PERPUSTAKAAN UMP

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SELF-CLEANING SOLAR CELL MODULE WITH SUN TRACKING USING

MICROCONTROLLER FOR BATTERY CHARGER

FONG KONG HING

Thesis submitted in fulfillment of the requirement

for the award of the degree of Bachelor of Mechatronics Engineering

Faculty of Manufacturing Engineering

UNIVERSITI MALAYSIA PAHANG

JUNE 2013

ABSTRACT

Nowadays, the use of electric energy is increasing every day. The source of electric energy is commonly using generator that generate from burning the fossil fuel or coal. The solar energy is now starting to replace old convictional method and become important to our world. Solar energy is solar radiation from sun converting to electric by solar panel for common electric application. Usage of solar energy still small compare to older conventional ways. Energy converted by solar panel is depending on the angle between the positions of the sun and surface of solar panel. Solar energy will receive maximum when surface of solar panel is vertical 900 to the position of the sun. Besides that, the efficiency converts solar energy to electric by solar panel surface is depend on the cleanness. The dust is effected the ability of the solar panel to gain the sun irradiation form sun. It is because the dust will block the sunlight though the solar cell in solar panel. This project is design, construct and implement a tracker that has ability to track the sunlight during daylight and have ability self-cleaning. The system is use a microcontroller-based on solar tracking system which will process input data from sensor or instrument and produce output for motor to move the solar panel. As the result, a prototype of self-cleaning solar cell with sun tracking system is operated and able to achieve the objective or goal for this project.

ABSTRAK

Pada masa kini, penggunaan elektrik atau tenaga semakin meningkat. Sumber elektrik atau tenaga biasanya menggunakan penjana motor untuk menjana elektrik daripada membakar bahan api fosil atau arang batu. Kini, tenaga suria mula menggantikan penjana motor untuk menjana elektrik atau tenaga clan menjadi sangat penting kepada dunia kita. Tenaga sUria adalah pancaran cahaya daripada matahari ditukar kepada elektrik daripada panel suria untuk aplikasi elektrik biasa. Penggunaan tenaga suria masih kecil berbanding dengan cara-cara konvensional yang lebih tua. Walau bagaimanapun, tenaga ditukar oleh panel suria adalah bergantung kepada sudut antara kedudukan mataharj clan permukaan panel suria. Tenaga suria akan menerima maksimum apabila permukaan panel suria adalah menegak 900 kepada kedudukan matahari. Selain itu, kecekapan menukar tenaga suria kepada elektrik dengan menggunakan panel suria juga bergantung kepada habuk yang wujud di permukaannya. Habuk boleh menpengaruhi keupayaan panel suria untuk mendapatkan penyinaran cahaya daripda matahari. la adalah kerana habuk akan menghalang cahaya matahari kepada sel suria di panel suria. Dalam kes ini, satu projek untuk reka bentuk,dan membina sistem pengesan untuk mengesan cahaya dari pagi hingga malam clan mempunyai keupayaan membersihkan permukaan panel suria. Sistem mi adalah kawalan oleh mikrocontollor. Sistem pengesanan suria yang akan memproses data input dari sensor clan menghasilkan data output kepada motor untuk menggerak panel suria. Sebagai hasilnya, prototaip yang mempunyai keupayaan membersihkan permukaan panel suria dengan sistem pengesanan kedudukan cahaya daripada matahari dikendalikan untuk mencapai objektifatau matlamat untuk projek mi.

TABLE OF CONTENTS

Page

SUPERVISOR'S DECLARATION

STUDENT DECLARATION iv

ACKNOWLEDGEMENTS

ABSTRACT

ABSTRAK

TABLE OF CONTENTS ix

LIST OF TABLE

LIST OF FIGURES .xiii

LIST OF ABBREVIATIONS xv

CHAPTER 1 INTRODUCTION

1.1 Introduction/Background 1

1.2 Problem Statement 3

1.3 Objective of Study . 3

1.4 Scope of Study . 3

1.5 Thesis Organization 4

CHAPTER 2 . LITERATURE REVIEW

2.1 Introduction

2.2 What Type of Sun Tracker System Existing on This World? 6

2.3 Fixed Solar System or Moveable Solar System Which Perform Well? 8

2.4 Two Axis Solar Tracker System or One Axis Solar Tracker 10

System Which Performs Well?

