FINAL PROJECT "AUTOMATED POULTRY PLANT"

Responsible Teacher

FRAYERTH ARGEMIRO ARTUNDUAGA MEDINA

ANDRÉS ESPINOSA

JOSE LUIS

LEONARDO SANTOS JIMENEZ

HUILA UNIVERSITY CORPORATION "CORHUILA"

INDUSTRIAL ENGINEERING

AUTOMATION AND CONTROL

PITALITO-HUILA

2019
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TABLE OF CONTENTS

No table of contents entries found.

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Summary

The present project aims to convert the conventional process of raising chickens that is

is currently used in most of the warehouses located in the rural areas of southern Huila in a

automated process, which will bring benefits to productivity and the health of the chickens, avoiding

the intervention of the hand of man. For this, it is necessary that the new design manages systems

of food and water distribution where the yield and utilization are the highest

possible and thus avoid waste, in addition a heating system will be implemented that

they will maintain the proper temperature in the shed, and finally a system will be installed

ventilation; this system will have curtains and a fan.

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Introduction

Nowadays, technology is advancing by leaps and bounds due to needs, whether in

the quality of the products as well as the competition between brands.

In all sectors, it is necessary to have technological growth as well as a

continuous improvement and optimization of all processes or products that are created.

For technology to advance and with it society, it is necessary on the part of the

large industries conduct research and investments in their plants to always have

products with cutting-edge technology and higher quality.

To meet all the requirements for higher quality and optimization with technology

it is necessary to have all processes controlled and automated in order to have a

greater production and better quality.

Automation is a system where production tasks are transferred,

habitually by human operators to a set of technological elements; and it is vital

the importance of implementing it in science, it is necessary to start applying this knowledge in

a productive process to generate greater efficiency and effectiveness in it.

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Objectives

General objective

Design an automated system at scale in the chicken breeding process on the farm.

poultry farming, allowing for control of the environmental conditions and the feeding within the

warehouses of the municipality of Pitalito Huila.

Objetivos específicos

Ensure the distribution of food given in the required portions and times.

Ensure the distribution of water is provided in the required portions and times.

Maintain an ideal environment in terms of temperature and humidity.

Develop the prototype using sustainable processes that do not harm the environment.

environment.
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Chapter 1

Project proposal

The present work aims to develop a scaled prototype of a shed.

consequently, the temperature control system and remote control will be implemented in the

model under conditions similar to those that would be handled in reality.

An automated system will be developed for a broiler chicken farm.

achieving that the entire food, care, and climate process is more

controlled, precise, and effective to provide a better result. The birds will be

provide: food, lighting, and ventilation, to achieve maximum profitability and

effectiveness in the production of these.

Regarding instrumentation in the project, an HC-SR04 ultrasonic sensor will be used.

MQ-135 sensor for air quality, and a liquid level sensor with a float; Besides, it is

It is necessary to use an Arduino Mega and a servo motor, so an interface will be created.

through microcontrollers. The actuators will be specifically developed for the project, the

curtains will operate with rails and motors, and the extractors will be small, scaled in size and

extraction capacity in relation to the real models.

Regarding the model, it will be made of wood with a rectangular shape, simulating the

shed now. The controller will be an Arduino Mega for control in reality.

The operation of the process will be the same as in reality, just scaled up, this

particular of the model will provide an efficient practical research tool for a

future implementation at scale.

It is necessary to make a hole in the foundations of the shed for the installation of the

motors that will be responsible for raising and lowering the green canvas curtains automatically, also
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It is necessary to manufacture a base on the roof part for the tank's deposit.

storage of drinking water for the chickens, a base will be constructed

on one side of the shed where the rainwater storage tank will be, and finally

the installation of the extractor fans will be carried out in the front parts of the warehouse to

maintain the correct temperature and humidity.

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Identification of needs

Conventional warehouses have a series of problems that make the

more difficult process. It is necessary to emphasize that the chicken breeding process requires a lot of care and

the problems that are most involved are the distribution of food, and the temperature of

shed.

In the distribution process of food from conventional barns, it is handled from

manual way; that is to say the man has to be depositing the food into a feeder and

water fountain at the same time generating health problems in the people who do this work and

causing a series of stress in the birds. Now then; temperature is a very serious problem

important that must be managed properly because the south of Huila is a region in

where constant climate changes occur, causing birds to get sick easily and

in many cases cause their death.

