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MISSION STATEMENT
Mechanical System Design

COIN SORTER AND COUNTER Submitted by Eng. Mahmoud Refaat Saad Submitted to Prof. Dr. Mohamed Ezz Faculty Of Engineering, Cairo University Mechanical Design and Production Department

Its required to develop a low cost coin sorter and counter system which can automatically separate and count different Egyptian new coins (0.25, 0.5 & 1 L.E).

MISSION STATEMENT

MISSION STATEMENT

The developed system should be easy to use, easy to maintain, eliminate jams and reliable

o Small volume is a must o 2 months at maximum to submit a detailed design of the system

o Initial 20% market share of all supermarket cashiers, to reach 80% in two years o 30% profit margin o Return on investment in 18 months o Primary market: Supermarkets secondary market: Low cost products traders, Banks o Stakeholders: Supermarket cashiers, accountants, sales and service forces

COINS DATA
Diameter Thickness Mm Mm Mass Gm

TARGET SPECIFICATIONS

Cain value

Image

25 Piasters

21

1.26

4.5

50 Piasters

23

1.7

6.5

1 Pound

25

1.96

8.5

Counting speed up to 3000 coin/min. Hopper capacity 1000 coin Acceptable diameter from 20 to 25 mm Acceptable thickness from 1 to 3 mm LED display of counter Power supply: 220V / 50Hz Max Dimension: 300 x 300 x 300 mm (Width x Depth x Height) Max Weight: 5 kg standard coin (counterfeit) detection: Yes

Table 1 New Egyptian Coins. http://w ww.cbe.org.eg/1historical_review_for_currency.htm

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CONCEPTUAL DESIGN

SORTING

Sorting

Rotating disks and coin locator

Different width path

Image processing

1- Rotating disks and coin locator: Consist of a rotating disks, a fixed disks, and locator. Coins located in the rotating disk holes The locator allows only one coin to pass through Then each coin dropped in the corresponding hole in the fixed disk

Two disks

SORTING

SORTING

2- Different width path: Coins are moved through a specified path At each turn the width decrease which expel high diameter coins Expelled coins then collected and counted

Image processing: Image processing packages used to identify coins, measure their diameters and count them.

Original image

Processed image

CONCEPTUAL DESIGN

CONCEPTUAL DESIGN

Counting

Counterfeit detection Image processing Light sensor

Scalar tubes

Weight

Mechanical sensor

Optical coin discrimination sensor

Image processing

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OPTICAL COIN DISCRIMINATION SENSOR

CONCEPTUAL DESIGN

Consists of: 1. Coin path 2. encoder 3. Light source 4. Light detector 5. Controlling circuit

o How did we put the conceptual design? o The rating reference is:
excellent
very good good not bad bad

4
3 2 1 0

CONCEPTUAL DESIGN

CONCEPTUAL DESIGN

o 2.3.1 driving power

weight 1 0.8 0.5 0.3 0.7 0.9 0.5 0.9 0.9 cost performance(jamming and speed) eff maintainability reliability safety environmentally friendly ease of use industrial design features sum (weight x rate) electrical 2 3 3 3 3 3 4 3 3 20.3 gravity 4 1 2 2 4 4 4 4 2 21

o 2.3.2 sorting system

weight 1 0.8 0.5 0.3 0.7 0.9 0.5 0.9 0.9 cost performance(jamming and speed) eff maintainability reliability safety environmentally friendly ease of use industrial design features sum (weight x rate) Rotating different width path discs 3 4 3 3 4 3 2 3 4 4 20.7 2 2 3 3 4 4 2 2 18.8 image processing 0 4 4 1 3 4 4 3 3 18.6

