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PACKING LINE CONTROL
Submitted in the partial fulfillment of the requirement for the award of
“DIPLOMA IN MECHANICAL ENGINEERING {FOUNDRY}”
SUBMITTED BY:
1. R. VINOTH KUMAR 4. S. SOLOMAN RAJ 2. L. PRAMOSH 5. K. NEDUMARAN 3. C. N. SHANKARAN 6. S. SARAVANAN
Under guidance of
Mr. V.K.RAJENDRAN, M.E
OCTOBER 2007.
DEPARTMENT OF MECHANICAL ENGINEERING{FOUNDRY}
A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103
A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103
BONAFIDE CERTIFICATE
This is to certify that this Project work on
“PACKING LINE CONTROL”
submitted by …………………… ……………. Reg. No. ……………
in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING{FOUNDRY}
This is the bonafide record of work carried out by him under our supervision
during the year 2007
Submitted for the Viva-voce exam held on ……………..
HEAD OF THE DEPARTMENT PROJECT GUIDE
INTERNAL EXAMINER EXTERNAL EXAMINER
ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement
and valuable advice.
we thank our Esquired Head of Department Mr R. RAJKUMAR,
A.M.I.E, M.E., for presenting his felicitations on us.
We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.,
for guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Engineering (FOUNDRY) Department.
Ultimately, we extend our thanks to all who had rendered their co-
operation for the success of the project.
CONTENTS
CONTENTS
Chapter No. TITLE
1. INTRODUCTION
2. SYNOPSIS
3. CONSTRUCTION
4. WORKING PRINCIPLE
5. MECHANICAL ASSEMBLY DIAGRAM
6. ELECTRICAL CIRCUIT DETAILS
7. ELECTRICAL WIRING DIAGRAM
8. COST ESTIMATION
9. CONCLUSION
10. BIBILOGRAPHY
INTRODUCTION
INTRODUCTION
In our technical education the project work plays a major role. Every
students is put in to simulated life particularly where the student required to
bring his knowledge, skill and experience of the project work.
It helps how to evolve specifications under given constrains by
systematic approach to the problem a construct a work device. Project work
thus integrates various skills and knowledge attainment during study and
gives orientation towards application.
As the students solve the various problems exposed by the project
work, the students get the confidence to overcome such problems in the
future life. It helps in expanding the thinking and alternatives for future
applications.
SYNOPSIS
.
SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select this project work is to acquire practical knowledge in the
field of automation using Microcontroller.
We selected ““MATERIAL CONVEYING & COUNTING CONTROL
SYSTEM” as our project work and we used principles of Mechatronics in
developing this project. This project consist of two conveyors, the first
conveyor (feeding conveyor) is used to feed the job and it is mounted
above the second conveyor(packing conveyor) .The packing conveyor
feeds the packing box .The jobs are feeded from the feeding conveyor to
the packing conveyor through the IR sensor which is used to count the job
while feeding to the packing box.
When the switch is pressed, the packing box slides on the packing
conveyor and the packing conveyor is stopped by the magnetic sensor at
packing station. The jobs are fed by the feeding conveyor to the packing
box through the IR sensor which sends the signal to the Microcontroller. The
Microcontroller stops the feeding conveyor after the counter reaches the
preset value and the same process is repeated again.
.
CONSTRUCTION
CONSTRUCTION DETAILS
This project consists of following units
1.Controller System
2.Job feeding conveyor unit
3.Packing box feeding conveyor unit
4.IR sensor unit
5.magnetic sensor
1. MICRO CONTROLLER SYSTEM:
This system monitors the engine condition by using PIC 16F870 (28
pin IC Package) micro controller. The pin details of micro controller are
shown in figure.
The circuit diagram for this micro controller board is shown below,
the LDR sensor is connected to PORTA (i.e)pin no 2&5.The pin no 1 is
RESET switch..The bulbs are connected to port B .
2.JOB FEEDING CONVEYOR;
This conveyor is used to feed the jobs continuously towards the packing
conveyor through the IR sensor.The jobs are conveyed through the belt
conveyor .The conveyor belt is rotated between the driving and driven
pulley by the A.C .Synchronous motor.The A.C .Synchronous motor and the
conveyor belt assembly is mounted separately on a wooden board .The
height of the job feeding conveyor unit is arranged slightly above the
packing conveyor unit.The job feeding conveyor is shown in fig.
3.PACKING BOX FEEDING CONVEYOR UNIT;
This conveyor feeds the packing box. The packing boxes are conveyed
through the belt conveyor. The conveyor belt is rotated between the driving
and driven pulley by the A.C. Synchronous motor. A wooden stage is
arranged below the nylon belt in order to avoid the slack. A plastic channel
is arranged on the stage to guide the packingbox.A magnetic sensor is fitted
at the side of the plastic channel.The whole arrangement is shown in figure.
