Egg Incubator - Project Report
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Effat University Students: Haneen Bawayan Jauahir Al-‐‑Bakri Maha Nour Maryam Tora Course Instructor: PROF. Dr. Muhammad Ghazi Shihata
Saturday Jan, 14, 2011
EGG INCUBATOR
Outline … Abstract Introduction Chapter I: Literature Review i.
What Is an Egg Incubator
ii.
The 1st Egg Incubator
iii.
Egg Incubators Time Line
Chapter II: Class Project – Chicken Egg Incubator i.
Project Objective
ii.
Required Circuits
iii.
Incubator’s Body
iv.
Additional Improvements
Chapter III: Class Project – Problems, Difficulties and Solutions i.
In Circuits
Conclusion Appendix A
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Abstract … The following report examines the combined work integrated in building an egg incubator for hatching bird eggs; the project was the result of the collective work of 4 students in the ECE 240 – Linear Control System course. The report sheds the light on the circuits constructed, the mechanical experience gained and the difficulties faced by the team through out the construction process over the span of 5 weeks.
Introduction … Since the dawn of time, the human kind had used the eggs of animals as a source of food, wither they were the eggs of birds, reptiles, amphibians or fish did not mater. But as the time passed the humans abilities to survive improved resulting in an explosion of population around the glob, that outburst resulted in sustenance becoming a challenge. But as they say the need is the drive behind invention, in this report, one of these inventions – The Egg Incubator -‐‑ is built and discussed. This report follows through with the work of this group over the span of 5 weeks.
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Chapter I: Literature Review i.
What Is an Egg Incubator: An egg incubator is used to hatch bird or reptile eggs. The incubator keeps the eggs warm, allowing the fetuses inside of them to grow and hatch without the mother present. Each bird type has certain properties for their eggs to hatch as shown in the table bellow: Humidity
Incub. Period
Temp
Humidity
Do not turn
(days)
(F.)¹
(F.)²
after
Chicken
21
99.5
85-87
18th day
90
18th day
Turkey
28
99
84-86
25th day
90
25th day
Species
Last
Open vent more
3 days²
Duck
28
99.5
85-86
25th day
90
25th day
Muscovy Duck
35-37
99.5
85-86
31st day
90
30th day
Goose
28-34
99
86-88
25th day
90
25th day
Guinea Fowl
28
99.5
85-87
25th day
90
24th day
Pheasant
23-28
99.5
86-88
21st day
92
20th day
Peafowl
28-30
99
84-86
25th day
90
25th day
Bobwhite Quail
23-24
99.5
84-87
20th day
90
20th day
Coturnix Quail
17
99.5
85-86
15th day
90
14th day
Chukar
23-24
99.5
81-83
20th day
90
20th day
Grouse
25
99.5
83-87
22nd day
90
21th day
Pigeon
17
99.5
85-87
15th day
90
14th day
ii.
The 1st Egg Incubator: A Napoleon E. Guerin invented the first egg incubator in the year of 1843; he received the patent for his creation in the city of New York (No. 3,019). The patent described a "ʺmode of distributing steam heat, purifying air, etc."ʺ for hatching chickens by artificial heat.
iii.
Egg Incubators Time Line: The years between 1843 and 2011 are packed with substantial developments and changes on the original work of Guerin, and can not possibly fit to the requirement of this project’s report, thus; for additional information on the history of the egg incubator please refer to appendix A.
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Chapter II: Class Project – Chicken Egg Incubator i.
Project Objective: The resolve of this project was to build a complete, fully functioning and hand made egg incubator and the chosen species was birds. The students were to construct a design for the egg incubator blocks and circuits. After finding the circuit diagrams corresponding with the specifications listed by the course instructor. In addition to the experience, the students had an opportunity to try their hands in the mechanical aspects of the project and test their creative capabilities.
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ii.
Incubator Design: • Block Diagram:
iii.
Block Diagram Description:
The egg incubator consists of three main blocks, which they are the temperature controller block, humidity control block and motor control block. First off all, the temperature control block contain fan circuit and heater circuit to keep the egg incubator temperature suitable for the eggs. Second, the humidity control block which consist of water level circuit. Finally, Motor movement control block. This block consists of timer circuit that allow the motor to move from time to time. However, the motion is important for the eggs to hatch, but not in all days. Therefore, this circuit has a switch connected to the power supply to open/close it when its needed. All of them are supplied by 12 V power supply. That’s why there is a switch connected to the power supply and the 110 RMS. It’s the main switch that open and close the egg incubator. In addition, there is a small fan connected to the power supply so, its on whenever the power supply is open. This fan is to cool the circuits and increase the incubator life. This incubator has a lamp to allow the user to see what’s happening inside it. Also it can be use as additional heater if needed. This lamp has an external switch that connects it with 110 RMS to turn it on/off depends on the user needs.
