AUTOMATIC EDIBLE OIL CONVEYING & FILLING BY WEIGHT COMPUTERIZED SYSTEM

Guide Dr J L Juneja Principal Co - Guide Asst. Prof. D. M. Patel Mechatronics Dept. External - Guide Mr. Parag Taktawala Zenn Systems

NARENDRA A. PATEL (07CAD09)

U V PATEL COLLEGE OF ENGINEERING
GANPAT UNIVERSITY

What is Automation ?
Automation is a technology concerned with the application of mechanical, electronic and computer based systems to operate and control production.

What is Fixed Automation ?

A process using mechanized machinery to perform fixed and repetitive operations in order to produce a high volume of similar parts.

Fixed automation is a system in which the sequence of processing operations is fixed by the equipment configuration.

Each of operations in the sequence is usually simple involving perhaps a plain linear or rotational motion or an uncomplicated combination of the job typical features of fixed automation are as under.

High investment in general purpose equipment. High production rate. Relatively inflexible in a computing product variety.

The economic justification for fixed automation is found in products that are produced in very large qualities and at high production rates.

Case Study (Problem Definition)

Indian Solvent Industries Limited, Rajnandgaon, Chattisgrah. (Consultant : Zeen Systems, Ahmedabad) Present Method For Conveying and Filling Oil Drums In this industry presently they are doing manual work for conveying, filling and sealing of the Edible oil. They having much more constrained about the space as well as they want to increase the capacity of plant near to double in short span. They are also struggling due to more setup time and wastage of the oil in manual conveying, filling, packaging of the Edible oil. The present capacity of the plant is 100 tones/day. They want to increase the capacity of the plant up to 200 tones/day in same space. Now they are using 6 Machines for filling the oil. The machine will take approximately 20-30 second for filling of the one drum of the oil having capacity of 15 liter and setup time is approximately 5-8 second for each drum.

Objective
Indian Solvent Industries Limited, Rajnandgaon, Chattisgrah. (Consultant : Zeen Systems, Ahmedabad)

The objective of the dissertation work is to solve the above problem by automating the plant. By automation we will try to achieve the capacity of the plant up to 200 tones/day by automatic filling of the drum. The conveying system is accurate which results the minimum setup time and the loose or the wastage can be minimize by automating it.
This Automated system can. Make operation simpler Reduce Labor cost Reduce Lead Time Increase Production Rate Minimize Losses Improve overall Efficiency of the Plant

Literature Review
The literature review of the project work is divided in some suitable subdivision for the simplicity.

Filling Machine Pneumatic System Conveyor Other Components

I have been collected near about 80 articles and industrial documents from different journals of IEEE, ASME, Emerald etc. Out of that I have been covered some important and related articles in this presentation.

Filling Machine
Literature Review
1. Automatic Feed System Based On Machine Vision (Yan Sue, Ping Fue, Automation, Robotics and Vision, IEEE 2008) This paper include use of Sensors, computer system and integration of the all components along with image processing for exact location detection as well as mathematical modeling of the non linear calibration. 2. Automatic can-filling machinery (PIGMENT AND RESIN TECHNOLOGY, Emerald 1973) An automatic can-filling machine suitable for the paint, chemical and similar industries is to be marketed in the U.K. by Allied International Co. Ltd. This machine will accurately fill any size can from to 6 gallons automatically without spilling.

Filling Machine
Literature Review
3 Machinery - What's new in filling and labeling equipment (PIGMENT AND RESIN TECHNOLOGY, Emerald 1986 ) This paper include high speed filling equipments for paint and ink filling. It also include the concept of filling different size of drum along with the solution of problem which we face in that conditions.) 4. HIGH-INTEGRITY FILLING EQUIPMENT (Richard Simon, INDUSTRIAL LUBRICATION AND TRIBOLOGY, Emerald 1986) In this paper they covered complete filling machine along with conveying system with detailed components.

Filling Machine
Literature Review
5. Case Study - Unloading, feeding, conveying, storage, security sieving and drum filling of lactose (TECHNOLOGY FOR BULK SOLIDS HANDLING, More Contain - www.gericke.net ) This document include The application of unloading from big bags and pneumatically conveyed to a feeding hopper 6. Automatic Filling of Drums and Barrels at John Miller's (Scientific Lubrication , Emerald 1957) This document consist completely mechanical automated filling machine along with automatic lubricating properties of the machine.

