1. IMPLEMENTATION AND
AUTOMATION OF LIFTER FOR
DEEP FREEEZER UNLOADING
FROM CONVEYOR
(Deep Freezer Department)
Submitted to:
Sir Ahmed Ayub Bhatti
Submitted by:
Asif hashmat – UET Taxila

2. 2
Executive Summary:
A project was assigned to the group of interns to be completed in one month. The main
project assigned to the group was to design and implement an automatic lifter that takes deep
freezer from the main conveyor and bring it down towards the work testing chamber without
any external worker push.
Firstly the details about the project were told to the group of interns and an activity chart was
made to ensure that all the work required was completed in a desired time period. The
activity charts are shown below.

3. 3
Table of Contents:
1.0 Introduction………………………………………………………………………………...
2.0 Design.........………………………………………………………………………………...
2.1 Cons (current manual control)..…………………………………….........................
2.2 Pros (proposed automatic control)……………………………………….................
3.0 List of Componenets…………….……………………………………….............................
4.0 Working of Project………………………………………………………………………….
4.1 Working......................................................................................................................
4.2 Safety.........................................................................................................................
5.0 Block Diagram.........................................................................................................
6.0 CircuitDiagram………………………………………………………………………….......
7.0 System Diagram……………………………………….........................................................
8.0 Arduino Program....................................................................................................................
9.0 Conclusion..............................................................................................................................

4. 4
1.0 Introduction:
PEL (Pak Elektron Limited) is a company that is the pioneer producer of electrical products.
It has been in this field since 1956 and has been producing Deep Freezers since 1987. PEL
promises the quality that no other company offers and it provides that at an amazing rate
which can only be matched by a few.
The main objective of the project was to focus on such aspects on the industry which could
be improved and would have a significant effect on the production of appliances. This project
focused primarily on the deep freezer production and in that, emphasis was put on the
automation of production line.
To make the deep freezer production line automatic was the primary concern in the project.
When the deep freezer reaches a specific point on main conveyor, the lifter that lifts up and
takes the deep freezer without allowing any external push. When deep freezer is completely
placed on the lifter, the lifter automatically brings it down and pushes it towards the testing
chamber.

5. 5
2.0 Design:
2.1 Cons (current manual control):
 Requires manual pressing of buttons to run and stop the conveyor
 Requires an extra worker to control the position of lift
 Requires a push to unload the deep freezer from the rollers
 Greater probability for a deep freezer to fall down from the lift, hence causing
damage to its body.
2.2 Pros (proposed automatic control):
 Proposed design is to automate the whole conveyor and lifter system
 Does not require an extra worker to control lift position
 New proposed design will have greater efficiency and factor of safety
 Would increase production rate
 New proposed design will require lesser manpower

6. 6
3.0 List of Components:
Name of Component Quantity Unit Price
Analogue Infrared Sensor 5 1000
Light Emitting Diode(LED) 3 -
Limit Switch 2 15
Arduino UNO
Microcontroller
1 1000
4.0 Working of Project:
4.1 Working:
The main conveyor is always running, as soon as the freezer reaches in front of the Sensor1,
The main conveyor stops and the lift begins to move up. As soon as the lift reaches top the
Sensor4 is pressed and the main conveyor runs again.
The deep freezer further move forward and reaches in front of the Sensor2. As Sensor2 gives
an output, the main conveyor stops and Rollers begins to run. So freezer reaches in front of
Sensor3. As sensor 3 gives an output, the rollers stop and the lift begins to move down.
As soon as the lift reaches down, the Sensor5 is pressed and rollers run again until it is
completely unloaded from the lift section.
4.2 Safety:
If due to any reason the system restarts and a deep freezer is already on the lift, then there is a
chance of collision of two deep freezers which may result in a huge loss. So we have also
included this condition. Our system is too smart to respond to this situation by shutting down
the main conveyor, until or unless the freezer is removed from lift.

