MilkFillingSystemMSDProject

DoneBy

RamiAlDirini 0051209

AdhamNoubani 0057364

KhalafAlHamayel 0057379

NatheerMteireen 005

AhmadNour 0057362

Instructor

DrLutfiAlShareef

Abstract

Inafactorythatproducesmilkinbottlestherearemanyprocessesbeforethemilkbottleisavailableontheshelfofthenearestsupermarket.Firstly,thebottlesneedtobemanufactured.Thisisusuallydoneinaplasticfactory.Itisvitalthathygienicpracticesbegivengreatconsiderationandattention,asthesebottlesshallbeusedbyhumanconsumers.

Thesecondstepistotransferthesefilledbottlestothefactoryresponsibleforfilling,cappingandlabelingthemilkbottles.Incaseglassbottlesareusedinareuseablemanner,cleaningneedstobedonefirst.Onethecleanbottles;eitherplasticorglass,areavailableatthefactory,theyaretobeplacedalongaproductionline.Herebottlesaretobefilledwiththeproperamountofmilk.Then,thefilledbottlesaretobecappedwithcaps.Finally,eachbottleistobelabeledandtransferredtotheretailstoresthatsellthesemilkbottlestotheconsumer.

Inthisdocument,wepresentadesignforafillingcappinglineinafactory.Wewillsuggesttwodesignsandchoosethebetterdesign.Oncethisisdone,wewillsearchthemarketforcomponentsthatmakeourdesignrealizable.Finally,wewillrecommendcertainproductsfromspecificmanufacturersandprovideaCADmodelforourdesignforbettervisualization.

TableofContentsAbstract................................................................................................................2

Introduction..........................................................................................................4

RisksandHazards.................................................................................................5

SequenceofoperationforSystem1....................................................................6

SequenceofoperationforSystem2..................................................................10

System1FlowChart...........................................................................................13

LadderDiagramforSystem1.............................................................................15

System2FlowChart...........................................................................................17

LadderDiagramforSystem2.............................................................................19

SystemSelection................................................................................................21

ComponentsSelection.......................................................................................22

TransducersandSensors............................................................................22

ActuatorsandMotors................................................................................24

ConveyerBelts............................................................................................26

MaintenanceoftheSystem.......................................................................27

ImportantConsiderationsintheDesign....................................................27

SystemSpecifications.................................................................................30

AppindexA.........................................................................................................31

DATASHEET1:MotorSpecifications..............................................................31

DATASHEET2:Limitswitches183322............................................................32

DATASHEET3:CG1seriesCylinderfromSMC................................................34

DATASHEET4:WeightCellSpecifications......................................................35

DATASHEET5:NCJ2seriesCylinderfromSMC..............................................36

DATASHEET6:NCA1seriesfromSMC............................................................37

DATASHEET7:NCMseriesfromSMC............................................................38

DATASHEET8:ACCESSTMS7I/OInput/FestoOutputDevicemanufacturedbySiemens......................................................................................................39

AppendixB:ProEngineerScreenShots..............................................................41

Introduction

Nowadays,massproductioncanbeconsideredanecessityratherthanaluxury.Theconsumptionrateshaveincreasedrapidlyandthedemandforproducthasnotyetreachedalimitwherepeoplewouldnotneedmore.Hence,therehasbeenanincreaseinthenumberoffactoriesandasignificantimprovementinthetechniquesandmethodsadoptedformassproduction.

Amongtheneedsofpeopleismilk.Peopleofdifferentages,gendersandbackgroundsneedasupplyofmilktobereadilyavailable.Consequently,anumberofcompetitorsinthemilkindustryseemtohavereservedtheirshareofthemarket.However,forthosecompaniestokeeptheircompetitionoverthemarket,itisvitalthattheyprovideforsufficientmethodforprovidingmilktotheconsumer.

Milkisusuallydeliveredinbottles,howeverinavarietyofvolumes.Nevertheless,whateverthevolumeofthebottle,thereneedstobeaefficientmethodforfillingthosebottles.Inthisdocument,wewillpresentadesignforamilkfillinglineinafactoryalongwitharecommendationonsomecomponentsfortheproposedsystem.Wewilloutlinetwosuggesteddesignsandchoosetheoptimumone.Furthermore,wewilltrytosearchforcomponentsfromdifferentsuppliersandrecommendthebetterchoiceathand.Finally,wewillprovideforaCADsimulationofthesystemtoprovideforabettervisualizationoftheproposedsystem.

RisksandHazards

1. HygieneSystem:Milkfillingprocessshouldbehygieneduethefactofitsconsumedbyhumananditssocriticalissueifitspollutedasitmakesitunconsumable.

2. TheTransportationprocess:WedealingwithbottlesmovingonconveyerbeltanditsobvioustheirariskofthebottlesTippingonbeltwhichmakeawasteofmoneyandcandelayproductionprocess.