2.5 What are The Parameters Affects the Performance of Solar Cell? 11

CHAPTER 3 METHODOLOGY

3.1 Introduction 13

3.2 Project Flowchart 13

3.3 Process Flow of Solar Tracking System 15

3.4 Process Flow of Self-Cleaning System 16

3.5 Design and Construct Mechanical Structure 17

3.6 Design and Construct Electrical Circuit 18

3.7 Hardware Overview 19

3.7.1 Solar Cell 19 3.7.2 Solar Tracking System 19 3.7.3 Light Sensor 20 3.7.4 Microcontroller 21 3.7.5 DC motor 22 3.7.6 PlC Microcontroller Start-Up Kit (SK40) 23 3.7.7 UICOOB USB ICSP PlC Programmer 24

3.8 Program Design 25

3.9 Mechanical Structural Design 27

3.10 Electric Circuit Design 28

3. 10.1 DC Motor Control Circuit 30 3.10.2 Sensor Circuit 30 3.10.3 Microcontroller Circuit 31 3.10.4 Voltage Regulator Circuit 32 3.10.5 Self-cleaning Circuit 32

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 33

4.2 LDR Sensor

4.3 Microcontroller 34

4.4 DC Geared Motor Controller 36

4.5 Solar Cell Module System 37

4.6 Self- Cleaning System 38

4.7 Prototype Test 39

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Introduction 41

5.2 Conclusion 41

5.3 Recommendation 42

REFERENCE 43

APPENDICES 45

A Program Code 45

B List of Component 48

C List of Material 49

D Photo of Prototype 50

LIST OF TABLES

Table No. Title Pages

2.1 Experimental average daily total solar radiation in MJ/m 2 . 9

2.2 The peck power of each condition 12

2.3 Comparison is between cooling system and non-cooling system 12

4.1 LDR sensor output voltage during hardware measurement 34

4.2 Operating Condition for Microcontroller 36

4.3 Motor Operating Condition 37

4.4 Specification of the dual axis solar tracking system 38

4.5 Data for solar panel during hardware testing 40

A111

LIST OF FIGURES

Figure No. Title Pages

2.1 Type of sun tracker 8

2.2 Results of 1A-3P tracking PV and fixed PV in March, 2010 9

2.3 Tracking solar panel versus fixed solar panel 10

2.4 Power generation comparison of fixed angle type and tracking systems 10

2.5 Variation of cell power with day time 10

3.1 Flowchart of the project 15

3.2 Process flow of solar tracking system 16

3.3 Process flow of self-cleaning system 17

3.4 Flowcharts for Design and construct mechanical structure 18

3.5 Flowchart of the Design and construct electrical circuit. 19

3.6 CdS photo transistor circuit 21

3.7 Shade balancing principle 22

3.8 Plc i 6F877A microcontroller 23

3.9 SPG30-300K DC geared motor 24

3.10 Plc Microcontroller Start-Up Kit (SK40C) 25

3.11 UICOOB USB ICSP PIC Programmer 25

3.12 Connection between UICOOB and SK40C 26

3.13 Flowchart for solar tracker system program. 27

3.14 Flowchart for self- cleaning system program 27

3.15 Isometric view solar tracking system desgin 28

3.16 Right view solar tracking system design 28

3.17 Top view solar tracking system design 29

3.18 Back view solar tracking system design 29

3.19 Block Diagram for designed system. 30

3.20 Overall circuit using ISIS Pro 30

3.21 DC motor Control Circuit 31

3.22 LDR sensor circuit 32

3.23 Microcontroller 32

3.24 Voltage regulator circuit 33

3.25 Schematic of solar panel and viper

33

4.1 LDR sensor circuit

35

4.2 Microcontroller circuit

36

4.3 DC Geared motor controller 38

4 • 4 Prototype of .designed system 39

4.5 Mechanical structure for self-cleaning system

39

4.6 Graph of electric power per hour curve for static solar panel system 41 and dual axis tracking solar panel system

LIST OF ABBREVIATIONS

DC Direct Current

LDR Light Dependent Resistor

plc Peripheral Interface Controller

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Nowadays, the electricity was important to entire world. It is because the

electricity was main source to supply the factory, transportation, communication,

commercial building and residential house. Without the electricity will cause many

problems in daily life. The entire world now was faced short supplying electric power

due to not enough sources to generate electric. Usually source that uses to generate

energy or electric is not renewable source such as fossil. Besides that, using fossil will

lead to environment destruction to our planet such as global warming. The environment

issue was being regarded by most critical problem when using fossil to generate the

electricity. Therefore, the goal is to emphasize to obtain the clean energy supplies of the

electric energy. Renewable source is now an alternative solution to generate the electric

energy for example, sunlight. A free sunlight will produce energy that environmental

friendly.