CONCEPTUAL DESIGN

CONCEPTUAL DESIGN

o 2.3.3 counting system

weight 1 0.8 0.5 0.3 0.7 0.9 cost performance(jam ming and speed) eff maintainability reliability ease of use sum (weight x rate) weight light sensor 2 3 3 3 2 3 10.9 2 2 3 2 3 2 9.6 scalar tubes 4 3 3 4 3 4 14.8 mechanical sensor 2 3 2 2 2 2 sum (weight x rate) image processing 0 4 4 1 3 3 10.3

o 2.3.4 building materials

weight 1 0.8 cost performance(jamming and speed) eff maintainability reliability safety environmentally friendly ease of use industrial design features sum (weight x rate) plastic 3 3 fiber 1 4 aluminum 2 2 wood 2 3

0.5 0.3 0.7 0.9

0.5 0.9 0.9

4 1 4 3
2 3 4 20.5

4 2 4 3
2 3 3 18.7

3 2 3 2
3 2 2 14.7

2 2 2 4
4 3 3 sum (weight x rate)

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CONCEPTUAL DESIGN

FINAL SPECIFICATIONS

Driving power: electricity and gravity Sorting method: using two disks and coin locator Counting method: scalar tubes Building materials: plastic

Counting speed up to 1500 coin/min. Hopper capacity 300 coin Acceptable diameter from 20 to 25 mm Acceptable thickness from 1.1 to 2 mm Scalar tube for counting Power supply: 220V / 50Hz Max Dimension: 310 x 150 x 150 mm (Width x Depth x Height) standard coin (counterfeit) detection: No

SCENARIO

SCENARIO

SCENARIO

SCENARIO

A batch of coins are inserted in the hopper Due to hopper shape, coins are grouped in the tube ready to be feed one by one to the rotating disc

Coins

The distance between the hopper and the fixed disk is 2mm while the rotating disk is 1 mm thickness. This combination of gaps helps in carrying only one coin per hole and eliminate jams.

hopper Rotating disk

Fixed disk

25piasters=1.26mm, 50 piasters=1.7mm, 100piasters=1.96mm

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SCENARIO

SCENARIO

Now assuming we have 100 piasters coin in the rotating disk hole The coin is transferred by the rotating disk passing by the 25 piasters hole at first(smallest diameter), then the 50 piasters hole and finally the 100 piasters hole Using this order of holes helps in sorting coins regularly

The coins dropped in scalar tube which represents the amount of coins in it. The scalar tubes are able to removed and re-attached again.

VIDEO

PRELIMINARY DESIGN

PRELIMINARY DESIGN Motor selection: For speed= 1500 coin/min, and rotating disk with 6 holes Then rotating disk speed = 1500/6=250 rpm torque needed=.mg.r; =coeff. of friction, mg=coin weight, r= torque arm. As torque needed is too small, a motor of 60wt and 250rpm was selected in such a case of jamming

PRELIMINARY DESIGN

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PRELIMINARY DESIGN

PRELIMINARY DESIGN

Hopper shape In our case, the funnel holes instead of being concentric, they will be tangent at the same plane. Which gives the following advantages: 1. The existence of a straight surface helps in adjusting the coins while moving in the cover and to the cup. 2. Different funnel slopes which gives different velocities for coins while slipping, which eliminate jams.

PRELIMINARY DESIGN

PRELIMINARY DESIGN

Coin tubes dimensions For a capacity of 300 coin from the hopper Then capacity per each tube 100 coin then length of 100 piasters tube = 100*1.96200 mm then length of 50 piasters tube = 100*1.7170 mm then length of 100 piasters tube = 100*1.26130 mm Take an average length of tubes = 180mm

1.3 Coins holes diameters: Taking a 1 mm tolerance for coins flow inside the hole gives the following diameters:
Coin value 0.25 0.5 1 Coin diameter mm 21 23 25 Hole diameter mm 22 24 26

PRELIMINARY DESIGN Rotating disk: the rotor thickness=1mm As the min coin thickness is 1.26mm (for 25 piasters) The disk thickness shouldnt exceed it in order to avoid jamming. the holes diameter=26mm The disk holes should accept the largest coin diameter which is 25mm

THANK YOU