sadath pg my presentation

FORMULATION OF RESEARCH PROBLEM- AN APPROACH Speaker : Dr. Govind R. Kadambi

Final Dissertation Presentation DissertationM.Tech in Sensors and Control System Engineering

M. S. Ramaiah University of Applied Sciences

#University LogoDepartment: EEEProgramme:M.Tech in SCEBatch: FT-14Sadath Ahmed Ghouri14ETEE035006Faculty of Engineering and TechnologyStudent Details


#University LogoAutomation and Control of Special Purpose Packaging Machine

SupervisorSupervisor 1: Mr. Praveen KumarSupervisor 2: Mr. S.N. Nagananda

Place of Work : Akuva Infotech, IND Labs MSRUAS, Bangalore


#University LogoOutlineTitle IntroductionSummary of Literature ReviewAim and ObjectivesPresentation of the Dissertation WorkObjective wiseResults and DiscussionsConclusions and OutcomesSuggestion for future workReferences


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Title

Automation and Control of Special Purpose Packaging Machine


#University LogoIntroductionIndustrial Automation is the International trend in manufacturingPackaging machines are widely used in Industries for process automation Currently there are no commercially available watchstrap packaging machines in the market. So, scope for the commercialization existsThis project aims at developing a packaging machine with innovative design which is able to pack 5000 pieces of watchstraps per day


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#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)1Bruce G Bachelor and Paul F Whelan 1996Automated Packaging systems A systems engineer ApproachAutomated Packing Systems using Engineering ApproachSize and Shape of Packing and packed material remain same.Reducing the amount of packing materials.The strengths of the heuristic approach to problem solving, with a powerful shape manipulation mechanism.Packaging of irregular shapes,Robotic grippers are less efficient in picking.For Packaging of Irregular shapes, Strong Robotic grippers are required.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)2T. Gasperini - C. Zagnoni2005Automatic packaging machine designGet high Speeds during packagingCAD, CAM and ADAMS dynamic analyser. Creating new designs and parameterized models.Virtual prototyping technology can be integrated with automatic machine Design.Only CAD/CAM Simulation is discussed, no insight about the accuracy and the reliability of the ADAMS.ADAMS simulation provides only the Basic idea. More informative software required.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)3A.S.ZEIN EL DIN1996High performance PLC Controlled Stepper Motor in Robot ManipulatorFunctionality and robustness of PLC ControlPLC Ladder Logic, Stepper Motors and Drivers.Controlling five axis robot using stepper motors.PLC Control is successfully done to Control Robot in both clockwise and anticlockwise direction.Robot motion only through rotational movement i.e. clockwise and anti-clockwise, which consumes timeOther functions like timing and counting can be used to further enhance performance and productivity .


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)4Nathan Spiegel & Sean Ivey2006Design of Automated Packaging Machine Box folding for paperclip FactoryPaper packing in the form of boxes.Step wise direct procedure for box packaging.Machine completed the equivalent work done by 12 women in a given time.However the boxes being cuboids, irregular shapes are packed as cuboids.packaging in the form of cuboids of definite (Fixed) sizes has to be done.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)5Qiao QiaoAndJian-gang Zhang 2009Control System Design of Automatic Down-FillingMachine Based on TMS320F2812Developing down-filling machine with high efficiency and low cost by using fuzzy Controller.Man-machine interface, motor Control, FLASH memory AT29C020, use of weighing sensor, close loop ControlSerial communication feedback, Achieving high complex Control with low cost.Results show that the system hardware is of high stability and fast speed in fuzzy inference.Process changes involve complex time consuming processes .Process time should be reduced.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYearTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)6Alhade A. Algitta , Mustafa S., Ibrahim F., 2015Automated Packaging Machine Using PLCPacking the materials into boxes 4 per each boxPLC, switches Inductive proximity sensors, photoelectric sensorsTasks such asmaterial filling, bag forming, sealing temperature control, statusdisplay are performed using microcontroller and AC motorsMitsubishi ladder logic implementation enables packing of 4 similar boxes in a short time.1. Box sizes measuring few centimetres are obtained , sensor alignment can be done.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)7Yuming Lu, and Yingui Liu, Guozhi Song, Mingzhe Liu, Weixin Liu2010Design of Automated Packaging machine using Atmega-128.Machine Control using MicroControllerOp-Amplifiers, opto-isolator, Controller. Control of the packaging process using ATmega-128.Using of AC motors reduce the Cost of setup compared to stepper motor and servo motors.Proper Microcontroller operation control and interfacing is required.The complex control procedure can be made simple.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)8Chandrashekhar N. Sakhale Rajesh G. Khatod, 2012Design and Fabrication of Liquid Dispensing Machine Using Automatic Control for Engg. Industry Liquid dispensing using automatic ControlProgramming using VB.net. Micro-controller A89C51, RS232.Metering , measuring quality and measuring accuracy improvementsLiquid dispensing for high precision was developed.Study limited only to liquids of one kind.Process time is more, It should be reduced.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)9Padraic J. Sweeney2010Packaging Machinery:Sustainability and CompetitivenessMarket study of packaging industry.Manufacturer case studies, surveys and reviewsThe need of Packaging to the U.S. market.U.S Packaging offers more sustainable technologies and lead the competition.Focus only to U.S market. This is only the study of markets success and failure.The study for growing markets like Indian markets have to be done.


