Milk Filling System

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  • 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