In Malaysia, the climate is usually bright sunny day and raining day. The sun

radiation in Malaysia is high due to location of Malaysia on earth. The monthly solar

radiation is approximately around 400-600 MJ/m2 in Malaysia (Mekhilef et al., 2012).

Hence, using sun radiation to generate electric in Malaysia is very useful and suitable. A

solar electric system that mostly use in Malaysia is photovoltaic (PV) system.

Furthermore, mostly solar panel that install on residential house in Malysia is static

solar panel. Static solar panel is not generating high efficiency when converting solar

2

energy to electric energy. To maximum solar panel to generating electric using the sun

radiation, the solar panel must perpendicular to the light source (sunlight). So, a tracker

is needed to make the solar panel is follow location of sun. This is because the sun is

moving for one location to other location. So that, function of tracker is to make sure

that solar panel is always perpendicular with light source to produce maximum electric

in a day. Long period use solar panel will cause the existence of dust on the surface of

solar panel. Dust will block solar panel to get light source. This will affect the efficiency

of the solar panel to generate electric. So, the surface solar panel needs to always clean.

The cleaning function is added to solar panel system. So, it can make sure the surface

solar panel is always clean.

The innovation valUe for this project is the added function for the sun tracker

which is ability to self-cleaning. The self-cleaning for sun tracker for this project is

passed on the concept of the viper car. The self-cleaning is use to clear the dust on the

surface of the solar panel. By combine the concept of the viper car into the solar cell

with sun tracker, it is able to improve the efficiency for gain maximum solar energy to

generate the electric energy.

The solar cell with sun tracker is become common in this world. Besides that,

the self-cleaning is already available on the market. Usually existing self-cleaning

system is using the mini robot to cleaning the surface of solar panel. So, it is using the

electric energy is high and cause the output product to the user is low. Besides that, mini

robot moving is slow and block the sunlight may affect the efficiency of solar panel.

Second type of self-cleaning system is adding the chemical or addition component to

the solar cell. So, the solar cell can using solar energy to clean the dust and it is most

effective way to clean the dust but it is expensive. For this project, differentiates itself

from existing or matured technology is the addition of self-cleaning ability on the solar

Panel system with concept of viper car. Besides that, it is cheaper way to cleaning the

dust even not effective like other existing self-cleaning system in the market.

1.2 PROBLEM STATEMENT

Mostly the solar panel use in commercial is static at a specific location to gain

the sunlight. The problem is a static solar panel only gain the sun irradiation w/m 2 at

specific location and direction. Therefore, the solar panel is not fully generating energy

from sun radiation for product maximum power. The second problem is long period

using solar panel will cause existence of dust on the surface of solar panel. The problem

that dust exists on surface solar panel is the solar cell in the solar panel gain the sunlight

become low and less effectiveness to generate the energy by solar cell. It is due to the

dust block the sunlight through to the solar cell in solar panel.

So, this project is to overcome the problems that occur. The solar tracking

systems have ability to detect the position of light source. Furthermore, the self-cleaning

ability is added on the solar tracking system can clear out the dust on the surface of the

solar panel. Hence, the solar panel able to generate optimum electric energy from

sunlight during daily.

1.3 OBJECTIVE OF STUDY

There are the objectives for the project:

To design and implement the solar system that able to tracking sunlight to gain

the optimum of the electric energy that transform from sunlight radiation.

To design and implement the solar cell module that able to charge the battery for

small electric apparatus.

To design and implement the solar cell module that has ability to clear the dust

on surface of solar panel.