7. 7
5.0Block Diagram:

8. 8
6.0 Circuit Diagram:
7.0 System Diagram:

9. 9
7.0 Arduino Program:
const int analogInPin = A0; // 1st sensor
const int analogInPin1 = A1; // 2nd sensor
const int analogInPin2 = A2; // 3rd sensor
const int analogInPin3 = A3; // limit sensor 1
const int analogInPin4 = A4; // limit sensor 2
int a=0;
int sensorValue = 0; // value read from the pot
int sensorValue1 = 0;
int sensorValue2 = 0;
int sensorValue3 = 0;
int sensorValue4 = 0;
int outputValue = 0; // value output to the PWM (analog out)
int outputValue1 = 0;
int outputValue2 = 0;
int outputValue3 = 0;
int outputValue4 = 0;
void setup()
{
pinMode(2, OUTPUT); // main conveyor (led)
pinMode(3, OUTPUT); // pneumatic valve
pinMode(4, OUTPUT); // rollers
}
void loop() {
digitalWrite(2, HIGH); // Main conveyor
digitalWrite(3, LOW); //Pneumatic

10. 10
digitalWrite(4, LOW); // roller
sensorValue = analogRead(analogInPin);
sensorValue1 = analogRead(analogInPin1);
sensorValue2 = analogRead(analogInPin2);
sensorValue3 = analogRead(analogInPin3);
sensorValue4 = analogRead(analogInPin4);
sensorValue = analogRead(analogInPin);
outputValue = map(sensorValue, 0, 1023, 0, 255);
if (sensorValue>200){ /// waiting for sensor value to become greater than 200
while(sensorValue1>200 || sensorValue2>200)
{
sensorValue1 = analogRead(analogInPin1); // checking sensor value
outputValue1 = map(sensorValue1, 0, 1023, 0, 255);
sensorValue2 = analogRead(analogInPin2); // checking sensor value
outputValue2 = map(sensorValue2, 0, 1023, 0, 255);
digitalWrite(2, LOW); // Main conveyor
digitalWrite(3, LOW); //Pneumatic
digitalWrite(4, LOW); // roller
}
digitalWrite(2, LOW); // Main conveyor stops
digitalWrite(3, HIGH); //Pneumatic Valve actuated
while(sensorValue3<400) // waiting for sensor value to become greater than 400
{
sensorValue3 = analogRead(analogInPin3); // checking sensor value
outputValue3 = map(sensorValue3, 0, 1023, 0, 255);
}
digitalWrite(2,HIGH); // Main conveyor runs
while(sensorValue1<400) // waiting for sensor value to become greater than 400
{
sensorValue1 = analogRead(analogInPin1); // checking sensor value
outputValue1 = map(sensorValue1, 0, 1023, 0, 255);
}
digitalWrite(2,LOW); // Main conveyor stops

11. 11
digitalWrite(4,HIGH); // Rollers run
while(sensorValue2<200) // waiting for sensor value to become greater than 200
{
sensorValue2 = analogRead(analogInPin2); // checking sensor value
outputValue2 = map(sensorValue2, 0, 1023, 0, 255);
}
digitalWrite(4,LOW); // rollers stop
digitalWrite(3,LOW); // pneumatic stops
while(sensorValue4<400) // waiting for sensor value to become greater than 400
{
sensorValue4 = analogRead(analogInPin4); // checking sensor value
outputValue4 = map(sensorValue4, 0, 1023, 0, 255);
}
digitalWrite(4,HIGH); // rollers run
while(sensorValue2>200) // waiting for sensor value to become less than 200
{
sensorValue2 = analogRead(analogInPin2); // checking sensor value
outputValue2 = map(sensorValue2, 0, 1023, 0, 255);
}
delay(500);
digitalWrite(4,LOW); // rollers stop
}
else
{
}
delay(100);
}
------------------------------------------------------------------------------------------------
8.0 Conclusion:
There is always room for improvement in every industry. Some improvements result in
increased quality of the product while others focus more on production rate. Our Focus was
to increase the production rate and revenue being generated by the company. This automation
will result in a greater and faster production of deep freezers. The new automatic system
results in providing greater safety for deep freezers and number of freezers being transported
in a given time.