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Journal of Engineering Research and Applied Science
Available at www.journaleras.com
Volume 1(2), December 2012, pp 98-106
ISSN 2147-3471 © 2012 ENT Ltd
1. Introduction
Design has been performed continuously for phases, methods and techniques have been developed
centuries. It was only by the middle of the 20th (Evduomwan NFO et al. 1996, Finger S and Dixon
century when design an intense human activity JR 1989). According to Ullman (1992), the product
became the focus point of controller and its design process consists of six phases (see on Fig. 1).
techniques. Design philosophies, models, design
Wani and Gandhi (1999) developed a maintainability factors are applied to map the degree of facilitation
index for mechanical systems. Maintainability is an among them. The maintainability index is determined
important aspect of the life-cycle of a product and by the permanent of a matrix that has as elements
plays significant role during its service period. It these weight factors. Permanent is a standard matrix
facilitates the performance of various maintenance function used in combinatorial mathematics and it is
activities, such as inspection, repair, replacement and similar to determinant without the alternating signs.
fault diagnosis that must be performed in quick Permanent matrix takes into account all the possible
possible time but also with optimal resources. Weight combinations among the attributes.
98
Journal of Engineering Research and Applied Science Volume 1(2),Dec. 2012, pp 98-106
Byun and Elsayed (1996) presented a producibility g100 g_1 to impart flavor (TSE, 1982). However,
index vector, which provides a quantified measure with the increased demand and advancement in
that takes into account both the quality and cost manufacturing technology, ayran is now produced
requirements for production. The producibility is from homogenized and pasteurized (90–95°C, 5–10
defined as a measure of the desirability of a product minute) milk using prophylactic acid cultures which
and the process design in terms of quality and increase consistency and reduce serum separation. In
manufacturing cost. the industrial manufacture of ayran, milk with
adjusted dry matter content is fermented using
Moulianitis et al. (2002) introduced a mechatronics exopolysaccharide producing cultures and the
index that includes three elements namely, viscous curd obtained is further diluted with salt-
intelligence, flexibility and complexity which containing water. Ayran is separated from other
characterize most of the mechatronics products. The fermented milk beverages being a yoghurt drink with
attributes of every element is analyzed and salt and without any fruit flavoring. The Shelf life of
formulated. The intelligence level of a system is ayran is reported as 10–15 days at 48C by the
determined by its control functions and a structure manufacturers. Ayran is prone to textural instability
for information processing of mechatronics systems during storage due to its low pH as other acidic milk
is used to model intelligence. A technique to measure beverages. Main textural defects in ayran are low
the flexibility of manufacturing systems was used for viscosity and serum separation during storage. Ayran
the estimation of the flexibility of a mechatronic should have a high enough viscosity for good mouth
product. The various types of flexibility were feel. Ayran sold at retail in Turkey was found to have
classified in three main categories, namely: product up to 30% serum separation (unpublished data).
flexibility, operation flexibility and capacity Nowadays Ayran is also directly made from yoghurt
flexibility. The complexity was modeled using seven bacterium into mixing bowls. Yoghurt bacterium,
elements. Weighted mean used to formulate this water and salt definite ratio mixed into mixing bowl
index and the maximum value of this index indicates aided with mixer. Due to ayran manufacturing there
the best solution. are many difficulties and negativities being done
mixing ratio of each elements and ambiance
Vitturi (2004) studied on the implementation of PC- factors.Also, ambiance and conditions of the mixing
based automation systems has been favoured by the bowl is suitable that ayran making cool place, pure
recent considerable diffusion of field networks, and clean bowl etc.
which allow for the realization of manufacturer
independent configurations. In this paper, after a
In the first part of this paper, describe the general
general description of the PC-based automation
structure of the PLC-based automation systems and
systems and he consider, as an example of
mechatronics design structure. The results obtained
application, the automation of blowing machines
from a practical application designed to investigate
producing PET bottles. Vitturi’s research results have
the possibility of adopting a PLC based automation
shown, as far as the tests executed, that the
system and Ayran mixing and filling system as a
performances of the PC-based automation system are
replacement of the traditional one semi automatic
better than those of the traditional one.According to
manuel system was presented. After that a
Buur (1990), the trade-in of increasing the
mechatronics design application of PLC based
intelligence and flexibility is the increase of
system called Ayran Production and Filling System.
complexity, which is likely to cause difficulties in
Finally the results obtained have been compared with
designing the product and in the interface between
those of an equivalent machine equipped with a
the product and the use.
traditional Ayran filling system based on manual
pneumatic circuit works.
