MilkFillingSystem

MSDProject

DoneBy RamiAlDirini 0051209 0057364 0057379 005 0057362

AdhamNoubani KhalafAlHamayel NatheerMteireen AhmadNour

Instructor DrLutfiAlShareef

Abstract
Inafactorythatproducesmilkinbottlestherearemanyprocessesbeforethe milkbottleisavailableontheshelfofthenearestsupermarket.Firstly,the bottlesneedtobemanufactured.Thisisusuallydoneinaplasticfactory.Itis vitalthathygienicpracticesbegivengreatconsiderationandattention,as thesebottlesshallbeusedbyhumanconsumers. Thesecondstepistotransferthesefilledbottlestothefactoryresponsiblefor filling,cappingandlabelingthemilkbottles.Incaseglassbottlesareusedina reuseablemanner,cleaningneedstobedonefirst.Onethecleanbottles; eitherplasticorglass,areavailableatthefactory,theyaretobeplacedalonga productionline.Herebottlesaretobefilledwiththeproperamountofmilk. Then,thefilledbottlesaretobecappedwithcaps.Finally,eachbottleistobe labeledandtransferredtotheretailstoresthatsellthesemilkbottlestothe consumer. Inthisdocument,wepresentadesignforafillingcappinglineinafactory.We willsuggesttwodesignsandchoosethebetterdesign.Oncethisisdone,we willsearchthemarketforcomponentsthatmakeourdesignrealizable.Finally, wewillrecommendcertainproductsfromspecificmanufacturersandprovidea CADmodelforourdesignforbettervisualization.

TableofContents
Abstract................................................................................................................ 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/FestoOutputDevicemanufactured bySiemens ...................................................................................................... 39 AppendixB:ProEngineerScreenShots..............................................................41

Introduction
Nowadays,massproductioncanbeconsideredanecessityratherthanaluxury. Theconsumptionrateshaveincreasedrapidlyandthedemandforproducthas notyetreachedalimitwherepeoplewouldnotneedmore.Hence,therehas beenanincreaseinthenumberoffactoriesandasignificantimprovementin thetechniquesandmethodsadoptedformassproduction. Amongtheneedsofpeopleismilk.Peopleofdifferentages,gendersand backgroundsneedasupplyofmilktobereadilyavailable.Consequently,a numberofcompetitorsinthemilkindustryseemtohavereservedtheirshare ofthemarket.However,forthosecompaniestokeeptheircompetitionover themarket,itisvitalthattheyprovideforsufficientmethodforprovidingmilk totheconsumer. Milkisusuallydeliveredinbottles,howeverinavarietyofvolumes. Nevertheless,whateverthevolumeofthebottle,thereneedstobeaefficient methodforfillingthosebottles.Inthisdocument,wewillpresentadesignfora milkfillinglineinafactoryalongwitharecommendationonsomecomponents fortheproposedsystem.Wewilloutlinetwosuggesteddesignsandchoosethe optimumone.Furthermore,wewilltrytosearchforcomponentsfrom differentsuppliersandrecommendthebetterchoiceathand.Finally,wewill provideforaCADsimulationofthesystemtoprovideforabettervisualization oftheproposedsystem.

RisksandHazards
1. HygieneSystem: Milkfillingprocessshouldbehygieneduethefactofitsconsumedby humananditssocriticalissueifitspollutedasitmakesitun consumable. 2. TheTransportationprocess: Wedealingwithbottlesmovingonconveyerbeltanditsobvioustheir ariskofthebottlesTippingonbeltwhichmakeawasteofmoneyand candelayproductionprocess. 3. Preciseamountofmilkneeded: Asitwellknownweneedfixedamountofmilkoneachbottlewitha veryhighprecisionandfromheretheriskofnotEqualorunaccurate fillingprocessraisesup. 4. Bottleshapeandoutsidepressure: Thefactthebottlemovingandwillbepressedtocovermakeariskof losingitsshape.Also;ifthebottlehitabodywhilemovingatcertain speedsthismayresultadeformationonitsshape. 5. Malfunctionalityofsomepartsduewear: Underindustrialenvironmenteachmovingpieceisgettingsomewear somehowlikegearsbeltmotorandthismayresultmalfunctionon them. 6. Lubricationandoverheating: Asweknowconveyerisdrivingbymotorandontheoperationwehave manyrotatingpartsandoverheatingforthemmayresultapermanent ortemporarydamagethateffecttheprocess.

