge are connected together rand the
corresponding external terminal can be used for the connection of an external
sensing resistor. An additional Supply input is provided so that the logic works
at a lower voltage.

3.6.2.1 FEATURES:

 High operating voltage, which can be up to 40 volts.

 Large output current, the instantaneous peak current can be up to 3A.
 With 25W rated power.
 Two built in H-bridge, high voltage, large current, full bridge driver,
which can be used to drive DC motors, stepper motors, relay coils and
other inductive loads.
  Using standard logic level signal to control.
 Able to drive a two-phase stepper motor or four-phase stepper motor, and
two-phase DC motors.
 Adopt a high-capacity filter capacitor and a freewheeling diode that
protects devices in the circuit from being damaged by the reverse current
of an inductive load, enhancing reliability.
 The module can utilize the built-in stabili volt tube 78M05 to obtain 5v
from the power supply. But to protect the chip of the 78M05 from
damage, when the drive voltage is greater than 12v, an external 5v logic
supply should be used.
 Drive voltage: 5-35V and logic voltage: 5V

3.6.3 NODE MCU ESP8266:

Node MCU is an open source IOT platform. It includes firmware which

runs on the ESP8266 Wi-Fi from Espressif Systems, and hardware which is
based on the ESP-12 module. The term "Node MCU" by default refers to the
firmware rather than the development kits. The firmware uses the Lua scripting
language. It is based on the eLua project, and built on the Espressif Non-OS
SDK for ESP8266. It uses many open source projects, such as lua- cjson and
spiffs.

The module is mainly based on ESP8266 that is a low-cost Wi-Fi microchip

incorporating both a full TCP/IP stack and microcontroller capability. It is
introduced by manufacturer Espressif Systems – A manufacturer based in
Shanghai, China.
 Arduino Modules and Microcontrollers have always been a great choice to
incorporate automation into the relevant project. But these modules come with a
little drawback as they don’t feature a built-in Wi-Fi capability, subsequently,
we need to add external Wi-Fi protocol into these devices to make them
compatible with the internet channel.

This is where NodeMCU comes handy that incorporates a built-in WiFi

support, giving an easy pathway to design IoT applications as per your technical
requirements.

Fig-3.3 NODEMCU

Open source firmware gives you the flexibility to edit, modify and rebuilt
the existing module and keep changing the entire interface until you succeed in
optimizing the module as per your requirements.
 USB to UART converter is added on the module that helps in converting
USB data to UART data which mainly understands the language of serial
communication.

Instead of the regular USB port, Micro USB port is included in the module
that connects it with the computer for dual purposes: programming and
powering up the board.

The board incorporates status LED that blinks and turns off immediately,
giving you the current status of the module if it is running properly when
connected with the computer.

3.6.3.1 NODEMCU PIN:

NodeMCU V3 comes with a number of GPIO Pins and the following

figure shows the Pin out of the board.
 Fig-3.4 NODEMCU pin configuration

3.6.3.2 HOW TO POWER NODEMCU:

You can see from the pinout image above, there are five ground pins and
three 3V pins on the board. The board can be powered up using the following
three ways.

USB Power - It proves to an ideal choice for loading programs unless the
project you aim to design requires separate interface i.e., disconnected from the
computer.

Provide 3.3V - This is another great option to power up the module. If you have
your own off-board regulator, you can generate an instant power source for your
development kit.

3.6.3.3 FEATURES OF NODEMCU ESP8266:

 Open-source
 Arduino-like hardware
 Status LED
 MicroUSB port
 Reset/Flash buttons
 Interactive and Programmable
 Low cost
  ESP8266 with inbuilt wifi
 USB to UART converter
 GPIO pins

3.6.4 BATTERY:

The Sky cell Premium LiFePO4 Rechargeable Battery Pack is a 12s 5p

battery pack with a nominal voltage of 36V and can be fully charged up to
43.8V. This battery pack has 60 cells which gives it a capacity for 1C (30A)
continuous discharge and 3C (90A) discharge for a few seconds. The nominal
capacity of the battery pack is 30000mah. The battery pack has an in-built BMS
which prevents the battery from over charging above 43.8V and also prevents it
from over discharging below 33.5 volts.

The Sky cell Premium LiFePO4 Rechargeable Battery Pack is made using
Sky cell High Quality Lithium Iron Phosphate (LiFePO4) rechargeable cells
which are one of the most powerful and most stable cells available
along with an amazing life cycle of approximately 3000 cycles. The
High Quality LiFePO4 is a 6000 mah cell with a 1C(6A) continuous discharge
and 3c(18A) peak discharge. These cells can work in high temperature
environments which might not be favourable for the Li-ion or Li-po cells. The
cell is available in the 32650 / 32700 size which means that the diameter of the
cell is 32mm and height is 70 mm which is quite compact for the power it
gives. With a life cycle of approximately 3000 cycles with good performance,
this is a fit and forget solution for our battery packs.