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iv.
Required Circuits: • Heater Circuit:
Purpose: The purpose of this circuit is to control the temperature also inside the egg incubator by keeping the egg worm as in their real environment. This circuit opens the heater when the temperature value goes below adjusted temperature. On the other hands its turned of when the temperature value increase above the adjusted value range. Circuit diagram:
Parts: -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐
50 K Ω NTC Thermistor (TTC05503) OP-‐‑ Amp (UA 741 CN) Transistor 2N2222 Potentiometer to 100 K Ω DC Power supply 12 V Resistors (10 K, 5K, 50 K, 68 K, 150K, 10K, 20K, 4.7 K, 1k) Capacitor (0.01 ! F) Electrode capacitor (10 ! F) Relay Diode Air heater with 110 V
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Descripting: This circuit is also has the 50 K Ω thermistor that vary inversely with the temperature as shown above in the figure. Consequently, the voltage changes across the thermistor proportionally. The voltage drop across the thermistor is connected to the positive node of the Op-‐‑ Amp, unlike the fan circuit when it was connected to the negative node. Furthermore, The voltage drop across the summation of resistors R7 and R8 is connected to the negative node. If the voltage drop in the positive node is greater than the voltage in the negative node, then the Op-‐‑Amp value will be enough to activate the transistor. As a result, the current will bass from the collector to the emitter. At this moment, the relay close its switch and the fan will be on. Otherwise the fan will be in the off mode. For example, 37 °C was the required temperature value to reach which is equivalent to 30k Ω in this thermistor. The variable resistor was adjusted to 50k Ω. If the temperature is less than 37 °C that mean the thermistor value is above 30k Ω. therefore the voltage across the thermistor (positive node) is greater than the voltage in the negative node (30k Ω = R7 + R8) therefore the heater is on. If the temperature goes above 37°C that means the thermistor value is less than 30 k Ω. furthermore, the voltage in the positive node is less than the voltage in the negative node. As a result the heater is off.
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• Fan Circuit: Purpose: The purpose of this circuit is to control the temperature of the egg incubator. When the temperature increase than the adjusted temperature (depends on the egg type) the fan opens to cool down the eggs. Otherwise it will be close. Circuit diagram:
Parts: -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐
50 k Ω NTC thermistor (TTC05503) OP-‐‑ Amp (UA 741 CN) Transistor 2N2222 Potentiometer to 100 K Ω DC Power supply 12 V Resistors (15 K , 47 K , 20 K ,150K, 1K, 5K, 20 K , 4.7 K , 1k) Capacitor (0.01 ! F) Electrode capacitor (10 ! F) Relay Diode Fan with 110 V
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Descripting: The thermistor shown in the circuit above (50K at 25 °C) vary depends on the temperature value. When the temperature increase the resistor value decrease as it is shown in the figure below:
The red line (TTC 05503) is the behavior of 50 k
ohm thermistor
Therefore, the voltage varies across the thermistor. The voltage drop across the thermistor is connected to the negative node of the Op-‐‑ Amp. On the other hand, the voltage drop across the summation of resistors R6, R5 and R7 is connected to the positive node. If the voltage drop in the positive node is greater than the voltage in the negative node, then the Op-‐‑Amp value will be enough to activate the transistor. As a result, the current will bass from the collector to the emitter. At this moment, the relay close its switch and the fan will be on. Otherwise, the fan will be in the off mode. For instance, the required temperature in the egg incubator was 37 °C which is equivalent to 26.5 k Ω in this thermistor. Then the variable resistor was adjusted to 50 k Ω. now if the temperature is less that 37 °C than mean the thermistor value is above 26.5 k Ω. therefore the voltage in this node (negative node) is larger than the voltage across the 26 k Ω (R6 + R7 + R8) therefore the fan is off.