1. Pulley and Belt
Here there are two Pulleys, called as driving Pulley and driven Pulley is
rotated freely on the shaft which is held in bracket.
The belt is made of nylon materials, which is red in color. The width and
length of the belt is cut from the main sheet and its ends are pasted.
MOUNTING BRACKETS FOR MOTOR AND PULLEYS:
The motor and Pulley mounting brackets are made from 2 mm M.S.
sheet .The sheet is cut and bend to the required shape and drilled as per the
dimensions given in the sketch, the brackets can be placed and screwed on
the novopan The sheet is cut and bends to the required to shape as shown in
fig.
BELT TIGHTENING MECHANISM:
The driving Pulley is mounted in fixed position and the driven pulley
is mounted at a distance so that the belt can be stretched enough by using
tension mechanism. Here two nuts are used. One is used for adjusting the
tension and the other is used as a lock nut.
4.IR SENSOR UNIT;
To count the jobs for the packing an I.R. sensor is used..The I.R. sensor is
fixed at the side of the cross rail which is held in taper between the two
conveyors. The jobs are passed through the IR transmitter &receiver and is
shown in fig.
4.MAGNETIC SENSOR;
The magnetic sensor is fixed at the side of the plastic channel and it is used
to stop the packing box at the packing station. The magnetic sensor is shown
in fig.
WORKING PRINCIPLE
WORKING PRINCIPLE
This project consists of two sections.
1. Component feeding section (upper rail)
2. Packing box feeding section (lower rail)
1.Component feeding section:
TO start the operation press the ON switch in the switch box and the
components are fed on the job feeding conveyor. These jobs are conveyed
from the job feeding conveyor to the packing box conveyor through the
cross rail. When the jobs are passed through the IR sensor which send the
signal to the input of the Microcontroller. The counter in the Microcontroller
counted the IR signal and gives output when the counted value reached the
preset number in the Controller counter.
2.Packing box feeding section:
When the components are counted up to the setting limit, Microcontroller
stops the upper rail motor to ‘OFF’ position and switch ON the lower rail
motor. Hence the component filled packing box shifted, and the next empty
packing box is comes to the packing station. A magnetic sensor is fixed in
the plastic channel at the packing station. The magnetic sensor sends signal
to the Microcontroller input by the magnet which is fitted on the packing
box. The Micro controller switched OFF the supply the lower rail motor
when the magnet sends the signal to Microcontroller input. Again the same
process is repeated and packing boxes are filled and shifted with required
components.
MECHANICAL
ASSEMBLY AND
SPARE PARTS
DRAWINGS
MECHANICAL ASSEMBLY AND SPARE PARTS
DRAWINGS
1. CONVEYOR ASSEMBLY UNIT
2. DC MOTOR MOUNTING PLATE
3. DRIVEN PULLEY MOUNTING PLATE
4. DRIVEN PULLEY HOLDING BRACKET
5. DRIVING AND DRIVEN PULLEY
6. BELT TIGHTENING MECHANISM
7. IR SENSOR HOLDING BRACKET
ELECTRICAL CIRCUIT DETAILS
ELECTRICAL CIRCUIT DETAIL
1. Micro controller system
2. Interface Circuit
3. Power supply (230V A.C. to 12 V and 5V DC)
MICRO CONTROLLER SYSTEM:
This system monitors the engine condition by using PIC 16F870 (28
pin IC Package) micro controller. The pin details of micro controller are
shown in figure.
The circuit diagram for this micro controller board is shown below,
the LDR sensor is connected to PORTA (i.e)pin no 2&5.The pin no 1 is
RESET switch..The bulbs are connected to port B .
POWER SUPPLY UNIT
INTRODUCTION:
All the electronic components starting from diode to Intel IC’s only
work with a DC supply ranging from +5V to +12V. We are utilizing for the
same, the cheapest and commonly available energy source of 230V-50Hz
and stepping down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer,
it can either be stepped down or stepped up depending on the value of DC
needed. In our circuit the transformer of 230V/15-0-15V is used to perform
the step down operation where a 230V AC appears as 15V AC across the
secondary winding. Apart from stepping down voltages, it gives isolation
between the power source and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a
solid state diode. Diode has the property that will let the electron flow easily
in one direction at proper biasing condition. As AC is applied to the diode,
electrons only flow when the anode and cathode is negative. Reversing the
polarity of voltage will not permit electron flow. A commonly used circuit
for supplying large amounts of DCpower is the bridge rectifier. A bridge
rectifier of four diodes (4 x IN4007) are used to achieve full wave
rectification. Two diodes will conduct during the negative cycle and the
other two will conduct during the positive half cycle, and only one diode
conducts. At the same time one of the other two diodes conducts for the
negative voltage that is applied from the bottom winding due to the forward
bias for that diode. In this circuit due to positive half cycle D1 & D2 will
conduct to give 0.8V pulsating DC. The DC output has a ripple frequency
of 100Hz. Since each alteration produces a resulting output pulse, frequency
= 2 x 50 Hz. The output obtained is not a pure DC and therefore filtration
has to be done.
