INJECTION MOULDING PROTECTION

SYSTEM CONTROLLER
YOGAVINOOTHON A/L VATHIVELLU
BEKC
B011210246
SUPERVISOR : DR. AHMAD ZAKI BIN HJ SHUKOR
PANEL 1: DR.MARIAM BINTI MD GHAZALY
PANEL 2: PN NUR MAISARAH BT MOHD SOBRAN

MOTIVATION

Plastics is an important element to fulfils our life.

An injection moulding machine produces plastic components.

Chiller removes heat from the liquid which produces in the

moulding part.

PROBLEM STATEMENT

When the heater is off, the workers forget to turn off the chiller
and this causes the electricity bill to increase.

If the chiller doesnt supply cool water to the machine, the

moulding will be affected and will incur high cost to replace it.

When system have problem and stop, the workers unable to

determine whether machine is working or not. This will cause
the daily production to reduce.

OBJECTIVE
To design a system that will make the :
Heater stop when the water not cool enough or the water
stops flowing to the machine
Send an email alert to mobile phone if the heater stop
operating.
Chiller to shut down after 2 minutes the heater is off.
Bypass system that will make all system to run as usual if
this new system have problem.

SCOPE
Applied at injection section in the company
Applied between the chiller and mounding machine
Required 1x 1 meter to be fixed on the wall
A 3 phase supply for the chiller and for the heater
A smartphone to receive the email alert from the system
5

PROJECT BACKGROUND
Injection Moulding Protection System Controller is a system that
controls the heater and the chiller to protect the injection moulding
machine.
If no water flow detected, heater will turned off.
If the temperature of the water is hot, the heater will turned off.
This system control the chiller by shutting it down if the heater is
off for more than two minutes.
If the system shuts down the heater, the Arduino system will send an
email to the engineers.
6

VIDEO OF THE PROJECT OVERVIEW

Play
here

LITERATURE REVIEW

Table comparison
of the journal

LITERATURE REVIEW

Table comparison
of the journal

FIRST OBJECTIVE
Check manually the chiller and heater in good
condition.
The heater and the chiller have to be turn on by
manually but only the chiller will be operate.
The chiller will operate for only 2 minutes and in
that duration the flow switch and the thermostat
will turn on.
This will make the heater to turn on and operate
as normal.
If the flow switch does not detect the water flow
or the thermostat does not sense the set
temperature, the heater will off and will sent an
email to the engineers.
10

HARDWARE FOR
FIRST OBJECTIVE

ARDUINO AND ETHERNET SHIELD

THERMOSTAT
11

CONTACTOR

THERMOCOUPLE

FLOW SWITCH

SECOND OBJECTIVE FLOW

CHART
This system will operate only if the protection
system have problem.
If the system have problem, the protection
should be off by manually.
After this process, the chiller will
automatically on for 2 minutes and this bypass
system should be on by manually.
After this process the chiller and the heater will
operate without the protection system until the
protection system is been repaired.
12

HARDWARE FOR SECOND

OBJECTIVE

Circuit Breaker

13

Timing Relay

MAIN CIRCUIT
Heater Main
Supply

Chiller Main
Supply

The main power supply is connected to

the contactor and to the bypass MCB.
Connect the supply from the contactor
and the bypass MCB to the machine.
The neutral part is taken direct from the
main neutral and connected to the.
The main circuit is fully connected.

14

Heaters

Chiller

CONTROLLED CIRCUIT

15

PRELIMINARY SIMULATION
RESULT

16

NORMAL OFF CONDITION

PRELIMINARY SIMULATION
RESULT

17

NORMAL ON CONDITION

PRELIMINARY SIMULATION
RESULT

MALFUNCTION OF FLOW SWITCH

18

PRELIMINARY SIMULATION
RESULT

AFTER 2 MINUTES OF FLOW SWITCH MALFUNCTION

19

PRELIMINARY SIMULATION
RESULT

MALFUNCTION OF THERMOSTAT
20

PRELIMINARY SIMULATION
RESULT

AFTER 2 MINUTES OF THERMOSTAT MALFUNCTION

21

PRELIMINARY HARDWARE
DRAWING

22

CONCLUSION AND
FUTURE WORK
As a conclusion, both 1st and 2nd objective simulation been
carried out in this FYP 1.
The analysis for the expected error are discussed.
The task that will be carried out in FYP 2 is to create a full
hardware system.

23

REFERENCES
1)

Oyetunji, Development of small injection moulding machine for forming small plastic articles for smallscale industries, Journal of Engineering Science and Technology, (2010).
2) Himanshu Arora, Dhirendra Pratap Singh and Sunil Kumar, Parametric effect during plastic injection
moulding process on polypropylene material International Journal of Science, Technology & Management,
(2015).
3) Nik Mizamzul Mehat, Shahrul Kamaruddin and Abdul Rahim Othman, Modeling and analysis of injection
moulding process parameters for plastic gear industry application.
[Online].Available:http://www.hindawi.com/journals/isrn/2013
4) Jui Ming Liang and Pei Jen WangSelf-learning control for injection moulding based on neural networks
optimization Journal of Injection Molding Technology, (2002).
5) Rashi A.Yadav, S.V. Joshi, N.K.Kamble, Recent Methods for Optimization of Plastic Injection Molding
Process International Journal of Scientific and Engineering Research, (2012).
6) B.H Min, A study on quality monitoring of injection moulded parts Journal of Materials Processing
Technology (2003).
7) Wen-Chin Chen, Gong Loung Fu, Pei Hao Tai and Wei-Jaw Deng. Process parameter optimization for mimo
plastic injection moulding via soft computing Department of Mechanical Engineering, Minghsin University
of Science and Technology, (2004).
8) Kwong, C.K. and Smith, G.F. A computational system for process design of injection moulding,
International Journal of Advanced Manufacturing Technology, (1998).
9) Niebel, B.W. Draper, A.B and Wysk, R.A. Modern manufacturing process engineering, Mcgraw-Hill Book
Company, (1989).
24 10) Simonson, Engineering heat transfer, Mc-Graw-Hill Book Company, New York, (1997).

THANK YOU
25