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If the temperature is 37 °C exactly then the fan will still be off to keep the required temperature. In the circuit, if it was 37 °C which means 26.5 k Ω therefore the voltage drop across it is still higher than the voltage across the 26k Ω (above 37 °C). Therefore the fan is still off. Whenever the temperature increase above 37 °C that leads to decrease the thermistor value below 26 k Ω. that cause the voltage drop across the 26k Ω to be higher than the voltage drop across the thermistor. Therefore the fan will be turn on.
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• Timer Circuit: Purpose: The purpose for this circuit is to control the motor movement. The timer circuit moves the eggs from time to time automatically in the first 18th day then the user should switched it of until the hatching day. This circuit is designed to move the egg 90 sec each 100 minutes. Circuit diagram:
Parts: -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐ -‐
LM 555 Timer Three 4.7 m F electrodes capacitor 10 n F capacitor Relay Two 12 V power supply Transistor 2N2222 Resistors (10 K, 10 K, 360K) Diode Switch
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Descripting: 555 Timer was used to control the motor by producing pulses. The 555 timer used for this purpose to produce pluses as following:
The 555-‐‑timer was connected as shown in the figure to be in pulse generator mode (A stable Operation). By using these formulas: The charge tome (output high) is given by: t1= 0.693 (RA+RB)C The discharge (output low) is given by: t2= 0.693 (RB)C According to these equations the circuits were designed to have: RA = 360 K Ω RB = 10 K Ω C= 14.1 mF (three capacitor in parallel with 4.7 m F) t1= 0.693 (360 K+10 K) (14.1 m) = 3615.381 = 85 minute =1 hour and 25 minute t2 = 0.693 (10 K) (14.1 m) = 97.713 = 97 sec = 1 minute and 37 sec As its clear from the calculations that the time for charging (output high) is larger than the time for discharging (output low), but to control the motor movement we need the opposite. Therefore the
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relay was connected normally short and when there is current passing thorough the coil (85 minutes) its will disconnect the motor (off status) and when no current passing through (97 sec) the relay the motor will be connected (turn on the motor).
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• Water Level Circuit: Purpose: The purpose for this circuit is to control the humidity inside the egg incubator by controlling the water level in a tank that locates inside the egg incubator. Therefore, this circuit turns on/off the pump to fill the tank automatically when ever the water level decrease. Circuit diagram:
Parts: -‐ -‐ -‐ -‐ -‐ -‐ -‐
2 input NAND gate (HEF4011B) Transistor 2N2222 DC Power supply 12 V Resistors (100 K, 100 K , 1 M, 1M , 4.7 K) Relay Diode 12 V Pump
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Descripting: The water level circuit consists of 3 NAND gates that are taken from the 4 NAND gates in IC HEF4011B. Two of the NAND gates are used to create the !" flip flop as shown in the figure. The Third NAND gate’s inputs (2 input) are connected together and the NAND gate’s output is connected to the reset in the !" Flip-‐‑flop as you can see in the circuit diagram. In the water tank there are the threshold sensor, the triggered sensor and the common probe. If there is no water in the tank, then the threshold sensor and the trigger sensor are not connected to the common probe (the ground). This mean that both 10 K Ω resistors will act as an open circuit that leads to have high voltage drop across both 1 M Ω resistors. As a result the set node in the !" flip flop will be set high and the reset node will be !" Flip flop with 2 NAND gate
set low because the two inputs to the NAND gates is high. Therefore, the !" Flip-‐‑flop output (!) is high, which activate the relay to turn on the pump. While the pump is open, the water will conduct the common probe with the trigger sensor. So, the two NAND gate’s input will be deactivated and its out put will be high (!=1). The water doesn’t reach the threshold sensor yet, which keep the set node in the !" flip-‐‑flop activated. In this case when !=1 and !=1, the pump will continue filling because the out put of !" Flip-‐‑flop output (!) keep the old status of the last output. When the Water reaches the threshold sensor, the pump will be turned off. Since the threshold sensor is connected to the ground so the set node will be deactivated (!=0). Furthermore, the reset node will be activated ( ! =1) because the trigger senor is connected to ground and the output of the NAND gate is high when both inputs are low. Therefore the flip-‐‑flop output (!) is deactivated and the pump is turned off.
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v.
Incubator’s Body: The incubator’s body was constructed from wood, this was the only task not performed by the students for been beyond the capacity of this project. A carpenter was contracted to build it according to the measurements and design provided by the team. The shell was the only thing done by the carpenter, the students themselves did the accessories added to the incubator and they entitled the following: •
Inner roof ( using painting board).
•
The glass window (from old printer).