1.4 SCOPE OF STUDY

This project is focused to design and develop a solar cell module with sun

tracking using microcontroller for battery charger and have ability to clean up the dust

on surface of solar panel. Therefore, the project scopes are:

• Use microcontroller (16F877A) to rotate the DC motor.

-t

• Using DC geared motor (SPG30-300K)

• Using light Dependent Resister (LDR) as the sensor to detect the location of the

light source

. A solar tracker system which can detect the sunlight during daylight.

. A solar tracker system which can clean the dust on the surface of solar panel.

1.5 THESIS ORGANIZATION

This thesis has contained five chapters. It contains Induction, literature review,

methodology, result and discussion, and conclusion and recommendation. For this chapter,

it will discuss about introduction of project, problem statement for this project, objective

project, project scope, and thesis organization.

Chapter 2 is referring from several journals that related to this project. It will explain about

the best of the concept for solar tracking system use on solar panel and the parameter that

can cause the efficiency of the solar panel.

Chapter 3 includes the methodology for project. It will explain the procedure, and the way

to make sure how the project achieves the project goal on time. Additionally, this chapter

also discusses the process flow of the system, electrical circuit design, software design and

mechanical design for the project.

Chapter 4 is the result and discussion; it is containing the result for this project. It will

explain the sign gain from the light sensor to microcontroller and the output from

microcontroller, cooperation voltage value, current value, and power value between static

solar system and dual axis tracking solar system.

The last chapter is contained conclusion and recommendation. This chapter is concluding

the project and gives a recommendation to improve the project for future time.

CHAPTER 2

LITERATURE REWIEW

2.1 INTRODUCTION

Human has been used fossil fuel to generate electric energy for a long time ago but, the

supply of fossil fuel is become limited source for a day to other day. Fossil oil is one -

times non-renewable resource. Besides that, the combustion of fossil oil will cause large

amount of Carbon dioxide. It will cause large destruction of the environment in earth.

For example: Global warming. Therefore, human have been serious threat that use of

fossil oil. With development and research from sciences and engineering, clean, green

and saving energy has become a famous and hot topical issue for this era. One of the

green energy exist nowadays is solar energy. Hence, solar system is become wide use

in this world to generate electric energy. However, the solar system is not efficiency to

generate energy. Hence, many ways have been develop to increasing the efficiency to

generate energy. The most using control system for improve efficiency of solar system

is sun tracker system. There are several relevant question are connected and link to my

project. There are:

What type of sun tracker existing on this world?

Fixed solar system or moveable solar system which perform well?

Two axis solar system or one axis solar system which performs well?

What are the parameters affects the performance of solar cell?

The question will answer according the research paper, article, journal, or book that I

get from ScienceDirect and Google book.

2.2 WHAT TYPE OF SUN TRACKER SYSTEM EXISTING ON THIS

WORLD?

Sun tracker system usually divides to two main characteristic. There are active

(electrical) solar tracker and passive (mechanical) solar tracker. Sun tracker system that

existed is active tracker and passive trackers. (Poulek, and Libra, 1998). In a research

article by Mousazadeh et al. (2009), Main component for Passive solar tracker is

thermal expansion of a matter (usually Freon) or on shape memory alloys. The active

solar trackers are Microprocessor with electro-optical sensor based, date and time based

control by PC, auxiliary bifacial solar cell based and a combination of these three

systems (Mousazadeh et al., 2009). There are several research paper that been develop

and design the passive sun tracker. N, J. G et al. (2004) have developed a simple,

efficient smart sun tracking mechanism (SSTM) using SMA actuators. Poulek and Libra

(1998) have developed a low-cost single axis passive solar tracker based on a shape

memory alloy (SMA) actuators. The following researchers that have been develop the

active tracker system. Huang et al. (2011) have design, and build a 1 axis -3 position

(1A-3P) sun tracking PV. Abdallah and Nijmeh (2004) have developed a two axes sun

tracking system with PLC control, Afaruirazi et al. (2011) have design and develop an

automatic solar tracker Robot using Microcontroller. Suwandi (n.d.) has design and

implement dual axis sun tracking system with PV Panel as the sensor. Praveen (2012)

has design the automatic Dual-axis Solar Tracker using Microcontroller. The figure 2.1

is show the type of sun tracker in this world. For this project, the type of trucker use is

microprocessor and electro-optical sensor based active tracker.