SequenceofoperationforSystem1
Emptycleanplasticbottlesareplacedinarandommanneronaconveyerbelt, conveyerbelt1.Thebeltwillnotstartuntilastartbuttonispressed.Conveyer belt1hasthefollowingarrangementatitsend:
Conveyerbelt1 Milkbottles Limitswitches

Track
Ratchet Circular track

Conveyerbelt2

Figure1:endarrangementatconveyerbelt1 Thepurposeofthisarrangementistoensurethatonlyonebottleleaves conveyerbelt1atatime.Thisarrangementwillbelabeledsubsystem1from nowon. Assubsystem1detectsabottleatitsend,conveyerbelt1isprompttostop. Thisisachievedbysendingastop_motor1signalfromthePLCtothemotor drivingconveyerbelt1.Consequently,allbottlesonconveyerbelt1willbe broughttohalt.However,thedetectedbottleattheendoftheconveyerbelt1 willcontinuetomovealongtherampreachingtoconveyerbelt2.Itis importanttonotethatbothconveyerbelt1andconveyerbelt2willhavethe samesteadystatespeed.Thisiscriticaltoavoidtippinganybottlemovingfrom conveyerbelt1toconveyerbelt2. Atthismoment,conveyerbelt1isathaltandconveyerbelt2willcontinueto move,thusmovingthebottlesonitthroughtherestofthesystem.Conveyer belt1willremainatrestuntilthebottleonconveyerbelt2hasmoveda distanceequivalenttotheheightoftheplasticbottlemultipliedbyafactorof 1.1.Theimportanceofthispartofthesequenceisthatitensuresthatifany bottleforanyreasontipsover,noofthebottleproceedingitwilltipover resultinginadominolikeeffect.Therefore,assoonasabottleleavesconveyer belt1andentersconveyerbelt2,atimerstarts,andassoonasthetimer completesitscount,conveyerbelt1startstomove.Arepetitionofthis sequencewillmakesurethatbottlesmovingalongconveyerbelt2willbe

separatedbyasuitableseparatingdistance,allowingfortheupcoming processestobecompletedproperly. Now,asthebottlemovesalongconveyerbelt2,itwillundergoseveral processes.Thefirstprocessencounteredbyanybottleonconveyerbelt2will bethefillingprocess.Thesysteminchargeoffillingbottleswillbelabeledas fillingsystem.Figure2providesaschematicofthemainpartsand componentspresentinthefillingsystem.

Bottle Filling mechanism

Track

Figure2:maincomponentsofthefillingsystem Thefillingprocessstartswhenabottleisdetectedbythelimitswitchesshown inFigure2.Theselimitswitchesalertthesystemwhenabottleisdetectedby sendingadetectionsignaltothePLC.Consequently,thePLCwillsenda stop_motor1andstop_motor2commandstobothmotor1andmotor2; controllingconveyerbelts1and2respectively.Thiswillensurethatthebottle remainsstationarywhilebeingfilledwithmilk.Now,apneumaticactuatorwill movethefillingarmandheaddowntoanelevationsuitableformilkfillingto commence.Thenavalveopens,allowingforthemilktoflowintothebottle. Asmilkflowsintothebottle,anaccuratebalancewillcontinuouslymeasure theweightofthebottleandthemilkfillingit.Theoutputfromthebalancewill serveasanindicationofthemilklevelpresentinthebottle.Themilkwill continuetoflowuntilthedesiredmilklevel(1L)isobtained.Figure3providesa schematicofthearrangement.

 Bottle WeightCell/Balance Figure3:schematicoftheweighingmechanismarrangement. Whenthedesiredlevelofmilkhasbeenfilledintotheplasticbottlethe balancealertsthesystemthatthedesiredlevelofmilkhasbeenreached. Consequently,thePLCsendsastop_milksignaltothevalvecontrollingthe flowofmilk,thusstoppingtheflowofmilktothebottle.Afterthisisdone,the fillingarmandheadarrangementisretractedandallconveyerbeltsstart movingagain. Thesecondprocessabottlehastogothroughwhileonconveyerbelt2isthe cappingprocess.Thesysteminchargeofcappingthebottleswillbereferredto asthecappingsystem.Figure4showsaschematicofthearrangementofthe maincomponentsofthecappingsystem.
Track Bottle Capping mechanism

ConveyerBelt2

Figure4:Arrangementofthemaincomponentsofthecappingsystem. Thecappingprocessstartswhenthelimitswitchesdetecttheentryofabottle. Thedetectionisagaindonethoughtwolimitswitchesfixedonthesidesofthe trackwhichdefinesthemotionofthebottles.Theselimitswitcheswillprompt thePLCtoissueastop_motor1andstop_motor2commandstostopboth conveyerbelts.Whenthebottlehascompletelystopped,apneumatically