Currently, there is a need to generate a change in this process and take advantage of the

technological advancement so great that the world presents. In this way, the intention is to bring to the

practice the knowledge learned and the talent of each one to provide a solution to it

problem; and in this way achieve the implementation of methods and technological systems that

improve production and deliver higher quality results with the same efficiency but in

shorter times and without fewer procedures.

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Theoretical Framework

Shed

According to the dictionary of the Royal Spanish Academy (RAE), a shed can be

a shed, a storage room, or a barn. Its design is usually very simple, as it is not sought after.

to meet aesthetic criteria, but to achieve functionality.

Automation

Julián Pérez Porto and María Merino. (2016) clarify that automation is the act and the

consequence of automating. This verb, for its part, refers to making certain actions

become automatic (that is, develop on their own and without direct participation of

an individual).

Sensor

The term sensor refers to a measuring element that detects the magnitude of a

physical parameter and changes it to a signal that the system can process. To the active element of

A sensor is commonly known as a transducer.

Arduino

Arduino is an open-source electronics creation platform, which is

based on free hardware and software, flexible and easy to use for creators and

developers. This platform allows the creation of different types of single-board microcomputers.

platforms that the creator community can use in different ways.

Hardware

It is the physical part of a computer or information system. It is made up of the

electrical, electronic, electromechanical, and mechanical components, such as circuits of

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cables and light, plates, memory, hard drives, peripheral devices and any other material in

physical condition that is necessary to make the team function.

Software

It refers to a program or set of computer programs, as well as data,

procedures and guidelines that allow for performing different tasks in a computer system.

Nutrition

Food is a very important component of the total production cost of chicken.

Fattening. In order to support optimal performance, it is necessary to formulate the rations.

to provide these animals with the correct balance of energy, protein, and amino acids,

minerals, vitamins, and essential fatty acids. (Aviagen, 2009)

Relative humidity

The relative humidity, RH [%], is the proportion of actual water vapor in the air.

compared to the amount of water vapor needed for saturation at the temperature

corresponding. Indicate how close air 16 is to saturation. It is measured in percentage between

0 and 100, where 0% means completely dry air and 100% saturated air (Meruane &

Garreud, Determination of Humidity in the Atmosphere, 2006.

Temperature

In practice, temperature is represented according to a numerical scale; the higher it is

its value, the greater is the average kinetic energy of the atoms of the body in question (Virgoni,

2008).

Servomotor

Es un motor eléctrico que cuenta con la capacidad de ser controlado, tanto en velocidad

like in position.
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Background

This work is inspired by support for poultry development in the south.

from Huila, using automated technology, in order to improve the quality of the products

from this sector through the control of external parameters.

Having an automated system allows for the improvement of the technical parameters of the birds;

also managing to produce them on a larger scale, having better control with a larger

number of birds.

By improving productivity, efficiency is directly increased.

production as human and monetary resources are utilized more effectively to

achieve producing in the desired way.

Thanks to the joint work of Fenavi-Fonav, the Ministry of Agriculture, and DANE that

In 2002, the first national census of industrial poultry farming was conducted in the country for the first time.

it has statistical information about this sector. This document states that for that

In Colombia, there are 2,996 commercial poultry farms, of which 1,870 are

dedicated to chicken fattening.

According to the farm registry reported by FENAVI on its official page, there are

3,366 farms with a capacity to house 97,193,789 broilers. Of the total of

existing chicken farms, Cundinamarca has 803, followed by Santander (648), Valle del

Cauca (379) and Nariño (199). The remaining 1,337 farms are distributed in the others.

departments.
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Chapter 2

Proposal

Design the prototype of a scaled warehouse that has a control system

temperature and remote control that will be implemented under conditions similar to those in

reality would be managed. In addition, the entire process of feeding, care, and

de climatización en el galpón sea más controlado, preciso y efectivo para brindar un mejor

result. Regarding instrumentation in the simulation project, a sensor will be used.

ultrasonic Hc-sr04, an Mq-135 sensor for air quality, and a liquid level sensor

with a float; Additionally, it is necessary to use an Arduino Mega and a servomotor, so

an interface will be created using microcontrollers. The actuators will be developed

specifically for the project, the curtains will operate with rails and motors, and the extractors

They will be small, scaled in size and extraction capacity compared to the real models.

It is necessary to make a drilling in the foundations of the shed for the installation of the

motors that will automatically raise and lower the green canvas curtains, also

it is necessary to manufacture a base on the roof for the tank deposit

storage of drinking water for the chickens, a base will be constructed

on a side of the shed where the rainwater storage tank will go, and finally

the installation of exhaust fans will be carried out at the front parts of the shed to

maintain the correct temperature and humidity.