I Type of Sun trackers

One axis tracking

\raI4xs{Azimut1i tiuckei) I inclined axis

N-Sisctt NI-S axis set aL

mcltnatioo l ink latitude inclination

Mnxrniurn 611v \h'iimuin Eiim angle: 9p

beam rnSmn rridi ui r so!4tr t Y poir trcbing

noon;

Two axis; 0=0; —z

Portatlic, &ivatoriai(o) - Gl UvatiOn I a) indepemdent t1inith fi it H1Qata14i iackcr &tn1e and angle cquat to

Positions latitude angle.

htl k IN-S horizontL axiE-

(901111 Mir 11 at ̂ 1110)

W tIing

Sun a114 116c, Surface twkingi Ti*kmg wi th a Tricking for maimurn tiaLking z for maximum cxitnt roltio1ia1 Will iindance.

beam irradiance

Figure 2.1: Type of sun tracker.

Source: Mousazadeh et al. 2009

100

80

70

F0 I 30

20

10

2000

1800

1600

1400

1200

1000

800

a600

400

200

2.3 FIXED SOLAR SYSTEM OR MOVEABLE SOLAR SYSTEM WHICH

PERFORM WELL?

The fixed solar system is the solar panel is not moving, where moveable solar

system is the system that using sun tracker to moving the solar panel to gain maximum

efficiency. In a research article by Huang et al. (2011), Monthly-total power generation

was increasing between 18.5% and 25.8 % using 1A-3P sun tracking PV. The result for

this article is show in' figure 2.2. The following five research article attempts to support

and demonstrative the hypothesis. In a research article by Abdallah et al. (2004), total

daily collection for using two axes tracking surfaces was increasing about 41.34% when

compare with the 32 0 tilted fixed surfaces. Table 2.1 is indicates the daily measured

solar energy on the two axes tracking system and fixed solar system.

01 0 3/1 3/3 3/3 3/7 0/9 3111 3/13 3/15 3117 3/19 0121 3120 3/15 3121 3/29 3101

date (2010)

Figure 2.2: Results of 1A-3P tracking PV and fixed PV in March, 2010.

Source: Huang etal. 2011.

Table 2.1: Experimental average daily total solar radiation in MJ/m2.

Date of day Two axes tracking Fixed ® 32 latitude % Gain 0710512001 41.266 27.746 48.73 10/05/2001 27.49 20.73 32.61 11/05/2001 34.534 23.661 45.95 12105/2001 36.057 26.11 38.09Average 34.83675 24.56175 41.34

Source: Abdallah et al., 2004

T — Pr3

-

1900 Tin", A 3001,21M INOO 1440 1500 la"

Figure 2.3: Tracking solar panel versus fixed solar panel.

2

I1

The average power using moveable solar system can increased up to 19.72

percent compare to fixed solar system (Afaruirazi et al., 2011). The result from this

article is show in figure 2.3. The efficiency solar system with solar tracking is higher

than with fixed angle solar system about 6.7 percent. (Huang et al, 2009). Figure 2.4 is

show the result of this research article. In a research paper by Praveen (2012), the

results (figure 2.5) indicates that the output power for the dual axis Sun-tracking system

that compared with the fixed PV system is overall increase about 30-45%.

Source: Afarulrazi, A. B., et al., 2011.

Fi1 aDITJin

2O IOM I0,30 llO 110V INO 123 13:00 I3) I4)) 1430 ISM 130 Toe

I-FM -iI

Figure 2.4: Power generation comparison of fixed angle type and tracking systems.

Source: Huang, Y. J., et al, 2009.

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i1,w1 ?4zdf

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cavrww thufl

Figure 2.5: Variation of cell power with day time.

Source: Praveen, C., 2012

2.4 TWO AXIS SOLAR TRACKER SYSTEM OR ONE AXIS SOLAR

TRACKER SYSTEM WHICH PERFORMS WELL?