The DC voltage appearing across the output terminals of the bridge
rectifier will be somewhat less than 90% of the applied rms value. Normally
one alteration of the input voltage will reverse the polarities. Opposite ends
of the transformer will therefore always be 180 degree out of phase with
each other. For a positive cycle, two diodes are connected to the positive
voltage at the top winding.
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester
always follow the rectifier unit. This capacitor is also called as a decoupling
capacitor or a bypassing capacitor, is used not only to ‘short’ the ripple with
frequency of 120Hz to ground but also to leave the frequency of the DC to
appear at the output. A load resistor R1 is connected so that a reference to
the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as
a low pass filter, i.e. it passes only low frequency signals and bypasses high
frequency signals. The load resistor should be 1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V : for maintaining the stability of the voltage at the load side.
0.1f : for bypassing the high frequency disturbances
BLOCK DIAGRAM FOR POWER SUPPLY
STEP DOWN BRIDGE POSITIVETRANSFORMER RECTIFIER CHARGE
CAPACITOR
5V 12V REGULATOR REGULATOR
MOTHER DISPLAY BOARD BOARD RELAY
VOLTAGE REGULATOR:
The voltage regulators play an important role in any power supply
unit. The primary purpose of a regulator is to aid the rectifier and filter
circuit in providing a constant DC voltage to the device. Power supplies
without regulators have an inherent problem of changing DC voltage values
due to variations in the load or due to fluctuations in the AC linear voltage.
With a regulator connected to the DC output, the voltage can be maintained
within a close tolerant region of the desired output. IC7812 and 7912 is
used in this project for providing +12V and 12V DC supply.
SPECIFICATION:
Resistors R1 and R2 maintain line load regulation.
At the secondary side of the transformer, applied vlltage = 15V
Conducting drop across the diodes = 2 * 0.6 = 1.2V
Without capacitor:
Vavg = (15-1.2)V = 13.8c pulsating DC
Frequency = 100Hz
With capacitor:
V = Vavg * 1.414 (form factor) = 19.51V
Frequency = 0 Hz
with 7812 voltage regulator:
V0 = +12V
with 7912 voltage regulator: V0 = -12V
c) 5 to 12V interface circuit:
Here we have to drive the 12V DC load. The 5V signal from the PIC
16F870 micro-controller is fed into the input of interface circuit. TIP 120
Darlington transistor is used here for high speed switching purpose and the
Diode IN 4007 is for the safety of TIP 120 transistor during the collapsing of
magnetic field from the 12 DC motor coil. This interface circuit is shown in
fig.
COST ESTIMATION
COST ESTIMATION
1. Microprocessor control Board ---------------------- 2000.00
2. DC. Motor (2 Nos)-------------------- 1500.00
3. Belt (2 No)--------------------------------------------- 200.00
4. Motor & pulley mounting Brackets---------------- 100.00
5. Driver & Driven Pulley------------------------------ 300.00
6. Novo pan plywood----------------------------------- 200.00
7. Magnetic sensor-------------------------------------- 100.00
8. IR sensor ----------------------------------------------- 300.00
9. Push button, Wires, & Jack Connectors------------ 200.00
10.Belt supporting guides (Plastic) --------------------- 300.00
11.Project Report work---------------------------------- 700.00
_______________
Total 5900.00
_______________
CONCLUSION
CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of pneumatic system
and how automation can be effectively done with the help of pneumatic
system.
It is concluded that any automation system can be done with the help
of micro controller & pneumatic system.
We have successfully completed the project work on using pneumatic
control at our Institute.
By doing this project work, we understood the working principle and
uses of various controls, switches, relays etc.
It will be of no doubt that pneumatic system will be an integrated part
of any automation process in any industry.
Once again we express our sincere thanks to our staff members.
BIBILOGRAPHY
BIBILOGRAPHY
1. Low cost automation with pneumatics - FESTO
2. Electro pneumatics - FESTO
3. Hydraulics & pneumatics for Power Production - Harry L – Stewart
4. Basic pneumatics - FESTO
5. www.google.com
6. Workshop Technology - Hajra Chowdry
7. Production Technology -R.S. Khurmi