actuatedgrippedisextractedtoholdthebottlefirminitpositionsoastoallow forthecappingprocesstobecompletedproperly.Assoonasthegripper extendsfully,anotherpneumaticactuatorextendstopushthecappinghead towardsthefilledbottle.Pushforcewillresultinthecapbeingfirmlyattached tothebottle.Themomentthisisdone,bothpneumaticactuatorsare retracted,andthePLCissuesasstart_motor1andstart_motor2commands; causingbothconveyerbeltstostartmovingagain.Attheendoftheconveyer belt2,thebottleistransferredtoalabeling Itisworthnotingthatboth;thefillingandthecappingprocesses,takeplace concurrently,howeverondifferentbottle.Inotherwords,whenabottleis detectedbythefillingsystem,thecontrollerchecksifanotherbottlehasbeen detectedbythecappingsystem.Ifthecappingsystemhasdetectedabottle thenthecappingprocesscontinues.However,ifthecappingsystemfailedto detectabottle,thenthecappingprocessdoesnottakeplace.Ineithercase, thefillingprocessisunaffectedbythebottledetectionatthecappingsystems side.Furthermore,forthissequencetotakeplace,theseparationbetweenthe twosystemsshallbeamultipleofabottlesheight.Therefore,asuitable separationbetweenthefillingandthecappingsystemswouldbetwicetothree timestheheightofabottle.Thisseparationconstitutesacompromisebetween allowingforenoughspacebetweentheequipmentwiththelowestpossible reductionintheproductionrate. Furthermore,asasafetyprecaution,assoonasthestartbuttonispressed,the systemwillcheckifthetankhasenoughmilkinitandifthecappingsystemhas enoughcapsplacedinthecapscompartmentinthecappingsystem.

SequenceofoperationforSystem2
Emptycleanplasticbottlesareplacedinarandommannerona conveyerbelt,conveyerbelt1.Thebeltwillnotstartuntilastartbuttonis pressed.Assoonasthestartbuttonispressed,thesystemmakessurethat thereisenoughmilkinthetankandthecapholdershaveenoughcapsinstalled inthem.Ifeitherconditionisnotsatisfiedthesystemwillnotstartandan alarmLEDwillturnonindicatingwhichconditionisnotsatisfied.Inthiscase, humaninterventionisrequired,whereaworkeristogoandresolvethe problemmanually.Oncethisisdone,theoperatoristopressthestartbutton onceagaintostartthesystem.Thiswillstartmotor1,whichisresponsiblefor themotionofConveyerbelt1.Conveyerbelt1hasthefollowingarrangement atitsend:
Limitswitches

Conveyerbelt1

Milkbottles

Circular track

Ratchet Track

Figure5:endarrangementatconveyerbelt1 Thepurposeofthisarrangementistoensurethatonlyonebottle leavesconveyerbelt1atatime.Furthermore,assoonasthebottlehasbeen detectedandhasenteredthroughtheratchet,analertLEDwilllightup, indicatingthatnomorebottlesshallbeplacedontheconveyerbeltatthis moment.TheLEDwillturnoffassoonasthebottlestartsmoving. Asthebottleenterstheroundtrackitremainsstationaryuntila grippergrabsit.Thereareeightgripperarrangedinastarlikepatternasshown inFigure6.EachgripperwillgrabonebottleatpointA,andwillreleaseitat pointBafterbeingfilledandcaped.Moreover,eachgripperhasamilkfilling mechanism,acapfittingmechanismandabalanceattachedtoit.This arrangementisillustratedinFigure3.


Conveyerbelt2

Circulartrack

Conveyerbelt1 Figure6:grippersandroundtrackarrangement.
Pneumaticactuator responsibleforinterchanging betweenfillingadcapping mechanisms

Grippers

Filling mechanism

Capping mechanism

Bottle

Gripper

Figure7:gripper,milkfillingandcapfittingmechanisms,andbalance arrangement

Assoonasthegrippergrabsthebottle,alimitswitchalertsthesystem thatabottlehasbeengrabbed.Apneumaticactuatorisusedtointerchange thepositionofthefillingandthecapfittingmechanisms.Indefaultposition, theactuatorisnormallyretracted.Atthisactuatorposition,thefilling mechanismislocatedstraightabovetheemptybottle.Atthismoment,thePLC issuesastart_fillingcommand.Thiswillopenthevalvecontrollingtheflowof milkfromthetanktothebottle,thusallowingmilktoflowintothebottle.Milk willflowcontinuouslyintothebottleuntilthedesiredmilklevelisachieved.In ourdesign,wewilldependonabalancetocontinuouslyprovideanindication ofthelevelofmilkinthebottle.Assoonasthebalancesignalsthatthelevelof milkinthebottlehasreachedthedesiredlevel1,thePLCissuesastop_filling command.Thiswillclosethevalvethatcontrolstheflowofmilk. Now,afterthefillingprocesshasbeencompleted,thePLCissuesa start_capingcommand.Thiswillforcethepneumaticactuatortomovethe fillingmechanismawayfromthebottleandbringforththecapping mechanism.Thecappingmechanismconsistsofacapsholder,astationaryarm andacappingarm/head.Thecappingarm/headcanmoveupanddownina controlledmanner.Wheneverthecappingprocessstarts,thecapping arm/headwillbeforcedtomovedown,pressingthecapagainstthebottle.If enoughforceisapplied,thecapwillbefittedonthebottle. Oncetheabovementionedprocesses(i.e.thefillingandthecapping processes)havebeencompleted,thebottlewouldhavetraveledfrompointA topointBonthecirculartrack.AtpointB,asecondconveyerbeltwillmove thefilledbottletoadifferentplaceinthefactory,wherelabelingand packagingshalltakeplace. Itisimportanttonotethatweareassumingthelevelofmilkinthe tankissufficienttoprovidefortheminimumflowofmilkrequiredforthe bottletobefilledandcappedbeforereachingpointBonthecirculartrack.

