MINOR PROJECT REPORT AUTOMATIC WEIGHING AND PACKAGING MACHINE

CHAPTER 1

INTRODUCTION

In Industry weighers & weighing mechanisms are to be very accurate. Without this accuracy,

extraction figures are meaningless. Weigher is the necessity either to weigh or to weigh the final

products to calculate extraction rate. Low cost automatic weighing machine using latest

technology of servo control and Programmable Logic Control (PLC) was designed and

developed considering the advantages of electronic weighing and linear motion guide ways

moving accuracies. The results of studies carried out for automatic weigher indicated that the

equipment could be used as weigher. Statistical analysis indicated that there was no significant

difference in mean value of measurements from set weights and measured weights at the 95%

probability level. Automatic weighing equipment can be successfully used for weighing and

dosing of products into bags, containers in automated production processes.

Automatic weighing machine consists of hopper, weigher with hooks arrangements for

empty bag & drop hole mechanism. Full open to half open or full close of the gate operates

through drop hole mechanism is used to fill the specified quantity of matter into the bag which

affects the accuracy of weighing. Continuous monitoring of set weight and matter feeding was

absent. Conventional filtering methods employed in dynamic weighing systems have limitation

in improving accuracy and throughput rate .Fluctuations in the bulk density of the raw materials

in volumetric or rotary charger dosing results in alterations in weight. Weighing machines

equipped with platform scales or beam balances with dials do not ensure the required accuracy of

weighing batch materials. Mechanical scales are not reliably precise and their applications in

automatic lines are complicated. Mechanically operated weighers are obsolete and maintenance

oriented. Electronic weighers are sophisticated and calibrate themselves by using built in

calibration procedures and saves the data themselves. Load cells are widely used in a variety of

industrial weighing applications such as wending machines and weighing systems. Load cells

interfaced with integrated electronics convert the weight force to an electric signal and deliver

the output signal to an automation system. Linear motion guide ways accompanied with

precision ball screw can greatly enhance moving accuracy. Hence, considering the advantages of

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electronic weighing accuracy and linear motion guide ways moving accuracy, the present project

is undertaken to design and develop state of art technology i.e. low cost automatic weighing

machine using latest technology of servo control and Programmable Logic Control (PLC)

concepts.

The equipment works on the basic principle of batch weighing. Working flow diagram is as

shown in the Figure.1. Raw material to be weighed is automatically fed to the weighing hopper

through a quantity regulating servo slide. The movement of the slide is controlled by precision

linear motion guide way assembly which is driven by brushless servo motor. Feeding of the

material from the collection hopper to the weighing hopper is done in coarse and fine feed.

Automatic weighing cycle starts with wide opening of the servo slide followed by weight register

by the load cells. During rapid movement of the servo slide, more quantity of material is passed

to the weighing hopper. As the weight of the weighing hopper is nearing to the set weight, servo

slide moves slowly to provide fine feeding of the grain. As soon as the weight of the material in

the weigher hopper achieves the set value, the servo gate of the storage hopper closes and the

weigh hopper gate opens to discharge the set quantity of material on to a downstream process

line. Micro controller registers and updates the exact quantity of material discharged. When the

weigh hopper becomes empty, weigh hopper gate closes and the storage hopper servo slide

opens for the next weighing cycle.

The below figure shows how the process will go in the project . Firstly the the product which is

to be packed must be check that in what form it is present then the product is to placed in hopper

in bulk.

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Figure 1.1 Flow chart of process.

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CHAPTER 2

PROJECT DESCRIPTION

2.1 Shutter

The shutter is made up of iron in which we have use the iron sheet and ball bearings which help

in rotating the sheet according to our requirement . In this the size of the sheet is kept in such a

way that it covers the mouth of hopper from the bottom . The length and breadth of sheet is kept

(9x18 inches). The ball bearing which are used in it are such that when sheet is connected to the

motor used it drives the shutter forward & backward movement . Fig 2.1 sow the real shutter.

Figure 2.1 Closed Shutter

When the shutter moves in forward direction the path beside it left vacant which show that the

process is going on . Fig. 2.2 show the ball bearing & open view of shutter.

Figure 2.2 Opened Shutter

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2.2 Hopper

A hopper is a large pyramidal shaped container used in industrial processes to hold particulate

matter that has been collected from expelled air. Hoppers are usually installed in groups to allow

for greater collection quantity. They are employed in industrial processes that utilize air pollution

control devices such as dust collectors, electrostatic precipitators, and bag houses/fabric filters.