•
The handles on the door and the roof.
•
The wheels on the bottom of the incubator.
•
The lamp, fan, heater, motor, circuits, power supply, thermometer and two switches.
vi.
Additional Improvements: The main parts obligatory were the circuits for the fan, heater, motor and timer. The students added each of the following improvements on the original requirements: •
The Lamp: A 60-‐‑watt bulb was added to help the user check on the eggs in the dark.
•
The DC Motor Switch: The controlling circuits were designed according the specifications required to hatch Chickens eggs. According to them, the eggs must swing for 90 sec every hour for the duration of 18 days out of the original 21 days, hence the switch to enable the user of turning the DC Motor’s circuit (responsible for the swinging) off.
•
The Power Supply Switch: Added to enable the user of On/Off the complete incubator.
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Chapter III: Class Project – Problems, Difficulties and Solutions i.
In Circuits: • Heater Circuit:
This circuit was done on the same concept of the fan circuit with some differences. Although, it didn’t work from the first time, then it was noticed that it is an open circuit (testing board circuits has near nodes we thoughts it is connected but it was connected to the node below it). While testing this circuit at the beginning, the heater device was not decided yet. Therefore, we used a lamp instead to represent the heater. When lamp is on that indicate the heater is on otherwise it’s off. After that, a hair drier (with 110V) was chosen to be the heater for the egg incubator and the lamp was replaced. However, the circuit did a great job while testing it as you can see in the link below: http://www.youtube.com/watch?v=uXLyK-‐‑SczVs
• Lamp: A lamp was connected to the switch and then to the 110 V. This connection was connected in wrong way that creates a short circuit between the two nods of the 110 V. Thus, when the switch was turned on the plug is burned. After that, the mistake was noticed and it was corrected.
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• Fan Circuit: The following difficulties were faced with the fan circuit: -‐
Wrong connection of the mechanical relay due to the lack of knowledge on how it operates, the connections between its pins. This problem was solved by opining one of the mechanical relays and studding its inner configuration vie a voltmeter.
-‐
A 47 KΩ was used in the beginning but it was replaced by a 4.7 KΩ after studding the data sheet.
-‐
The testing of the thermistor during different temperatures in order to compare the obtained results with the ones provided by the data sheet, which proved to be somewhat difficult with a digital thermometer due to the sudden -‐‑ instead of gradual -‐‑ changes in temperature.
-‐
In order to understand the circuit, the team had to learn how to read the algorithm provided by the data sheet.
-‐
The circuit was simulated using multi-‐‑sim software; the circuit’s behavior was studied by calculating the output voltage at different nodes that corresponds to different values of resistors.
-‐
The resistor values used in the circuit diagram were connected on series, that connection proved inefficient for the team’s purpose; hence they were connected on the parallel.
-‐
The variable resistor was unstable leading to soldering its three pins to a hard wire and then connecting it to the circuit.
-‐
The circuit was tested on a 12Vcc fan, after it was proven to work successfully; the fan was replaced with the 110Vcc intended fan.
-‐
The plug connecting the fan to the 110Vcc was unsteady, resulting in constant checking on its connection state. The plug was replaced and he problem was solved.