1Lofmilkweighs1.029kg

System1FlowChart

Figure8.1:System1FlowChartpartI

 Figure8.2:System1FlowChartpartII

LadderDiagramforSystem1

Figure9.1:LadderDiagrampartIIforSystem2


Figure9.2:LadderDiagrampartIIforSystem2

System2FlowChart

Figure10.1:System2FlowChartpartI

Figure10.2:System2FlowChartpartII

 LadderDiagramforSystem2

Figure11.1:LadderDiagrampartIforSystem2

 Figure11.2:LadderDiagrampartIIforSystem2

SystemSelection
Afterproposingthetwosolutions,andexaminingtheprosandconsof each,thefollowingconclusionwemade: Inthefirstdesign,themotorusedtodrivetheconveyerbeltswouldbe overloadedduetothecontinuousstartandstopcommands.Thiswillleadtoa lossofthetimeandmoney.Furthermore,thefrequentandsuddenbrakingon themotorwilloverloadthemotorandthusshortenitslifetime. Inthesecondsystem,thisproblemwasresolvedbyselecting continuousmodeofrunforthemotorwithouttheneedforfrequentand suddenbreaking. Asaconclusion,thesecondsystemwouldbepreferredoverthefirst system,andthustheselectionofthecomponentswillcontinueaccordingly.

ComponentsSelection
TransducersandSensors LimitSwitches Thelimitswitchesneededtodetectthearrivalofthebottletothe desiredpositiontodotheprocessessuchasfillingandcapping. Hereweneedtwolimitswitches,onetodetectthebottlearrivalto theendofthefirstconveyorbeltandtheothertodetectthebottlearrivalto itsfillingposition. Thelimitswitchesaremountedattheedgeoftheconveyor. AvailableOptions: Limitswitch183322fromFesto;electricallyactuatedfromtheleft,with roller.Theactuatingforceneededisabout5N,whichisreasonableforour application.Also,theoperationalvoltageis24V,whichallowsforPLC interface. Figure12:LimitSwitch183322fromFesto Fillinglevelinspection Therearemanywaystocontrolthefilledmilklevel: AvailableOptions: o Fillingusingweighingcells TheSensometicVPGWisafillingsystemdesignedforpressurelessfilling usingthegravityprinciple.Especiallynonconductiveproductscanbe processedideallywiththeweighingcellsintegratedinthebottleplates.The electropneumaticallycontrolledsystemenablesnoncontactfilling,thus beingsuitableformicrobiologicallysensitiveproductsaswell.Duetothe fillingvalvesclosingtowardsthetop,theproductcangentlyflowintothe bottleduringclosing.Fillingisthereforeterminatedwithoutdeflectingthe productjet.Asamatterofcourse,theSensometicVPGWissuitableforfilling glasscontainers,cansandplasticbottles.Thankstothemotorizedheight adjustmentoftheringbowl,thismachinecanquicklybechangedtodifferent containersizes.

Figure13:WeightBalance

Otherinspectionmethods

Thefollowinginspectiontechnologiescanbeusedforfilllevelinspections: a) InfraredInspection Inspectionoffilllevelaccuracyatthe labelfreesectionofthetranslucent container. Infraredtransmitterandreceiverina definedarea. b) XrayInspection PrecisefillheightinspectionwithXray measuringprocessindependentofthe product. AutomaticshuttingoffofXraysource uponmachinestop. Nointerferencethroughlabelsinthe inspectionarea. c) GammaRayInspection Precisefilllevelinspectionviagammaray system. Inspectionofcontainersof anymaterialregardlessof productorcontainer material. Automaticshuttingoffof gammasourceupon machinestop. Nointerferencethrough labelsintheinspection area. d) InspectionwithCameraTechnology Infrared Xray Gammarays Digitalcamera

Figure14:Levelinspectionmethods

Ahighlydemandingapplicationisthefilllevelinspectionwith simultaneouscheckofthepresenceorslantedpositionofclosures.ThisKrones patentedinspectionsystemusesanupstreamopticssystem,whichhastwo differentviewsandatelemetricimageprovidingoptimumprerequisitesfor downstreaminspectionalgorithms.