Steel is the typical material of choice for hopper construction . Hopper walls are insulated in

order to protect the outside environment and personnel from the discarded contents. Oftentimes,

the bottom ¼ - 1/3 of the container is heated to eliminate the possibility of condensation inside

the hopper. The greatest difficulty associated with the removal of dust from the hopper is the

compaction of the ash. Moisture content, particle shape and size, and vibration are all factors that

contribute to the compaction. Typically vibrators are installed on the outer walls of a hopper to

shake and release the dust.

Figure 2.3 Hopper

2.3 LCD interfacing with Load Cell

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The circuit shown below is of an 8051 based  bi directional motor  whose direction can be

controlled using 2 push button switches. The circuit is very similar to the previous one except

for the  two push button switches . These pushbutton switches are interfaced to  P0rt 3 of the

microcontroller. Resistors R2 and R3 are the pull down resistors for P3.0 and 3.1 respectively.

The code for the above project is so written that initially when power is switched ON, the motor

remains OFF. When push button switch S2 is pressed P1.0 goes high and P1.1 remains low. The

motor runs in the clockwise direction and this condition is maintained until S3 is pressed. When

push button switch S3 is pressed the logic of P1.0 and P1.1 toggles making the motor to run in

the opposite direction and this condition is maintained until the next press of S2.

Figure 2..4 Interfacing of LCD with DC Motor

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CHAPTER 3

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COMPONENTS DETAILS

3.1 LOAD CELL

The heart of any weighing system is the load cell. Whilst they are not exciting to watch, load

cells are highly accurate transducer which provides the user with information not generally

obtainable by other technology due to commercial factors. Load cells are designed to sense force

or weight under a wide range of adverse conditions; they are not only the most essential part of

an electronic weighing system, but also the most vulnerable. In order to get the most benefit from

the load cell, the user must have a thorough understanding of the technology, construction and

operation of this unique device. In addition, it is imperative that the user selects the correct load

cell for the application and provides the necessary care for the load cell during its lifetime.

Understanding these important issues and properly maintaining the load cells will ensure trouble

free weighing for a long period of time.

3.1.1 Origin of load cell

The sensing or spring element is the main structural component of the load cell. The element is

designed in such a way that it develops a strain, directly proportional to the load applied. Sensing

elements are normally made of high strength alloy steels (nickel plated for environmental

protection), precipitation - hardened stainless steels, heat treated aluminium alloys, or beryllium

copper alloys. By bonding strain gages to a precisely machined element, the force applied can be

identified in terms of resistance change. The strain gages, usually four or a multiple of four, are

connected into a Wheatstone bridge configuration in order to convert the very small change in

resistance into a usable electrical signal. Passive components such as resistors and temperature

depending wires are used to compensate and calibrate the bridge output signal.

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Figure 3.1: Strain gages

3.1.2 Accuracy of load cell

Load cells are ranked, according to their overall performance capabilities into differing accuracy classes. Some of these accuracy classes are related to standards which are used in legal for trade weighing instruments, while other accuracy classes are defined by the individual load cell manufacturer. Depending on the standard and the performance of a particular load cell type, an alphanumeric “accuracy grade” is given to the product. The alpha designate refers to the specific accuracy class, while the numeric part refers to the number of divisions. Revere Transducers manufactures products meeting NTEP, OIML and in-house specifications. These product are designated: Az Products meet the NTEP requirements for class III applications. Bz Products meet the NTEP requirements for class IIIL applications. Cz Products meet the OIML requirements for class III and IIII applications. CC/D3 These are arbitrary in-house classifications for products used in non-trade applications. Note “z” represents the number of divisions

(x1000), i.e. A3, B10, C6, etc.Most weighing systems use load cells where their working or measuring range is well below their rated capacity. In these situations, the values for the load cell utilisation and minimum verification interval (vmin) are important.The minimum verification interval is defined as the smallest value of a quantity (mass) which may be applied to a load cell without exceeding the maximum permissible error. It is specified as Emax/γ, where Emax represents the load cell’s rated capacity and γ represents a value which is specified by the load cell supplier.

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3.2: Digital Load Cell

Digital load cells are still niche products. They are available as calibrated C3 and C6 cells as well

as uncalibrated types. Typical applications are set-ups with long wires (where the digital signal

transmission is better than analog), when several load cells are processed by one single

controller, e.g. truck scales or in electro-magnetical noisy environments. The advantages can

therefore be concluded as: ƒ Long cable lengths possible without loss in signal strength.