-‐
The fan was situated inside the incubator without any holes to ventilate it, the mistake was later noticed and holes were added via a wood drill. At the end all the problems were fixed and the circuit was tested. Please check the link below: http://www.youtube.com/watch?v=UzHUmJI12XE&feature=related
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• Timer Circuit: At the beginning the timer circuit was connected in a way such that it functioned in a mono stable mode, which produce only one pulse. After going through the datasheet again and analyzing it carefully, we reconnected the circuit to be in the astable mode, in order for it to act as a pulse generator. To test the astable mode we connected a lamp with 6V instead of the actual motor, because it’s easier to observe the change. Since, the lamp is smaller in size and is very easy to more around in case of connection changes. By using !! = 10!Ω, !! = 4.7!Ω and calculating the time for turning ON/OFF the lamp, it was found that !! = 3,257 sec !" , !! = 10.187 sec !"" . After testing, the results were !! = 3.4 sec, !! = 11 !"#. The results were expected. After that we changed the values of both !! , !! with the (capacitance=100µμF), as a result, !! = 90 sec, !! = 100 !"#$%&', according to the required output, the values of both resistors were determined, such that!! = 51.7!Ω, !! = 216.45!Ω. Later, we noticed that the values are too high, the resistors act as an open circuit, and the lamp never turns ON because the resistors dissipate the current. Therefore, we decided to increase the value of the capacitor instead of the resistor. Consequently, we took a capacitor with a value of 1000µμF from an old power supply. We recalculated the values all over again, after that, we the!! = 5.1!Ω, !! = 21.65!Ω. After testing the circuit with these values, it was found that the lamp was also switched ON all the time, because !! = 5.1!Ω acts as an open circuit because of its high value. To solve this problem, we suggested, instead of increasing the resistor value we should increase the capacitance, therefore we created a schedule depending on the largest value of capacitance the electronic shop had available which was (4.7mF). Finally, we connected three capacitors in parallel to get a greater value, ! = 4.7! + 4.7! + 4.7! = 14.7!". !! = 0.693 14.1! 10! = 1!"#$%&, 37 !"#$%&! !! = 0.693 14.1! 10! + 360! = 1ℎ!"#, 25!"#$%& = 85!"#$%&' The circuit was then tested, by placing a camera in front of the circuit for two hours. After going through the film, we found out that it took 1 hour and 39 minutes for the lamp to be switched ON, and it stayed ON for 90 seconds, then it was turned OFF again. The link below show the timer circuits test: http://www.youtube.com/watch?v=TaNMxzs7V-‐‑o
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Finally, the last result was the result we took, the values were obtained from it and we designed the circuit accordingly. Even though there was a 14-‐‑minute error, it is an acceptable error and hopefully it will not affect the eggs.
• Water Level Circuit: -‐
At the beginning the circuit didn’t work normally as it should to. Then after checking all components in the circuit, we realized that there is no connection between pin 3 and 5 in the NAND gate. This missing wire is responsible for the connection between the output of NAND gate and the reset in !" flip-‐‑flop.
-‐
The pump didn’t work when it was connected to the power supply. Suddenly we noticed that the pump has negative and positive polarities so, the problem was fixed.
-‐
When the pump’s ends were connected to hose, the pump didn’t work until one of the ends (the one that suction water from the water storage tank) connected directly to the water surface.
-‐
Relay was not working (factor default). Then it was changed with a new one and t worked correctly.
-‐ -‐
While connecting the sensors in the water tank, that is made from plastic, the water tank broke. Soldering machine was used to solve the problem by melting a little part
of the plastic and reappear the broken part. Also, the soldering device was used to create small wholes to allow screws to enter the plastic without breaking it. In addition, silicon was used to prevent water leakage. -‐
At the end all the problems were fixed and the circuit was tested as you can see in the link below:
http://www.youtube.com/watch?v=LmVbmCQTtjA
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Conclusion: The objectives behind the project were fulfilled, from understanding the art of constructing circuits to creating our on electrical drill!! Add to that the acquired experience in facing the different types of problems and brain storming their solutions. In the end; the egg incubator worked successfully, the circuits functioned at the set controls and the body was constructed to fit the different elements integrated to produce the incubator.
Appendix A: The time Line of the Egg Incubator: 1843
On Mar 30, 1843 Napoleon E. Guerin of New York City, received a patent for an "ʺEgg Hatching Apparatus"ʺ (mode of distributing steam heat, purifying air, etc."ʺ); egg incubator for hatching chickens by artificial heat. 1879
In 1879, Lyman Byce and Isaac Dias invented the first practical egg incubator. Another Petaluman, Christopher Nisson, seized upon this invention and within a few years had established the world'ʹs first commercial hatchery. 1947 Feb 11, 1947 -‐‑ A new 10000-‐‑egg incubator has been installed in the poultry building. The new brooder house is de signed to brood 1700 poults "ʺoff he floor,"ʺ while a second unit to be constructed later will make "ʺon the floor"ʺ brooding for comparison. 1963
Apr 13, 1963 -‐‑ The first graders at Davis Elementary School had been told chickens came from eggs but they weren'ʹt sure until they saw it actually happen. They had been watching the egg in an improvised incubator.
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References: http://www.vishay.com/docs/29049/23816403.pdf http://www.es.co.th/Schemetic/PDF/TTC05.PDF http://pdf1.alldatasheet.com/datasheet-‐‑pdf/view/17675/PHILIPS/HEF4011BT.html http://en.wikipedia.org/wiki/Flip-‐‑flop_(electronics) http://www.todayinsci.com/3/3_30.htm http://www.poultryhelp.com/hatch.html
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