The benefits of the LiFePO4 cells over Li-ion and Lead acid batteries are:
 LiFePO4 cells are much more stable chemically and non combustible. At
high temperatures or if the battery is mishandled the phosphate based cathode
material will not burn. Hence LiFePO4 are much more safe for E-Vehicles and
mobile robots.

LiFePO4 cells offer much longer lifetime as compared to a Lead Acid or a

Li-ion cell. The LiFeP04 provides approximately 3000 cycles under proper
handling and upto 70% DOD( Depth of Discharge). Also the shelf life of the
cell is much longer with a lower self discharge rate.

The LiFePO4 cells offer higher performance compared to a normal 1C Li-

ion 18650 cell. The commonly available Li-ion cell are rated for 2 A discharge
rate whereas the LiFePO4 1C cell provides a 6A discharge rate. There is also
very little voltage drop during discharge which is much higher in a lead acid
battery.

The LiFePO4 is a nontoxic material, non-contaminating material which

contains no rare-earth minerals. This makes it a much more environment
friendly choice compared to the lead acid and Lithium batteries.

3.6.4.1 BATTERY SPECIFICATIONS:

 Nominal Voltage of battery : 36V (12s5p)

 Maximum Voltage of battery : 43.8V(at full charge)

  Operating Voltage: 33.5V -43.8V

 Minimum voltage allowed by BMS : 33.5 V ( BMS will cutoff the supply

once battery pack is discharged up till 33.5 V)

 Continuous Current Capacity : 30 A (1C )

 Peak Current Capacity : 90 A (3 C) only for few seconds)

 Nominal Battery Capacity: 30000mAh

 Max Charging Current (Continuous) : 1C (30A)

 Dimension: 330mm*200mm*80mm

 No of charge/discharge cycles : approximately 3000 cycles for 70%

DOD. This means that if the battery pack is used once daily then the life

is approximately 8 years for same.

3.6.4.2 APPLICATIONS OF LIFEPO4 BATTERY:

 Light electric car, e-bike, electric scooter, e-rickshaw, electric golf cart,

forklift, cleanness car, electric wheelchairs.

 E-tools like electric drill, electric saw, lawn mower and so on.

 Remote control cars, boat aircraft, toys.

 Solar and wind power generation energy storage devices.

 Small medical equipment and portable equipment.

3.6.5 WHEEL:

Wheel is used for the movement of the body from one place to another with
the help of Dc motor. A wheel is usually of circular shape and hard and made
up of durable material whose center has a circular hole through which an axle
bearing is placed about which the wheel rotates and when a moment is applied
by the torque to the wheel about the axis, thereby making together and also easy
movement of the automatic vacuum machine. When wheel is placed vertical
axis under a load-bearing platform , the wheel turning on the horizontal axis
makes it possible to transport heavy loads efficiently, when placed horizontally,
the wheel turning on its vertical axis makes it possible to control the spinning
motion used to shape materials , when mounted on a column connected to a
chassis mounted on other wheels, one can control the direction of a automatic
vacuum cleaner, when connected to a engine, a wheel control, release, or
transmit energy.
 Fig–3.5 Wheel

3.6.6 ULTRASONIC SENSOR:

An ultrasonic sensor is an instrument that measures the distance to an

object using ultrasonic sound waves. An ultrasonic sensor uses a transducer to
send and receive ultrasonic pulses that relay back information about an object’s
proximity. High-frequency sound waves reflect from boundaries to produce
distinct echo patterns. Ultrasonic sensors are a reliable, cost-effective solution
for distance sensing, level, and obstacle detection.

3.6.6.1 HOW ULTRASONIC SENSORS WORK:

Ultrasonic sensors work by sending out a sound wave at a frequency

above the range of human hearing. The transducer of the sensor acts as a
microphone to receive and send the ultrasonic sound. Our ultrasonic sensors,
like many others, use a single transducer to send a pulse and to receive the
echo. The sensor determines the distance to a target by measuring time lapses
between the sending and receiving of the ultrasonic pulse. The working
principle of this module is simple. It sends an ultrasonic pulse out at 40kHz
which travels through the air and if there is an obstacle or object, it will
bounce back to the sensor. By calculating the travel time and the speed of
sound, the distance can be calculated.
 Ultrasound is reliable in any lighting environment and can be used inside or
outside. Ultrasonic sensors can handle collision avoidance for a robot, and being
moved often, as long as it isn’t too fast. Ultrasonic are so widely used, they can
be reliably implemented in grain bin sensing applications, water level sensing,
drone applications and sensing cars at your local drive. Ultrasonic range finders
are commonly used as devices to detect a collision.