3. Preciseamountofmilkneeded:AsitwellknownweneedfixedamountofmilkoneachbottlewithaveryhighprecisionandfromheretheriskofnotEqualorunaccuratefillingprocessraisesup.

4. Bottleshapeandoutsidepressure:Thefactthebottlemovingandwillbepressedtocovermakeariskoflosingitsshape.Also;ifthebottlehitabodywhilemovingatcertainspeedsthismayresultadeformationonitsshape.

5. Malfunctionalityofsomepartsduewear:Underindustrialenvironmenteachmovingpieceisgettingsomewearsomehowlikegearsbeltmotorandthismayresultmalfunctiononthem.

6. Lubricationandoverheating:Asweknowconveyerisdrivingbymotorandontheoperationwehavemanyrotatingpartsandoverheatingforthemmayresultapermanentortemporarydamagethateffecttheprocess.

SequenceofoperationforSystem1

Emptycleanplasticbottlesareplacedinarandommanneronaconveyerbelt,conveyerbelt1.Thebeltwillnotstartuntilastartbuttonispressed.Conveyerbelt1hasthefollowingarrangementatitsend:

Figure1:endarrangementatconveyerbelt1

Thepurposeofthisarrangementistoensurethatonlyonebottleleavesconveyerbelt1atatime.Thisarrangementwillbelabeledsubsystem1fromnowon.

Assubsystem1detectsabottleatitsend,conveyerbelt1isprompttostop.Thisisachievedbysendingastop_motor1signalfromthePLCtothemotordrivingconveyerbelt1.Consequently,allbottlesonconveyerbelt1willbebroughttohalt.However,thedetectedbottleattheendoftheconveyerbelt1willcontinuetomovealongtherampreachingtoconveyerbelt2.Itisimportanttonotethatbothconveyerbelt1andconveyerbelt2willhavethesamesteadystatespeed.Thisiscriticaltoavoidtippinganybottlemovingfromconveyerbelt1toconveyerbelt2.

Atthismoment,conveyerbelt1isathaltandconveyerbelt2willcontinuetomove,thusmovingthebottlesonitthroughtherestofthesystem.Conveyerbelt1willremainatrestuntilthebottleonconveyerbelt2hasmovedadistanceequivalenttotheheightoftheplasticbottlemultipliedbyafactorof1.1.Theimportanceofthispartofthesequenceisthatitensuresthatifanybottleforanyreasontipsover,noofthebottleproceedingitwilltipoverresultinginadominolikeeffect.Therefore,assoonasabottleleavesconveyerbelt1andentersconveyerbelt2,atimerstarts,andassoonasthetimercompletesitscount,conveyerbelt1startstomove.Arepetitionofthissequencewillmakesurethatbottlesmovingalongconveyerbelt2willbe

Conveyerbelt1

Milkbottles

Track

Limitswitches

Ratchet Circulartrack

Conveyerbelt2

separatedbyasuitableseparatingdistance,allowingfortheupcomingprocessestobecompletedproperly.

Now,asthebottlemovesalongconveyerbelt2,itwillundergoseveralprocesses.Thefirstprocessencounteredbyanybottleonconveyerbelt2willbethefillingprocess.Thesysteminchargeoffillingbottleswillbelabeledasfillingsystem.Figure2providesaschematicofthemainpartsandcomponentspresentinthefillingsystem.

Figure2:maincomponentsofthefillingsystem

ThefillingprocessstartswhenabottleisdetectedbythelimitswitchesshowninFigure2.TheselimitswitchesalertthesystemwhenabottleisdetectedbysendingadetectionsignaltothePLC.Consequently,thePLCwillsendastop_motor1andstop_motor2commandstobothmotor1andmotor2;controllingconveyerbelts1and2respectively.Thiswillensurethatthebottleremainsstationarywhilebeingfilledwithmilk.Now,apneumaticactuatorwillmovethefillingarmandheaddowntoanelevationsuitableformilkfillingtocommence.Thenavalveopens,allowingforthemilktoflowintothebottle.

Asmilkflowsintothebottle,anaccuratebalancewillcontinuouslymeasuretheweightofthebottleandthemilkfillingit.Theoutputfromthebalancewillserveasanindicationofthemilklevelpresentinthebottle.Themilkwillcontinuetoflowuntilthedesiredmilklevel(1L)isobtained.Figure3providesaschematicofthearrangement.

Track

Fillingmechanism

Bottle

Figure3:schematicoftheweighingmechanismarrangement.

Whenthedesiredlevelofmilkhasbeenfilledintotheplasticbottlethebalancealertsthesystemthatthedesiredlevelofmilkhasbeenreached.Consequently,thePLCsendsastop_milksignaltothevalvecontrollingtheflowofmilk,thusstoppingtheflowofmilktothebottle.Afterthisisdone,thefillingarmandheadarrangementisretractedandallconveyerbeltsstartmovin