Inspectionofoverfill,underfill,andclosuresontransparentcontainers inoneprocess Highprecisioninspectionmethodwithoutexposuretoradiation Accuraciesof1mm Bottleheighttoleranceswithoutinfluencingthemeasuringresult LightingwithLEDsthatarecharacterizedbytheirevenlight distribution,longservicelife,andreducedenergyconsumption WithPETbottles,thereisthepossibilitytodefinethecarrierringasthe filllevelreferencepoint Optionaladditionalequipment:Cameraswitharesolutionof1,280x 1,024pixels,colorcameras.

TheSelection: Ourselectionwouldbetheweighingcellmethod(UsingSensomaticVPGW) becauseofthefollowingadvantagesoverothermethods: ActuatorsandMotors LinearActuators(Cylinders) Linearactuators(Cylinders)usedinmanypartsofthesystem; o o o Fillinghoseactuator:heretheactuatormovesthehosedownuntil reachthebottletofillit.Afterthat,theactuatorwillmovethehoseup. Cappingactuator:thisactuatormovesthecapperwithsuitablespeed andforce,pressingthecapagainsttheheadofthebottle. Forthispurposeofselection,wewillconsiderdifferentsuppliers.This willallowforacomparisontobecarriedonbetweenthedifferent optionsavailableinthemarket.Consequently,theoptimumoption shallbeselected.Thefollowingaretheoptionsathand: Infinitelyadjustablefillquantity Highfillquantityaccuracyduetocalibratableweighingcells. Noncontactfillingassuringhighmicrobiologicalsafety. Productandgaschannelsfreefromsprings,providingoptimum cleaningaccessibility. Weighingcellsasacompactandquicklyreplaceableunit.

Fillinghoseactuator AvailableOptions: o NCJ2seriesfromSMC(AppendixA:DATASHEET1): o CG1seriesfromSMC:(AppendixA:DATASHEET1)

Gripperactuator AvailableOptions: NCA1seriesfromSMC(AppendixA:DATASHEET1) CLAseriesfromSMC(AppendixA:DATASHEET1) HereweselectNCA1becauseofitscompactsizeitsreplaceablerodgland.This willallowformaintenanceof the actuator. Figure15:NCA1SeriesCylinder Cappingactuator Hereweneedhighpressure(forhighpressingforce).Furthermore,high speedisalsoarequirementforthesystem. AvailableOptions: NCMseries(SMCwhichhasgoodspeed(230)in/s,andhighpressure (250psi).(AppendixA:DATASHEET1) Figure16:NCMSeriesCylinder Armsandshaftdesignandmotorselection: Thefilling/gripperarmwillbemainlyacylinderofaluminiumwiththe followingdimensions: Outerdiameter=0.12m 0Innerdiameter=0.06m

Length=0.5m Densityofaluminium=2700kg/m3 TheAluminiumshaftwillhave8shaftsattachedtoit,with0.12in diametereach.Thespacingbetweeneachtwoshaftswillbe0.1m. Consequently,thecircumferenceoftheshaftwillbe(0.12+0.1)*8=1.76mand itsradiuswillbe0.28m.Theheightwillbe1mandtheinnerdiameterofthe shaftwillbe0.22m. Shaftmass=density*volume Ms=2700*( (R.outerR.inner)^2)*1=30.54kg Themassofthearm=densityofaluminium*thevolume Mr=*(.06.03)^2*0.5*2700=3.82kg Atworstcase,sevenofthegripperwillholdbottleswithtotalmassof7kg Thetotalweightofthesystem=(30.54+8*3.82+7)*g=668.061N Thetorquerequiredfromthemotorwillbe668.061*.28=187.1N.m Theneededfillingandcappingtimewillbeis40seconds. Asaresult,thespeedoftheshaftwillbeequaltothedistancedividedbythe timeneeded: MaxSpeed=2*(0.28+0.5)*0.75/40=0.092m/s Therotationalspeed=V/r=0.092/0.78=0.118rad/s. RotationalspeedinRPM=.118*60/2=1.13RPM Theoutputpowerofthemotorneededwillbeverylowandequaltotorque* =22W BecauseoftherelativelyverylowspeedrequiredsinglephaseACinduction gearedmotorwillbeused. Bison 016-762-1264 model is the best fit for the requirements. ConveyerBelts Thefirstconveyerbeltthatcarriesthebottlestothetracktobefilled willbemadeofPVC(polyvinylChloride)toallowforthebottletoslipifithits theratchetwhileanotherbottleisstillwaitingtobegrabbed.Also,thiswill enableustouseaDCmotorwithrelativelysmalloutputpowerandlowspeed. Thesecondconveyerbeltwillbemadeoutofrubberbecauseweneed relativelyhighcoefficientoffrictionwiththebottletopreventslippage.The

motorusedherewillbealsoaDCmotorwithrelativelylowspeedtorque capabilities.Thisisbecausetheloadontheconveyerbeltwillbelow. Selection Inourdesign,wehavetwoconveyerbelts: Conveyerbelt1:madefromPVC Conveyerbelt2:madefromrubber