Ultrasonic Sensors are best used in the non-contact detection of:

 Presence

 Level

 Position

 Distance

Ultrasonic are Independent of:

 Light

 Smoke

 Dust

 Color

Material (except for soft surfaces, i.e. wool, because the surface absorbs
the ultrasonic sound wave and doesn’t reflect sound) Long range detection of
targets with varied surface properties. Ultrasonic sensors are superior to
infrared sensors because they aren’t affected by smoke or black materials,
however, soft materials which don’t reflect the sonar (ultrasonic) waves very
well may cause issues. It’s not a perfect system, but it’s good and reliable.

3.6.6.2 APPLICATIONS OF ULTRASONIC

DETECTION:

Distance measurement is based on the measurement of time-of-flight. The

time between sending and receiving the reflected sound signal is calculated by
the sensor. Ultrasonic distance sensors, like the MB7360 HRXL-Max Sonar-
WR, are used as height monitors, in bin level measurement and proximity zone
detection applications.

Ex : Distance measurement would be applied in a garage parking application,

sensing when a vehicle is pulled completely into a garage.

The MB7360 has been used as a bin level sensor to detect the presence or
absence of grain and other materials in bin.
 Fig-3.6 Ultrasonic sensor

3.6.7 VACUUM CLEANER:

A vacuum cleaner, also known simply as a vacuum, is a device that can

order to remove debris from floors, upholstery, draperies and other surfaces. It is
generally electrically driven. The dirt is collected by either a dustbag or a
cyclone for later disposal. Vacuum cleaners, which are used in homes as well as
in industry, exist in a variety of sizes and models—small battery-powered hand-
held devices, wheeled canister models for home use, domestic central vacuum
cleaners, huge stationary industrial appliances that can handle several hundred
litres of dust before being emptied, and self-propelled vacuum trucks for
recovery of large spills or removal of contaminated soil. Specialized shop
vacuums can be used to suck up both dust and liquid.

Most vacuum cleaners are supplied with numerous specialized

attachments, such as tools, brushes and extension wands, which allow them to
reach otherwise inaccessible places or to be used for cleaning a variety of
surfaces. The most common of these tools are:

 Hard floor brush (for non-upright designs)

 Powered floor nozzle (for canister designs)

  Dusting brush

 Crevice tool

 Upholstery nozzle

3.6.7.1 SPECIFICATIONS:

The performance of a vacuum cleaner can be measured by several

parameters:

 Airflow, in litres per second [l/s] or cubic feet per minute (CFM or
ft³/min)
 Air speed, in metres per second [m/s] or miles per hour [mph]
 Suction, vacuum, or water lift, in pascals [Pa] or inches
 Weight, in kilograms [kg] or pounds [lb]
 Noise, in decibels [dB]
 Power cord length and hose length (as applicable)

Suction

The suction is the maximum pressure difference that the pump can create.
For example, a typical domestic model has a suction of about negative 20 kPa.

Input power

The power consumption of a vacuum cleaner, in watts, is often the only

figure stated. Many North American vacuum manufacturers give the current
only in amperes (e.g. "6 amps"), and the consumer is left to multiply that by the
line voltage of 120 volts to get the approximate power ratings in watts. The
rated input power does not indicate the effectiveness of the cleaner, only how
much electricity it consumes.

Output power

The amount of input power that is converted into airflow at the end of the
cleaning hose is sometimes stated, and is measured in airwatts, the measurement
units are simply watts. The word "air" is used to clarify that this is output power,
not input electrical power.

3.6.8 SMALL WATER TANK:

Water tanks are used to provide storage of water for use in many
applications, drinking water, irrigation agriculture, fire suppression, agricultural
farming, both for plants and livestock, chemical manufacturing, food
preparation as well as many other uses. Water tank parameters include the
general design of the tank, and choice of construction materials, linings. Various
materials are used for making a water tank: (polyethylene, polypropylene)
fiberglass, concrete, stone, steel (welded or bolted, carbon, or stainless).
 Fig-3.7 Small Water Tank

3.7 COMPONENTS DESCRIPTION:

POWER SUPPLY UNIT:

This section needs two voltages viz., +12 V & +5 V, as working voltages.
Hence specially designed power supply is constructed to get regulated power
supplies.