Combination of several load cells processed by a single processor ƒ Reduced sensitivity to EMI

ƒ Good replaceability as intrinsically calibrated cells. In order to get a more detailed picture of

what a digital load cell is or how its concept is like we have a look at its set-up nowadays. As

mentioned in the introduction it basically consists of the load cell itself combined with the

electronics which is a converter and a microcontroller.

Figure3.2: Load cell with analog to digital converter

The signal generated by the strain gages on the load cell are given to the electronics . Here an

A/D converter digitizes the analog signal and feeds the micro- controller or DSP with the A/D

raw count. The controller processes then the raw values, corrects them in terms of linearization,

filtering, hysteresis, etc. and finally puts out the digital signal.

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Digital load cells are still only used in special applications like truck scales, silo scales, container

scales, etc. In common standard scales like i.e. bench scales or legal for trade scales they are not

used very often.

But exactly in this area there is a lot of benefit in using DLCs, some advantages cannot be

realized by using the analog load cell. The idea of a new possible structure is illustrated in the

following picture:

Figure 3.3: Separation of analog (weighing) part and the digital part

The analog part includes the sensor (load cell) and the electronic. The knowledge about weighing

lies in this part, i.e. construction of a good load cell or to make calibration, temperature

compensation, etc. The output is fully digital signal which delivers the weighing information

already fully calibrated.

The pure digital part on the other hand receives the digital data stream and just handles tasks like

displaying of the weight, recognition of buttons or interface other devices (e.g. network scales).

Also, language or country localization can be done in the software here. To make the digital part

there is not much knowledge about weighing itself needed.

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3.3 Circuit diagram of Digital Load cell

Figure 3.4: Circuit diagram of load cell

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3.4 Components of load cell

1. Crytal Oscillator : It is an electronic oscillator circuit that uses the mechanical resonance of

a vibrating crystal of piezoelectric material to create an electrical signal with a very

precise frequency. This frequency is commonly used to keep track of time (as in quartz

wristwatches), to provide a stable clock signal for digital integrated circuits, and to stabilize

frequencies for radio transmitters and receivers. The most common type of piezoelectric

resonator used is the quartz crystal, but other piezoelectric materials including polycrystaline

ceramics are used in similar circuits.

Quartz crystals are manufactured for frequencies from a few tens of kilohertz to tens of

megahertz. More than two billion crystals are manufactured annually. Most are used for

consumer devices such as wristwatches, clocks, radios, computers, and cellphones. Quartz

crystals are also found inside test and measurement equipment, such as

counters, and oscilloscopes.

Figure 3.5:Crystal Oscillator

2. AT89S52: All four ports in the AT89C51 and AT89C52 are bidirectional . Each consists of a latch (Special Function Registers P0 through P3), an output driver, and an input buffer . The

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output drivers of Ports 0 and 2, and the input buffers of Port 0, are used in accesses to external memory. In this application, Port 0 outputs the low byte of the external memory address, time-multiplexed with the byte being written or read. Port 2 outputs the high byte of the external memory address when the address is 16 bits wide. Otherwise the Port 2 pins continue to emit the P2 SFR content. All the Port 3 pins, and two Port 1 pins (in the AT89C52)are multifunctional . The alternate functions can only be activated if the corresponding bit latch in the port SFR contains a 1. Otherwise the port pin is stuck at 0. It has less complex feature than other microprocessor.

Figure 3.6:Microcontroller

3. DC Motor : A DC motor is a mechanically commutated electric motor powered from direct

current (DC). The stator is stationary in space by definition and therefore so is its current.

The current in the rotor is switched by the commutator to also be stationary in space . This is

how the relative angle between the stator and rotor magnetic flux is maintained near 90

degrees, which generates the maximum torque.

DC motors have a rotating armature winding but non-rotating armature magnetic field and a

static field winding or permanent magnet. Different connections of the field and armature

winding provide different inherent speed/torque regulation characteristics. The speed of a DC

motor can be controlled by changing the voltage applied to the armature or by changing the

field current. The introduction of variable resistance in the armature circuit or field circuit

allowed speed control. Modern DC motors are often controlled by power electronics systems

called DC drives.

The introduction of DC motors to run machinery eliminated the need for local steam or

internal combustion engines, and line shaft drive systems. DC motors can operate directly

from rechargeable batteries, providing the motive power for the first electric vehicles. Today

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DC motors are still found in applications as small as toys and disk drives, or in large sizes to

operate steel rolling mills and paper machines.