In a research article by Taylor et al. (2010), the vertical-axis tracker is receives

18%, tilted (horizontal) —axis is receives 11%, and two axis is receives 30% more

annual solar radiation than the fixed-tilt system. Besides that, a research article by

Abdallah et al. (2004), The results indicate that the north—south, vertical, east—west

tracking, and two axes tracking were increases in daily measured solar energy up to

19.7%, 23.3% ,24.5%,and 41.34% as compared with the fixed surface inclined 32_ to

the south respective. Both of the researcher is show the two-axis sun tracker is more

efficient that one axis solar tracker system. There are two of research article is given the

result of the efficiency one axis solar tracker system. Chin et al. (2011) was show the

efficiency using one axis tracker system is 20%. Afarulrazi et al (2011) show that the

average power compares to static solar system is increased up to 19.27 percent. For the

result for two research article, we can conclude that the improvement of efficiency using

one-axis sun tracker is almost 20%. So, both of the research article is support the

research article by Taylor (2010), and Abdallah et al. (2004). One of the research

articles is show the efficiency when using two-axis sun tracker. In a research article by

Praveen (2012), overall increase of output power for the dual axis Sun-tracking system

compared to the fixed PV system is about 30-45%. But, one of the research article by

-i-i-

Huang et al. (2011), the 1A-3P tracking PV generates electricity about 3 0-45% than the

fixed PV.

2.5 WHAT ARE THE PARAMETERS AFFECTS THE PERFORMANCE OF

SOLAR CELL?

In a research paper by Sulaiman et al., (2011), performance of solar PV panel

can effect by the dust. The peak power that generate by solar panel can be reduce up to

18% (Table 2.2). The following research article is support this hypothesis. In a research

paper by Ibrahim, A. (2011), Short circuit current, Isc and open circuit voltage, Voc of

the solar cell when under deposited dust through field exposure were decreased 2.78%

and 0.863% respectively. Besides that, this research article is also given other parameter

which is shadow. Short circuit current Isc is more decreased in a high percent than open

loop voltage Voc for the solar cell under shadow, so the other solar cell parameters will

be decreased (Ibrahim, 2011). The other effect of the solar cell is heat. According to

Suwandi (n.d.), the cooling system could reduce 10 °C to 20°C depending on the

temperature difference between PV cell and the surrounding (Table 2.3).

Table 2.2: The peck power of each condition.

Pak power (W) ,Condition

255 Dm' 301 W/,n' 340 U7rn

No plastic 4.25 4.12 3.62

Clean plastic 4.25 3.75 3.16

Mud 3.48 3.43 3.49

Talcum 3.55 3.22 1.73

Source: Sulaiman, S. A., et al., 2011.

Table 2.3: Comparison is between cooling system and non-cooling system.

TEMP Voc 1 TEMP 2 voc 1

CooLiNG 43°C 2.12v 50°C NA

SYSTEM

N0NC00UNG 53°C 1.90v 70°C 1.80V SYSTEM

12

Source: Suwandi, F. W., n.d..

CHAPTER 3

METHODOLOGY

3.1 INTRODUCTION

This chapter will explain the flow work or the method for the project to achieve

the objective. Besides that, this chapter explains the process flow for sun tracking

system and self-cleaning system. Additionally, this chapter briefly explains the basic

theory of some important component using in this project. Furthermore, this chapter

also explains the hardware development, electrical circuit development, and software

development.

3.2 PROJECT FLOWCHART

This project is dividing several steps to design, construct the prototype of self-

clearing solar cell module with sun tracking system. Flow of the project to archive the

objective or goal of study is show in figure 3.1.

Firstly, the mechanical structure or part is designed. This is making sure that the

design of the mechanical part is suitable and able to support the system for a long time.

Next, simulate and design for the electrical circuit for the project. Electrical

circuit is simulated and design by using development software ISIS Proteus).

Next, design the program for microcontroller use in this project. The software

development is use to design and create the program for this project is MicroC.

ESU

Next, construct and test the electrical circuit for this project. All electronic

components use in this project is taken from laboratory and buy direct from electric

shop.

After that, install the program to microcontroller. To install the program to

microcontroller is need development software. The development software is PICkit2. it

will take the Hex file to install in the microcontroller.

Next, the mechanical structure is constructed and test for this project. it used to

make sure that the mechanical structure that produce is same to the design drawing.

Next, combine the mechanical structure, and electrical structure to final the

prototype for this project.

Lastly, testing and improve the prototype. It is to make sure the prototype can

work and able to achieve the target.

Figure 3A: Flowchart of the project.