DRIVERS:

This section is used to drive the relay where the output is complemented of
input which is applied to the drive but current will be amplified.

RELAYS:
 It is a electromagnetic device which is used to drive the load connected
across the relay and the o/p of relay can be connected to controller or load for
further processing.

DC MOTOR:

A DC motor relies on the fact that like magnet poles repels and unlike
magnetic poles attracts each other. A coil of wire with a current running through
it generates an electromagnetic field aligned with the centre of the coil. By
switching the current on or off in a coil its magnetic field can be switched on or
off or by switching the direction of the current in the coil the direction of the
generated magnetic field can be switched 180°.

GSM:

GSM, which stands for Global System for Mobile communications, reigns
as the world’s most widely used cell phone technology. Cell phones use a cell
phone service carrier’s GSM network by searching for Cell phone towers in
nearby area.

The origins of GSM can be traced back to 1982 when the Group Special Mobile
(GSM) was created by the European Conference of Postal and
Telecommunications Administrations (CEPT) for the purpose of designing a
pan-European mobile technology.

ULTRASONIC SENSOR:

The HC-SR04 ultrasonic sensor uses sonar to determine distance to an

object like bats or dolphins do. It offers excellent range accuracy and stable
readings in an easy-to-use package. It operation is not affected by sunlight or
black material like Sharp rangefinders are (although acoustically soft materials
like cloth can be difficult to detect). Similar in performance to the SRF005 but
with the low-price of a Sharp infrared sensors.

SOLAR PANEL:

Solar energy begins with the sun. Solar panels (also known as "PV panels")
are used to convert light from the sun, which is composed of particles of energy
called "photons", into electricity that can be used to power electrical loads.
Solar panels can be used for a wide variety of applications including remote
power systems for cabins, telecommunications equipment, remote sensing, and
of course for the production of electricity by residential and commercial solar
electric systems.

ARDUINO SUITE:

The Arduino is a single-board microcontroller, intended to make the

application of interactive objects or environments more accessible. The
hardware consists of an open- source hardware board designed around an 8-bit
Atmel AVR microcontroller or a 32-bit Atmel ARM. Current models feature a
USB interface, 6 analog input pins, as well as 14 digital I/O pins which allow
the user to attach various extension boards. Introduced in 2005, at the Interaction
Design Institute Ivrea, in Ivrea, Italy, it was designed to give students an
inexpensive and easy way to program interactive objects. It comes with a simple
Integrated Development Environment (IDE) that runs on regular personal
computers and allows writing programs for Arduino using a combination of
simple Java and C or C++.
3.8 HYSTERESIS THRESHOLDING:

As the name suggest this stage decides whether the edges are real or not.
The edges are evaluated on the basis of two threshold values which are min Val
and max Val. The edges which have intensity gradient more than max Val are
sure to be edge while those edges which have intensity gradient less than min
Val are non-edges i.e., not real edges.

For those edges whose intensity lie between the specified interval value are
considered to be a part of edges and are sure-edges. Otherwise they too can be
discarded.

Fig–3.8 Hysteresis graph

3.9 WORKING OF THE MODEL:

 In this system the ultrasonic sensors are used to sense the obstacles.
Ultrasonic sensors emit sound scopes with frequency lying in ultrasonic
spectrum (20KHZ), which is inaudible to human ears. The sound waves hit the
obstacle and bounces back to detectors. The ultrasonic sensor is used for
detecting objects/obstacles and move the direction of the robot. GSM module is
used by the blind person to contact to mobile numbers stored in the
microcontroller in case of any emergency. Using GSM technology robot
movement will be controlled. And using ultrasonic obstacle avoidance will be
done. Here an Arduino Uno is used as the microcontroller. Circuit consists of a
GSM module, an ultrasonic Sensor, two L293D driver ICs, two motors, a
cleaner and an LCD Display. The ultrasonic sensor triggers and echo pins are
connected PWM of Arduino respectively. The virtual terminal represents the
GSM Module. The RXD and TXD of GSM module is connected to TXD and
RXD of Arduino. Motor driver IC (L293D) for driving the two motors is
connected in such a way that the IN1 & IN2 for driving motor 1 and motor 2 are
connected L293D is connected to motor 1 and OUT3 & OUT4 are connected to
motor 2 LCD is interfaced in such a way that RS, E, D4-D7 of LCD is
connected.

Battery
Motor Driver

STM 32
Motors

Ultrasonic
Sensors
Wi-Fi

Fig-3.9 BLOCK DIAGRAM