Figure 3.7:DC Motor

4. Weighing scale :It is a measuring instrument for determining the weight or mass of an

object. A spring scale measures weight by the distance a spring deflects under its load.

A balance compares the torque on the arm due to the sample weight to the torque on the arm

due to a standard reference weight using a horizontal lever. Balances are different from

scales, in that a balance measures mass (or more specifically gravitational mass), where as a

scale measures weight (or more specifically, either the tension or compression force of

constraint provided by the scale). Weighing scales are used in many industrial and

commercial applications, and products from feathers to loaded tractor-trailers are sold by

weight. Specialized medical scales and bathroom scales are used to measure the body

weight of human beings.

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Figure 3.8:System Block Diagram

Figure 3.9: Digital Weighing Scale

5. Seven Segment Display: A seven-segment display (SSD), or seven-segment indicator, is

a form of electronic display device for displaying decimal numerals that is an alternative

to the more complex dot-matrix displays. Seven-segment displays are widely used in

digital clocks, electronic meters, and other electronic devices for displaying numerical

information. Seven-segment displays may use a liquid crystal display (LCD), arrays of

light-emitting diodes (LEDs), or other light-generating or controlling techniques such as

cold cathode gas discharge, vacuum fluorescent, incandescent filaments, and others. For

gasoline price totems and other large signs, vane displays made up of electromagnetically

flipped light-reflecting segments (or "vanes") are still commonly used. An alternative to

the 7-segment display in the 1950s through the 1970s was the cold-cathode, neon-lamp-

like nixie tube. Starting in 1970, RCA sold a display device known as the Numitron that

used incandescent filaments arranged into a seven-segment display. In a simple LED

package, typically all of the cathodes (negative terminals) or all of the anodes (positive

terminals) of the segment LEDs are connected and brought out to a common pin; this is

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referred to as a "common cathode" or "common anode" device. Hence a 7 segment plus

decimal point package will only require nine pins (though commercial products typically

contain more pins, and/or spaces where pins would go, in order to match industry

standard pinouts). Common cathode implementations require logic low (0) to turn on a

segment, common anode implementations require logic high (1) to turn on a segment.

Integrated displays also exist, with single or multiple digits. Some of these integrated

displays incorporate their own internal decoder, though most do not: each individual LED

is brought out to a connecting pin as described. Multiple-digit LED displays as used in

pocket calculators and similar devices used multiplexed displays to reduce the number of

IC pins required to control the display. For example, all the anodes of the A segments of

each digit position would be connected together and to a driver pin, while the cathodes of

all segments for each digit would be connected. To operate any particular segment of any

digit, the controlling integrated circuit would turn on the cathode driver for the selected

digit, and the anode drivers for the desired segments; then after a short blanking interval

the next digit would be selected and new segments lit, in a sequential fashion. In this

manner an eight digit display with seven segments and a decimal point would require

only 8 cathode drivers and 8 anode drivers, instead of sixty-four drivers and IC pins.

Figure 3.10 Seven Segment

6. LCD Display: A liquid crystal display (LCD) is a flat panel display, electronic visual

display, or video display that uses the light modulating properties of liquid crystals. Liquid

crystals do not emit light directly. LCDs are available to display arbitrary images (as in a

general-purpose computer display) or fixed images which can be displayed or hidden, such as

preset words, digits, and 7-segment displays as in a digital clock. They use the same basic

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technology, except that arbitrary images are made up of a large number of small pixels, while

other displays have larger elements. LCDs are used in a wide range of applications including

computer monitors, televisions, instrument panels, aircraft cockpit displays, and signage.

They are common in consumer devices such as video players, gaming devices, clocks,

watches, calculators, and telephones, and have replaced cathode ray tube (CRT) displays in

most applications. They are available in a wider range of screen sizes than CRT and plasma

displays, and since they do not use phosphors, they do not suffer image burn-in. LCDs are,

however, susceptible to image persistence. The LCD screen is more energy efficient and can

be disposed of more safely than a CRT. Its low electrical power consumption enables it to be

used in battery-powered electronic equipment. It is an electronically modulated optical

device made up of any number of segments filled with liquid crystals and arrayed in front of

a light source (backlight) or reflector to produce images in color or monochrome. Liquid

crystals were first discovered in 1888.[2] By 2008, worldwide sales of televisions with LCD

screens exceeded annual sales of CRT units; the CRT became obsolete for most purposes.