Werecommendbuyingbothconveyerbeltsfromthefollowingsupplier:

Thisisbecausetheyhaveawidevarietyofavailablemodels. MaintenanceoftheSystem Thefollowingmaintenanceproceduresaresuggested: Dailybase: 1. Cleanmilkofmaintankandremoveanytinysolidsiftheirany fromit,Astheycanleadtoblockageonthepipesafter. 2. CheckthesignalsreturnedtoPLCfromalltransducersbefore startoperationastoguaranteesafetyontheprocess. Weaklybase: 1. Checktheconveyertightandifitneedcalibration. 2. Checkcontactinglimitswitchesiftheirany. Monthlybase: 1. ChecktheTransducerdependingonthescheduled maintenance. 2. Checktheconnectingwiresandnetworkiftheiranyastogive rightsignalsformonitoring. Programmedmaintenance: SomeworkingpartshaveCertainLifespandependingonnumberofrevolutions orworkinghoursthoseshouldbemonitoredandapromptshouldbedonefor thosepartsbefore1monthastotakenecessaryactionneeded ImportantConsiderationsintheDesign 1. Hygienist TheChoiceofsystemdesignandthefillingprocessmethodtookthis pointintoconsideration,aswecanseefromthepicturetheselected

methodoffillingandweightingarecontactlesstothebottleasseenin thefigure.

Figure17:Contactlessfillingsystem Also,ThechoiceofMachinetobePneumaticguaranteegoodisolation andremovetheriskofusingoilasinhydraulicsystemwhichcanbe pollutingformilk. 2. ForthetransportationofbottlesprocessAndforPreventanyriskof tipping: OurDesignUsedGripperstoholdbottlesandlikethisweremovethis risktotally.

Figure18:Gripper 3. AccuratefillingSolution

Toguaranteeaccuratefillingwerunthroughmanymeasurement systemslikeinfrared,ultrasonic,flowmeterandfinallytheembedded onlineweightsensorwhichgotthebestresultsasithavethefollowing advantages: Weightingcelladvantages:2 Infinitelyadjustablefillquantity Highfillquantityaccuracyduetocalibratableweighingcells Noncontactfillingassuringhighmicrobiologicalsafety Productandgaschannelsfreefromsprings,providing optimumcleaningaccessibility Weighingcellsasacompactandquicklyreplaceableunit Andsoweselectittobeourtransducerforgettingaccuratebottle weight(andofcoursevolumeandlevel). 4. Bottleclosingwassolvedbythechoiceofthefollowingsystemwhichis suitabletoclosetheselectedtypeofbottlewithoutresulting deformationonit. 5. Thewear,Lubricationandheatissuesareallsolvedthroughregular maintenanceandalsohavingPneumaticsystemreducesthepossibility ofoverheat.

FormoreinforeferencetoWeightingCelldatasheetonappendixA

SystemSpecifications ProgrammableLogicController: ACCESSTMS7I/OInput/FestoOutputDevicemanufacturedbySiemens. SensorsandTransducers: Limitswitches183322;electricallyactuatedfromtheleft,withroller. SensometicVPGW from Krons

PneumaticCylinders: NCJ2seriesfromSMC CG1seriesfromSMC NCA1seriesfromSMC NCMseries from SMC Motor Bison0167621264

AppindexA
DATASHEET1:MotorSpecifications

SPECIFICATIONS: Performance Specifications AC Voltage Phase Shaft Speed (rpm) Continuous Current (amps) Continuous Torque (In-lbs) Output Power (HP) Rotor Inertia (oz-in-sec) Motor Type AC Construction Features Shaft Orientation Gearing Options Gearing Gearhead Model Gear Type Gearbox Ratio (: 1) Gearing Efficiency (%) Housing / Enclosure Units Motor Shape Diameter / Width (inch) Length (inch) NEMA Frame () Options Extreme Environment Other Specifications Feedback Features Environment Operating Temperature (F) Shock Rating (g) Vibration Rating (g) Environment Totally Enclosed Notes

120V/60Hz Single-phase 1 0.6000 1822 = 206N.m 0.0500

Hollow; Offset / Parallel

Gearmotor Hollow Shaft Gearmotor Spur 1264

English Cylindrical Body

High pressure die cast aluminum housing, precision hobbed gears

183322
DATASHEET2:Limitswitches183322
Grenztaster, elektrisch, Bettigung von links

2 4 1

Die beiden Grenztaster, elektrisch, Bettigung von links (Bestell-Nr. 183322) und Bettigung von rechts (Bestell-Nr. 183345) haben im Schaltplan das gleiche Symbol.