Filling Machine
Literature Review
7. Route to an Automation (PIGMENT AND RESIN TECHNOLOGY, Emerald 1974) The operator is relieved of all heavy lifting and handling tasks, and a girl can fill containers up to 25 litre capacity with ease. 8. Name of the company which are making Filling Machine

FULLERWEIGHING SYSTEMS (Filling Machine Controller) Inline Filling Systems, Inc (Filling, caping and Labeling Machine Manufacturer - http://www.fillers.com/) Universal Filling Machine Company (Filler Manufacturer http://www.universalfilling.com )

Pneumatic System
Literature Review
1. A Force-Controlled Pneumatic Actuator (D. Ben-Dov and S. E. Salcudean, ROBOTICS AND AUTOMATION, IEEE 1995) This paper presents a new pneumatic actuator for applications requiring moderate, but accurate, force control, such flapper valves and low-friction cylinders. Its force is controlled by differential pressure. 2. Accurate Position Control of a Pneumatic Actuator Using On/Off Solenoid Valves (Robert B. van, Varseveld and Gary M. Bone, ROBOTICS AND AUTOMATION, IEEE 1997) A PID controller with added friction compensation and position feedforward was successfully implemented. A worst case steady state accuracy of 0.21mm was achieved with a rise time of 180ms for step inputs from 0.llmm to 64mm

Pneumatic System
Literature Review
3. Experimental Modeling of a Pneumatic System (Ahmet Zorlu, Can Ozsoy , IEEE 2003) Pneumatic system model consists of a combination of two pressure models which each of them has two inputs and one output, defining pressure changes in the chambers and a velocity model which has one input-one output, defining piston motion. 4. Pressure Regulator for Pneumatic Valve (So-Nam Yun', Young-Bog Ham, Jung-Ho Park, SICE-ICASE International Joint Conference, IEEE 2006) The pressure regulator which is used for controlling the reducing pressure in the piezoelectrically driven pneumatic valve has been studied. The pneumatic valve of this study object is 2-stage type and consists of a piezoelectric actuator, a controller, a poppet valve and a pressure regulator.

Pneumatic System
Literature Review
5. Pneumatic Fittings and Tubings (Dayco Products, Inc. - 1999) This document include the complete specification of all type of pneumatic fittings along with its dimension and also with pneumatic piping systems. 6. Illinois Took Works, Inc. (User Manuals, 2007 - www.paslode.com) This Document include completely instructions related to Air systems, its installation, loading, operation, maintenance and trouble shooting details.

Conveyor
Literature Review
1. High Speed Indexing Of A Chain Based Conveyor (A. D. Barton, P. L. Lewin and D. J. Brown, Conference FACTORY 2000, IEEE 1997) This paper describes the research being undertaken into the position control of high speed, chain based, indexing conveyors. The design and construction of the laboratory test rig is described and the performance results for the system operating under PID control are presented. Factors causing performance degradation are identified 2. Modeling of chain conveyors and their equipment interfaces (Ali K. Gunal, Shigeru Sadakane, Edward J. Williams, Winter Simulation Conference, IEEE 1996) In this paper, we first delineate the situations in which micromodeling of material-handling equipment is appropriate. We then present an overview of conveyor types and terminology. Next, we describe the challenges of modeling chain conveyors accurately, and our recommendations for meeting these challenges within the framework of typical modeling tools and simulation-study contexts.

Conveyor
Literature Review
3. Optimum Schedule Control of Convever Line (Sadamichi Mitsumori, Conference on Automation and Control IEEE 1969) In this paper, the work condition of a conveyer line having N work zones is mathematically expressed, and the optimization of the conveyer-in sequence is shown as maximizing the minimum work allowance for all work zones and all semi-finished articles. 4. Development of an Automatic Online Gap-Detection Scheme for Levitated Industrial Steel-Plate Conveyance System (Cheng-Tsung Liu, Senior Member, IEEE, Yung-Yi Yang, and Sheng-Yang Lin, IEEE 1996) For stabilizing the steel-plate conveyance process, efforts on providing appropriate extra electromagnetic forces at the run-outtable of a steel mill have been extensively investigated. Such objectives can be achieved by implementing fixed poles on top of the rollers at the run-out-table to provide the controllable 2-D lift and propulsive forces, and the movable steel plate can then be driven in the desired directions.