#University LogoSummary of Up to Date Literature ReviewS NoAuthorsYear of PublicationTitleResearch FocusMethods and Methodologies usedResearch FindingsConclusions drawn by authorsLimitations of Study Critical Appraisal of the Published Work ( by the student)10P. R. Sarode, A.S. Patil, P. A. Salunke, V. P. Kuralkar.2015PLC based Oil filling machine for engine hydro mounts.Elimination of air bubblesPLC ladder logic, Pneumatic cylinders and Servo motors.Finding the best possible Controller for operation depending upon the application.Air bubbles were eliminated during filling, which increased the accuracy by 20%-25% Only air bubbles are eliminatedApart from air bubble reduction other factors like flow rate, air friction etc can be considered.


#University LogoAim and ObjectivesAim To Design and Develop a Vertical Fill-Form-Seal (VFFS) Packaging Machine for Watch Straps

ObjectivesTo carry out Literature review process on Controlling the VFFSTo arrive at a system level functional block diagram and details for each sub systemsTo arrive at a specification for load torque requirements and choose an appropriate motor to carry out the control operation


#University LogoAim and ObjectivesTo design and develop a control algorithm for VFFS and implement it on PLC To interface with the mechanical parts and check the functionality of the developed logicTo validate the developed control logic for the production rate and accuracy


#University LogoObjective 1 To carry out Literature review process on Controlling VFFSMethodologiesTo carry out literature review from patents, books, magazines, articles, internet, publications and conference proceedingsAn extensive review on available VFFS and list their features, control procedure, size etc. Review on motors and sensors for control operationGetting details of various available designs of heater for sealing operationReview on the details of PLCs for effective and efficient control of the machineIndustry survey to understand the various designs of available VFFS machines


#University LogoObjective 2To arrive at a system level functional block diagram and details for each sub systems

Figure 1: Functional block diagram for the developed systemPLCROMRAMProgramming portEAPROMCX Programmer

Start push buttonWatchstrap detectorRoller film detectorEmergency switch

InputsCB controlHeater controlCR Control

Pulse counter and timer

Outputs

Power supplyTemperature set

Manual rotator switch


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#University LogoPull-in Torque CurveShows the maximum value of torque at given speeds that the motor can start, stop or reverse in synchronism with the input pulses. The motor cannot start at a speed that is beyond this curve. It also cannot instantly reverse or stop with any accuracy at a point beyond this curve.Stop / Start Regionarea on and underneath the pull-in curve. For any load value in this region, the motor can start, stop, or reverse instantly (no ramping required) at the corresponding speed value.Pull-out Torque CurveShows the maximum value of torque at given speeds that the motor can generate while running in synchronism. If the motor is run outside of this curve, it will stall.

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Obtaining the flowchart to carry out control operationDesign of heaterSelection of Proportional and Integral values for the designed controller Obtaining the Motor and Sensor characteristics to decide the region of operationImplementation of developed control flow on PLC

Objective 4To design and develop a control algorithm for VFFS and implement it on PLC


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Load watchstrapsStartIs watchstrap present on C.B and the required temperature is setPunching the top seal for the watchstraps pouchesFilling of watchstraps in to pouchesStart watchstrap conveyor withpredetermined pulsesStart roller motor with a delay of 2sPunch the initial horizontal sealCounting the packed watchstraps pouchesStopIs rolling film present on rollersYes No YesFigure : Flowchart depicting the control process of the machine Objective 4Yes




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(a) (b) (C)Front view of the heater

3-D view

(C) Heater after applying loadsObjective 4- Modelling of heater


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Objective 4- Modelling of heater

Figure: Temperature distribution on heater for a period of 1 second




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Objective 4

Figure : PI controller design circuit to control the Temperature of the Heater


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Objective 4

The motor and sensor characteristics are essential to select the region of operation of the twoThe motor used is Autonics a16-g1268 with a torque of 1.5NmThe motor is able to rotate at a maximum speed of 4000 pulses per second

For the efficient rotation the motor should start at 750 PPS and run at a speed close to 1000 PPS


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Objective 4

The motors that are used for control operation are watchstrap motor, cover roll motor and a motor to rotate heater assembly.The diffused reflective type optical sensors are used for the control operationTwo optical sensors are used. One to detect the presence of watchstrap and other to check the presence of covering film