Aufbau Der Mikroschalter mit Rollenhebel und die elektrischen Anschlsse sind in einem Kunststoffgehuse montiert. Der elektrische Anschluss erfolgt mit Sicherheitsbuchsen. Die Befestigung der Einheit auf der Profilplatte erfolgt ber das Drehsystem mit blauer Griffmutter (Befestigungsvariante B).

Funktion Der elektrische Grenztaster besteht aus einem mechanisch bettigten Mikroschalter. Durch Drcken des Rollenhebels, beispielsweise mit dem Schaltnocken eines Zylinders, wird der Mikroschalter bettigt. ber die Kontaktanschlsse wird ein Stromkreis geschlossen oder geffnet. Nach Freigabe des Rollenhebels wird der Mikroschalter in die Ausgangslage gebracht.

Festo Didactic GmbH & Co. KG, 02/2009

nderungen vorbehalten

183322
Grenztaster, elektrisch, Bettigung von links

Hinweis Der Mikroschalter kann als Schlieer, ffner oder Wechsler geschaltet werden. Der Grenztaster soll bei groen Kolbengeschwindigkeiten nur in der vorgesehenen Richtung vom Schaltnocken des Zylinders angefahren werden. Die Grenztaster drfen nicht frontal bettigt werden.

Technische Daten
Elektrik Bauart mechanisch bettigter elektrischer Mikroschalter in Grenztastergehuse 24 V DC Max. 5 A Max. 200 Hz 0,2 mm 2,7 mm 5N fr 4 mm Sicherheitsstecker

Spannung Kontaktbelastbarkeit Schaltfrequenz Reproduzierbare Schaltgenauigkeit Schaltweg Bettigungskraft Anschluss Elektromagnetische Vertrglichkeit

Straussendung Strfestigkeit

geprft nach EN 500 81-1 geprft nach EN 500 82-1

nderungen vorbehalten

Festo Didactic GmbH & Co. KG, 02/2009

DATASHEET3:CG1seriesCylinderfromSMC

Forcompletedatasheet,seeattached.pdffile.

DATASHEET4:WeightCellSpecifications
Filling system

Sensometic VPGW
Type Pitch circle diameter (mm) Machine pitch (mm) 87 94 103 113 126

Number of filling valves 321 322 323 324 1440 1800 2160 2520 78 91 48 60 72 84 44 55 66 77 40 50 60 70 45 54 63

Design features: Cost-efficient, robust steel construction of front table with stainless steel housing Carousel structure: cast metal construction with acidproof finish Media feed with pipe joints Distributors and all product-contact and gas-contact parts in stainless steel Wst. AISI 304 Motorised adjustment of machine head with scaling HBM weighing cells below the bottle plate Weighing cells with calibratable measuring system with strain gauge Easily exchangeable change parts and container guides Ring bowl free of any inbuilt springs Air-conditioned electronics tower in the centre of the filling carousel Statistics evaluation of fill quantity, mean values and standard deviations

Non-standard equipment: Stainless steel carousel structure Distributors and all productcontact and gas-contact parts in stainless steel Wst. AISI 316 Handling parts in microbiologically optimised design Automatic ring bowl height adjustment Roof-Table design for all building sizes Bloc configuration with rinser and up to three closing systems, as well as a labelling machine

Additional equipment: Two-stage operating control cylinder for second flow speed Flushing packages CIP system

Servic e Our worldwide network of sales and service offices provides optimum support even after the start-up of your line. Our modern, decentralised storage system allows us to supply spare parts immediately if required. Our qualified service engineers ensure fast and reliable line maintenance and service.

KRONES AG Bhmerwaldstrae 5 D-93068 Neutraubling Phone: +49(+9401)70-0 Fax: +49(+9401)70-2488 internet: www.krones.com e-mail: info@krones.com

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DATASHEET8:ACCESSTMS7I/O Input/FestoOutputDevice manufacturedbySiemens

ACCESS S7-I/O Input/Output Device

TM

Applications Summary
The ACCESS electrical distribution communications system is designed to provide monitoring and control function. Low and medium voltage motor control, low and medium voltage switchgear, switchboards, and panelboards can all be connected to a data network through ACCESS compatible relays, trip units, meters and control devices. Within the ACCESS system, it is occasionally necessary to monitor or control power system elements that are not specifically designed for digital communications. The S7-I/O addressable relay provides that capability. The basic S7-I/O allows up to 14 digital inputs and 10 outputs in a small, easy to connect package. The S7-I/O capacity can be increased in blocks of 8, up to a total of 64 I/O points.

contactors, trip circuit breakers, provide remote indication of an event, or to communicate various levels of alarming to plant personnel.