1.1. Introduction of The Factory Automation of
Ayran Process
2. Ayran Filling System Modeling
Ayran is a word that comes from Turkish literature
and in all languages spelling same in Turkish. Ayran
The Ayran automation project was aimed at studying
is a yoghurt drink produced in Turkey. Ayran is
the possibility, availability and economical usage of
traditionally manufactured by addition of water at a
adopting a PLC based system for producing ayran, in
level of 30–50% and salt at a maximum level of 1%
alternative to that in use based on a traditional semi
to yoghurt. Salt is added at a maximum level of 1
automatic manual filling machining system. The kind
of Ayran filling machines consider in this paper are manuel system is not available for mixing the
used to fill Ayran to pet glass and closed the mouth materials which are base of Ayran. That’s why more
of the glass. At a maximum rate of semi automatic- efficient and useful mechatronics design on Ayran
manuel filling machine 950 glass per hour. The semi making and mixing process detail structure was
automatic manual system is only fills the Ayran or worked (Fig.2).
other liquid drinks in to pet glass. Semi automatic-
The features that made of Ayran like yoghurt Also the Ayran automation system was equipped
bacterium, water, salt and milk etc., tanks and mixing with UPS and relief valves in order to safety react to
unit design is an important part of the unit. There are power and pneumatic failures and attacks. When
3 material bowl/tank have been in design for these such events or conditions occur, a suitable recovery
materials. Outlets of each tank have connecting the task is immediately started on PLC programming
electrical motor. When the sensor started the electric aided with PC which is still working since supplied
motor, concerned outlet opened and material forward by power supply.
the mixing tank. Level control duties have to be
controlled by sensors aided software (Fig.3).
Preliminary material architecture defined on Table 1. mixing and filling automation system. And also the
Table 1 describes the set of equipments and devices total costs of the equipments can be described.
likely to be formed and employed in the Ayran
TOTAL 18.000
Other Equipments
TOTAL 1.000
101
Journal of Engineering Research and Applied Science Volume 1(2),Dec. 2012, pp 98-106
In WinCC library there are many application written application details and PLC programming output
those programming languages which are used make a signals was determined. After that designated and
new project for industrial controls. When starting made tags for the system used with WinCC library,
Ayran mixing application with WinCC the design center and tags editor as can be seen on Fig. 5.
S7 224 PLC CPU was the communicated WinCC machine. In semi automatic manual Ayran filling
aided with PcAccess software because of WinCC V6 machine which controlled under human operator time
is not allows S7 224 PLC CPU access and data and operation features by timer and manual
communicate without base software. When uploaded counter of the system were measured.
the software PC to PLC CPU, WinCC control center
worked properly. WinCC started with the cycling and The first round is the analysis of the system
monitoring application on PC monitor. WinCC is performances and their comparison with those of
critical operation on this process. traditional semi automatic system. Those
performances figures and data have to be confirmed
3. Results and Test Performed by experimental measurements. For these reasons it
was possible to measure delays, outputs and
The tests described have been performed during the equipment behaviors by software and PLC.
suitable conditions of the Ayran mixing and filling
103
Journal of Engineering Research and Applied Science Volume 1(2),Dec. 2012, pp 98-106
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1
10
0
In 1 Hour
4. Conclusions
This paper emphasized the opportunities, challenges of this work. Other traditional and semi automatic
and consideration the PLC based automation systems filling systems are not adequate to the firm which
for Ayran drink. Practical measurements have been works on liquid drinks. Also PLC based system as a
carried out on semi automatic Ayran filling machine. valid alternative that currently in used systems. Semi
After calculations on PLC controlled system, automatic systems can not mixing capability. They
software design and WinCC project synchronized the have only one tank for filling. But PLC based system
equipments properly. The measurements and has 3 material tank and mixing bowl. This has been
software outputs showed us as far as the test flexibility feature to the PLC based systems. Finally,
executed, that the performances and production validity of the measurements and software signal
capabilities of SCADA software aided PLC based curve tables has been confirmed by the obtained in
Ayran mixing and filling system is the best solution practice that an analysis may be used to the behavior
of the Ayran drink filling systems.