Displays for a small number of individual digits and/or fixed symbols (as in digital watches

and pocket calculators) can be implemented with independent electrodes for each segment. In

contrast full alphanumeric and/or variable graphics displays are usually implemented with

pixels arranged as a matrix consisting of electrically connected rows on one side of the LC

layer and columns on the other side, which makes it possible to address each pixel at the

intersections.

Figure 3.11 LCD Display

CHAPTER 4

RESULT

4.1 RESULT

Conceptual design was carried out and fabrication drawings were prepared. Assembly of

fabricated items and bought out items was carried out and trial run of the equipment was

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conducted. Evaluation of the system was done by taking wheat for weighing experiments which

had the following characteristics on dry basis: 9% moisture, 76 kg per hectoliter weight, 32

grams per 1000 kernel weight and hardness value of 10kg per grain. Above parameters indicated

that wheat used was medium hard type. Table1. shows comparison of set weights and measured

weights of wheat samples from 1000 grams to 5000 grams with an incremental value of 500

grams. P-values for 1500, 3500, 5000 grams were 0.889, 0.068 and 0.48 respectively. Fstatistical

values for 1500, 3500, 5000 grams were 0.019, 3.766 and 0.507 respectively. Fcritical values for

1500, 3500, 5000 grams were 4.414, 4.414 and 4.098 respectively. Fstatistical < Fcritical and P-

values > 0.05, there is no statistical difference in mean value of measurements from set weights

and measured weights. For 1000, 2000, 2500, 3000, 4000 and 4500 grams, P-values > 0.05 and

Fstatistical > Fcritical indicated that there is a significant effect due to weight measurements at

the 95% probability level.

Differences could be minimized by proper tuning of storage hopper gate open speed, feed speed

and close rapid speed parameters . Average percentage error was observed from 0.1% to 0.6%.

Minimum average percentage error (< 0.2%) was observed for 3500, 4000, 4500 and 5000grams

weight measurement. Maximum average percentage error (>0.2% and <0.6%) was observed for

1000, 1500, 2000, 2500 & 3000 grams weight measurement. This could be further minimized by

altering the position of reader limit switch and by tuning of storage hopper gate open speed, feed

speed and close rapid speed parameters.

Weight measurements on the dispensed material under repeatability conditions produced results

within ± 0.22% of displayed set weight for 3000,3500,4000,4500 and 5000 grams. Repeatability

of greater than ± 0.22% was observed for 1000, 1500, 2000 and 2500 grams displayed set

weights which were due to material weighing speed. Improve in repeatability limit could be

possible by slowing down weigh up cycle.

4.2 PROBLEM FACED

Due to heavy and large machine we are getting problem in doing shuttering.

Difficult to understand the load cell circuit

Errors in weighing.

4.3 PRECAUTIONS

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The load cell has to handle with care.

Its structure is to learn properly with conc.

Proper supply should be maintained and sensor should handled properly.

CHAPTER 5

FUTURE SCOPE AND CONCLUSION

5.1 CONCLUSION

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The results of studies carried out for the Design & Development of low cost, servo based PLC

operated grain / grain products automatic weigher indicated that the equipment could be used as

weigher in Flour mills. Statistical analysis indicated that there was no significant difference in

mean value of measurements from set weights (1500, 3500, 5000 grams) and measured weights

at the 95% probability level. Minimum average percentage error (< 0.2%) was observed for

3500, 4000, 4500 and 5000grams weight measurements. Weight measurements on the dispensed

material under repeatability conditions produced results within ± 0.22% of displayed set weight

for 3000,3500,4000,4500 and 5000 grams revealed that weighing of product by auto grain

weigher is very precise. Automatic weighing equipment can be successfully used for weighing

and dosing of any granular products into bags, containers in automated production processes.

5.2 FUTURE SCOPE

In India from very last year we are watching that many bags are being packed and weighed

manually but now there is a great shortage of man power in every field so to overcome this

problem we have design a machine which automatically weigh and pack the material that has to

weighed or packed so that there is less use of man power & it also save the time and money.

5.3 Automatic Machines Vs Prices in India

The following figure show how the prices in India has affect the use of automatic machines. The

machines are used in each and every part of life.

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Figure 5.1 Rate of uses of Automatic Machines in India

REFRENCES

1. http://www.radwag.com/pliki/artykuly/

good_weighing_practice_in_pharmaceutical_industry.pdf

2. http://mofpi.nic.in/images/cftri_rd.pdf

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3. http://en.wikipedia.org/wiki/Load_cell

4. http://www.rdjacobs.com/pdf/Loadcell_spec.pdf

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