Control power options include: 120/240 VAC or 24 VDC Standard DB9 connection port for connection to a RS-485 network

Construction
The ACCESS S7-I/O is built around the Siemens S7 micro PLC. It is preprogrammed for direct interface with the ACCESS system and is housed in a compact, fully self-contained assembly.

Mode of Operation
The S7-I/O device operates as a field device on the ACCESS communications system It has a digital address and is polled on a regular schedule by a supervisory computer. Speed of response depends on the number of field devices connected to the loop. The supervisory equipment can either be a host computer, a PC, a PLC or other compatible supervisory devices.

Features Summary

In combination with an ACCESS Power Meter, i.e. 9500 Power Meter, the S7-I/O can be used to provide an economical system for remote monitoring and control of a unit substation or similar piece of electrical distribution equipment. Protective and control relay operations could also be monitored via the discrete inputs available through the S7-I/O. Remote monitoring of any device equipped with an auxiliary contact (e.g. a molded case circuit breaker) is possible with the S7-I/O. Counter capability has been added to 8 of the discrete inputs allowing the S7I/O to track breaker or starter operations or count the pulsed output from a kWhr meter. Typical applications include monitoring transformer temperature relays and circuit breaker status (open or closed). The outputs can be used to close

The S7-I/O addressable relay is the link between the ACCESS electrical distribution communication system and the rest of your power system. The S7-I/O Status of the input and output states, provides the following features: 14 digital inputs and 10 digital outputs counter data and even log data is exchanged on a RS-485 serial link. on the base unit Connection to the ACCESS system is Expansion I/O modules, each containing 8 inputs or 8 outputs, can be added to the self-contained. base unit. A maximum of 5 expansion modules Expansion Modules can be connected to each base unit Analog input capability - blocks of 3 Expansion modules increase the number of inputs or outputs the S7-I/O device can up to a total of 12 inputs On board control power for expansion monitor and control. A maximum of five digital modules or 4 analog modules, each modules attached to the side of the other, can be used Counters on the first 8 inputs of the with one S7-I/O base module. When digital base unit and analog modules are used in Pulsed or latched digital states on outputs. Pulsed outputs can be used for breaker combination, there can be up to 5 digital and 2 analog modules. Expansion modules operation control include: Relay contact outputs that can be Digital Input (AC Power) manually controlled Digital Input (DC Power) Inputs can be dry contacts. Signal volt- Relay Output (AC Power) age is provided through the internal power Contact Output (DC Power) supply Analog Input

Global network of innovation

S7-I/O Technical Specifications Ordering Information

General Dimensions Digital Inputs Digital Outputs I/O Expansion Power Supply 24 VCD 120/240 VAC Counters Pulsed Outputs Environmental Operating Temperature Horizontal Vertical Operating Humidity 4.74w x 3.15h x 2.4d 14 Std. 10 Std. 40 Channels Max.

The order number is generated by inserting the selection code into the appropriate box. For additional information on ordering Siemens ACCESS products, please call 1-800-427-2256 or your SIEMENS representative.

0.5A 1.0A Yes Yes

Base Unit S7-I/O S7

Device

0-55C 0-45C 95% non-condensing

AC Control Power (85-269 VAC), Type 1 sinking DC inputs, relay outputs DC Control Power, Type 1 sinking DC inputs, sourcing transistor outputs

A C D C

Mounting Dimensions
4.74 in. (120.5 mm)

Module Type Expansion

2.4 in. (62 mm) 3.15 in. (80 mm)

Module
S7-EXP IA ID O A O D A

Input Module, AC Input Module, DC Output Module, Relay Output Output Module, DC *Analog Input Module

Base Unit

*Analog module only comes in DC input version. The order number is S7-EXP-IDA.

2.4 in. (62 mm)

Expansion Module

ISO 9002-94
Registration Cert# 002188

Siemens Energy & Automation, Inc.

Power Distribution Solutions 3333 Old Milton Parkway Alpharetta, GA 30005

For more information, call 1-800-427-2256 or visit www.sea.siemens.com/access

2002 Siemens Energy & Automation, Inc. All Rights Reserved

For Nearest Sales Office 1-800-964-4114

Siemens is a registered trademark of Siemens AG. Product names mentioned may be trademarks or registered trademarks of their respective companies. Specifications are subject to change without notice.

Order # PMSS-S7IOA-0802 082B&A

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