Load Cell
Literature Review 1. Measuring Object Location with Load Cells
(Nagy N. Bengiamin, Control System Magazine, IEEE 1987) This paper presents experimental results on the use of strain-gage load cells for the purpose of measuring the location of objects in the workspace of industrial robots. The measuring method and its realization steps are described. Data acquisition, signal conditioning, and interface with computers are addressed, and information about the hardware and software is given. Factors affecting the accuracy of the load cell method are discussed and recommendations are given.

Planning of Work
Literature Review Filling Machine Along With Title Selection Design, Modeling and Detailing Material Purchase, Mfg etc Performance and Testing Actual M/C Mfg With Trouble Shooting Design, Modeling and Detailing Material Purchase, Mfg etc With Trouble Shooting Preparation of Report April Mar Sept Aug Nov Feb Dec Jan May July Oct

Prototype Fab.
Experimental Work Actual Machine Fab Testing Conveyor Conveyor Fab. Testing Documentation

TENTATIVE ACTION PLAN

2008

2009

References
1. Automatic Feed System Based On Machine Vision (Yan Sue, Ping Fue,Automation, Robotics and Vision, IEEE 2008) 2. Accurate Position Control of a Pneumatic Actuator Using On/Off Solenoid Valves (Robert B. van, Varseveld and Gary M. Bone, ROBOTICS AND AUTOMATION, IEEE 1997) 3. Machinery - What's new in filling and labeling equipment (PIGMENT AND RESIN TECHNOLOGY, Emerald 1986 ) 4. HIGH-INTEGRITY FILLING EQUIPMENT (Richard Simon, INDUSTRIAL LUBRICATION AND TRIBOLOGY, Emerald 1986) 5. Case Study - Unloading, feeding, conveying, storage, security sieving and drum filling of lactose (TECHNOLOGY FOR BULK SOLIDS HANDLING, More Contain - www.gericke.net ) 6. Illinois Took Works, Inc. (User Manuals, 2007 - www.paslode.com) 7. Route to an Automation (PIGMENT AND RESIN TECHNOLOGY, Emerald 1974)

References
8. A Force-Controlled Pneumatic Actuator (D. Ben-Dov and S. E. Salcudean, ROBOTICS AND AUTOMATION, IEEE 1995) 9. Accurate Position Control of a Pneumatic Actuator Using On/Off Solenoid Valves
(Robert B. van, Varseveld and Gary M. Bone, Robotics And Automation, IEEE 1997)

10. Experimental Modeling of a Pneumatic System (Ahmet Zorlu, Can Ozsoy , IEEE 2003) 11. Pressure Regulator for Pneumatic Valve (So-Nam Yun', Young-Bog Ham, Jung-Ho Park, SICE-ICASE International Joint Conference, IEEE 2006) 12. Pneumatic Fittings and Tubings (Dayco Products, Inc. 1999) 13. Illinois Took Works, Inc. (User Manuals, 2007 - www.paslode.com) 14. High Speed Indexing Of A Chain Based Conveyor (A. D. Barton, P. L. Lewin and D. J. Brown, Conference - FACTORY 2000, IEEE 1997)

References
15. Modeling of chain conveyors and their equipment interfaces (Ali K. Gunal, Shigeru Sadakane, Edward J. Williams, Winter Simulation Conference, IEEE 1996) 16. Optimum Schedule Control of Convever Line (Sadamichi Mitsumori, Conference on Automation and Control IEEE 1969) 17. Development of an Automatic Online Gap-Detection Scheme for Levitated Industrial Steel-Plate Conveyance System (Cheng-Tsung Liu, Senior Member, IEEE, Yung-Yi Yang, and Sheng-Yang Lin, IEEE 1996) 18. Measuring Object Location with Load Cells (Nagy N. Bengiamin, Control System Magazine, IEEE 1987) 19. http://www.fillers.com 20. www.universalfilling.com 21. User manuals, Air Max India Limited, Ahmedabad