Regarding the model, it will be made of wood and straw cardboard, achieving good

resistance; the shed will have a rectangular shape. In addition, the respective ones will be used

connection materials to achieve the simulation of the process.

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Solution to needs

The project is carried out in order to improve and optimize the chicken breeding process.

sheds; the aim is to reduce the stress caused to the birds by constant human contact in the

food supplementation. In addition, there is a desire to prevent human diseases caused

due to the smell of the warehouses. On the other hand, there is a desire to expedite the breeding process and improve the

optimal conditions, achieving quality in them.

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Product description

The project is based on a scaled prototype of a shed in which simulations are conducted.

temperature and humidity conditions using lamps and a humidifier will also be simulated

the mechanical delivery of food and drink for the birds. In addition, a micro-controlled team,

scheduled, organized and prioritized by the ArdOs operating system.

ArdOs is an advanced operating system designed for the series of micro boards.

Arduino controlled. It is fully configurable to offer you flexibility and space savings.

The necessary components for the implementation of the project will be listed.

The microcontroller will read the environmental variables through the operating system.

temperature and humidity and will provide output signals to match its value to the set point

to maintain them later.

The actuating elements for increasing the temperature are the lamps and for

to decrease this variable we will use the extractors and the upper tab of our prototype.

I change the actuators for increasing humidity and for decreasing it.

used the strategically located exhaust fans for the expulsion of hot air to

interior of the breeding facility.

Process

For the creation of the model and the simulation of the process, it was necessary to take care of the

sensors because they were not found in the city of Pitalito, after which they were acquired.

necessary materials for its preparation. Initially, a sketch was made to understand

the way it was going to be carried out and the necessary measures; following that, work began on the

development of the model to achieve that the programming and the system would accomplish the simulation of

the entire process, and finally the source code, programming, and necessary connections were made.
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Now, each process serves a unique and important function; next, we

describe each one:

Feeding: The feeding of birds is subject to various aspects such as the

lighting, interior climate control of the warehouse, and the management of the balanced feed.

Regularly, it is necessary to start or move the feeders to maintain the food.

in front of the birds at all times, this will stimulate consumption, keep the food fresh and

will prevent waste. For this, an automatic feeder is ideal since even the noise the

stimulates.

The feeder will be designed specifically to cater to small farms, with no waste.

of food, taking up little space, made of original plastic, with a plate with grids that

they prevent birds from wasting food. Automatic supply system of

closed circuit food, with two lines, operated by an alternating current motor.

The feeders should be separated in such a way that each plate supplies approximately

40 adult chickens. Inside the barn, there is a line of automatic feeders, which are

find separated from the final walls at least 2.5 to 3 meters. Inside the shed

there is an automatic feeder system, which is formed by:

Hopper for food storage

It is located at one end of the line and has the function of storing a quantity

of food, its recharge is daily and manual, meaning that the operator will have to load the

I feed the hopper every day, which reduces productive work time.

Food transport line

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It is responsible for distributing the food, it has a simple design which is a steel tube

galvanized and which in turn has inside it a steel spiral that rotates under the influence of the

motor making the food travel and distribute along the feeders in this way.

Feeders

They are located along the transport line separated by an adequate distance for

that at least 40 birds are placed per feeder, if the number of feeders is greater, the number of birds

per plate decreases which will reduce competition for food. Each plate installed in the

The shed has five levels of food regulation that are adjusted according to the phase of

growth of the bird.

Water storage tank

It is located at the top of the warehouse and serves the purpose of storing water.

for the consumption of the chickens. Its refill will be automatic as it has a valve that

It will activate when the water level is low using a float switch.

Water fountains: They are located along the distribution line separated by a distance

suitable for 80 birds per waterer, if the number of waterers is greater, the

the number of birds per water trough decreases which will reduce competition for water.

Water distribution line

It is responsible for distributing the water, having a simple design which is a PVC pipe.

through which the water will flow by gravity and supply the drinking spots for the birds.

Lighting system: The lamps will be located at the top of the warehouse.

separated at a suitable distance so that its wave reaches all places in the shed, its

The function is to provide lighting to the birds in order to stimulate food consumption.
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Mechanism: For the curtains, it is made with green canvas achieving the simulation of a

roller blind system that uses a roller that houses the fabric as the motor

it performs the movement from its axis, the side rails that keep the canvas in its position and

it also facilitates movement.