For testing, white coloured background was used as it reflects maximum amount of light, about (90% remission)When a white object was used, the light remissions detected by the sensor is 90%

x: distance between sensor and objecty: min. distance between object and background


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Objective 4

The light remissions for grey light is found to be 18%The light remissions for black light was obtained as 6%


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Objective 4-Implementation in PLC

Figure: Inputs and outputs to the PLC


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Objective 4-Implementation in PLC

Figure: Sequence of the developed logic to control the manual operation


#University LogoObjective 4-Implementation in PLC

Figure: Auto control operation using PLC


#University LogoObjective 4-Implementation in PLC

Figure: Time delay, counter and continuity of the sequence


#University LogoObjective 5The final assembly of the watchstrap packaging machine consists of the rollers to guide the packing film

Electrical parts of the packaging machine are assembled on to the machine assembly

To interface with the mechanical parts and check the functionality of the developed logic

Figure : Assembly of Packaging machine


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Objective 5Parts to be interfacedOptical sensor

Heater assembly (a) before making grooves

(b) after making grooves

(C) Motor assembly

(d) OMRON PLC (e) Optical sensor

(f) Motor driver


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Objective 5

Apart from the parts mentioned in the figure, push buttons, emergency switches, SMPS and indicators are usedThe control logic developed is tested for the proper functionalityThe wooden outer body of the machine, enables to grooves holes, easily into the machine to accommodate fixtures like push buttons, indicator and emergency switchThe L shaped clamp is fixed on to the outer body to project the sensor parallel to the watchstraps and the cover film


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Figure 4: Simulation of part of the system part in Proteus when there is (a) no sensor output (b) sensor output

(a)(b)Objective 5 The control of output of motors from the input provided by the sensors is simulated in proteus using a Arduino UNO board


#University LogoObjective 6The pulses provided by the motors can be controlled to change the amount of the conveyor belt The time of the packaging cycle can be reduced by increasing the speed of the motorsEach control cycle lasts for about 7 seconds

To validate the developed control logic for the production rate and accuracyWatchstrap conveyor motorDelayCover motorDelay to start next operationTotal time to pack one watchstrap3 seconds1 second2 seconds1 second7 seconds Total straps packed per minute8 watchstraps


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Objective 6

The number of pulses in the PLC can be controlled using the PULS (886) instruction The speed of the motor can be changed by varying the pulse frequency using the sped(885) to further decrease the cycle time

The stepper motor can be varied appropriately to achieve the production target of Industry (5000 pieces per day)


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Results and Discussion

Figure: Watchstrap packaging machine hardware setup


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#University LogoMachine initialization


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#University LogoMachine Operation


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Figure: (a)Loaded straps (b) packed and sealed Strapsed (a)(b)


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#University LogoConclusions and Outcomes

Wooden outer body of the machine makes the machine lighter in weight, thus resulting in easy transportationThe innovative design of heater assembly ensures efficient packaging of watchstraps, without the wastage of the packing film The simple and innovative design of the machine ensures high speed packing operation and compactness, for easy mobility The developed watchstrap machine is able to pack close to 10,000 pieces of watchstraps per day


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#University LogoSuggestion for future workThe width of the conveyor system can be made adjustable to incorporate watchstraps of various sizesMultiple sensors can be placed near the conveyor belt region to detect the watchstraps more efficientlyAutomatic feeder can be added to the machine, provided leather straps are used


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#University LogoReferencesAlhade A. Algitta , Mustafa S, Ibrahim F, Abdalruof N and Yousef M,2015 May, Automated Packaging Machine Using PLC, Control Engineering Dep., College of Electronic Technology, Bani Walid 38645, Libya accessed from http://www.ijsrd.comIndustrial.omron.eu. (2016).Industrial Automation: CX-Programmer | Omron, Europe. [online] Available at: https://industrial.omron.eu/en/products/cx-programmer [Accessed 20 Jul. 2016].Kelvin Erickson (2011) Programmable Logic Controllers: An Emphasis on Design and Application, 2nd Edition, USA: Dogwood valley press, LLC.


#University LogoReferencesWU Wen jun. PLC Control of Feed Weight Measurement and Automatic Packaging. Packaging Engineering. 2006; 29(3): 87-89.Yuming Lu, and Yingui Liu, Gengyu Li, Guozhi Song, Mingzhe Liu and Weixin Liu (2010) Design and application of an automatic packaging machine controller based on ATmega 128, IEEE Trans, pp.410-414Zein El Din, A. (1996). High performance PLC controlled stepper motor in robot manipulator.Proceedings of IEEE International Symposium on Industrial Electronics.Nathan Spiegel, (2015). [online] Available at: https://www.wpi.edu/Pubs/E-project/Available/E-project-100606-125741/unrestricted/06A008M.pdf [Accessed 18 Feb. 2016].


#University LogoThank You


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