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