Temperature control: The temperature of the chickens varies according to their size.

the minimum temperature is 20°C and its maximum temperature is 32°C. The thermometer

The digital hygrometer will indicate to us what the temperature of the barn is and in

In case this is very high or very low, it will be controlled as follows:

Activation of the automatic mechanism of the curtains.

Activation of the gas heater in case the temperature is very low.

Activation of the extractors in case the temperature is very high.

Humidity control: The optimal humidity of the shed is between 50% as

minimum humidity and 70% as maximum humidity. The digital hygrometer thermometer

will be responsible for indicating to us what the humidity of the shed is and in case it is

very high or very low will be controlled as follows:

Activation of the automatic mechanism of the curtains.

Activation of the gas heater in case the temperature is very low.

Source code: the code was created in Arduino with the help of Ardos and Tinkercad.

a web application to create 3D designs and generate programming codes in addition to

allow the realization of circuit designs

The programming consists of two codes, the first code is the Arduino that is responsible

to receive commands and sends the reading of the temperature and humidity sensor. The second code is
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Appinventor that receives temperature data and applies a filter that sends orders depending

the data I receive

Illustration 1. Programming code

[Link]

Instrumentation

Description of sensors: The selected temperature and humidity sensor has the

possibility of measuring temperature and humidity with an accuracy of 1ºC, works based on

in a proprietary communication protocol.

Description of the actuators: For the control of the curtains, motors are used.

small toy items that operate with 3.3 VDC, a card was made that contains

four 5 VDC relays with a current handling capacity of 1 A. simply with

the objective of changing the direction of the motors.

System description:
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•Programmable Logic Controller: The PLC's main function is to be the axis of

system control in addition to being the communication hub with the office

the main HMI interface computer.

• Motors: The motors are coupled to a pulley system, they have

hook pattern that brings and takes the curtain.

Sensors: The sensors work by detecting changes in temperature, sending the signal.

to the PLC so that the corresponding process is carried out.

Minimum ventilation extractors: Minimum ventilation extractors are the

in charge of various functions including providing cooling, extracting

humidity, circulate hot air and provide minimum ventilation cycles.

Temperature and humidity sensor: The temperature and humidity sensor is the

most important element within the system, it is responsible for taking the temperature

and the environmental humidity and transform it into a 10-bit serial output protocol

for temperature and 8 bits for relative humidity. It is attached to a card.

of signal conditioning. This card provides operating voltage and of

control of commands and readings of values to the sensor.

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Chapter 3

Results

An automated system was successfully designed on a large scale for the chicken breeding process.

poultry farm, allowing for control over the environmental conditions and the

feeding of them inside the barns.

The method for the correct distribution of food and water was identified for

the chickens according to portions and required times.

Through sensors, a way was found to provide an ideal environment in terms of

temperature and humidity.

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Benefits

The automated warehouse will effectively increase the process by a notable percentage.

productive of the raising of broiler chickens in the following way:

The hiring of workers will be lower since the warehouse has implemented several

systems that will reduce the need for so much personnel to carry out these tasks.

The deterioration of the health of the workers in charge will be avoided due to their exposure.

the ammonia gases will not be as constant as in conventional warehouses.

Mortality and disease in chickens will be reduced thanks to management of

temperature that this shed offers us.

The process of growth and fattening will be faster through the

stress techniques and the feeding and lighting systems of the bird.

The economic benefits will be very broad and will be seen in the short term.
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Costs

The costs were estimated for all resources assigned to the project, that is, resources

work, material resources, etc.

The cost estimate for the project is outlined in the following table:

Cost Cost
Description Quantity
unit total
Ultrasonic sensor Hc-sr04 1 $ 5.000 5000
MQ-135 Sensor 1 $9,500 $ 9,500
Servo motor 1 $0 $0
Arduino Mega 1 $ 45,000 $ 45,000
Liquid level sensor 1 $ 9.520 $9,520
TOTAL $ 69.020 $ 69.020
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Conclusions

The automatic control system of the prototype was simulated in such a way that it can

to be used in a real-scale system without any problems.

Manipulating the two most well-known control methods for poultry breeding

it helps us achieve greater independence from the environment.

The correct management of the broiler chicken breeding process results in

excellent short-term economic benefits.

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Bibliographic Reference

AVIAGEN. (September 30, 2009). Ross Broiler Manual.

Donald J.O. (2009) AVIAGEN management of the environment in the broiler chicken shed.

Lozada M. (2001). MANUAL PRACTICO PARA LA CRIANZA DE POLLOS DE ENGORDE.

Quito-Ecuador.
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Attachments

(photos, drawing, part of the code, control links, plan)