Automatic condiment delivery system

MEHS-SEPM3

Created by :
Edgars Sala Stefan Bogdan Zoltan Balint Dmitrij Lukjanec Marius Barbieru

Automatic condiment delivery system

MEHS-SEPM3

Supervisors : Created by :
Peter Olsen Bo Leander Gylling Edgars Sala Stefan Bogdan

Automatic condiment delivery system

MEHS-SEPM3

Klaus Bahner Morten Carter

Zoltan Balint Dmitrij Lukjanec Marius Barbieru

Table of Contents
Created by :.................................................................................................... 1 Supervisors : Table of Contents Created by : 2 .......................................................................................... 3

List of figures and tables.......................................................................................... 5 Executive summary.................................................................................................. 6 1. Introduction ....................................................................................................... 10 2. Solution ............................................................................................................. 11 2. 1 Brainstorms.................................................................................................... 11 2.2 Criteria............................................................................................................ 17 2.3 Decision matrix............................................................................................... 19 2.4 Summary of calculations.................................................................................20 2.5 Suitable solution.............................................................................................. 20 3. Conclusion.......................................................................................................... 20 4. Task allocation:................................................................................................... 21 5. List of references................................................................................................ 23 6. Appendix........................................................................................................... 25 Created by :.................................................................................................. 25 6.1 Project description........................................................................................... 26 6.1.1 Background .............................................................................................. 26 6.1.2 Purpose .................................................................................................... 27 6.1.3 Problem formulation..................................................................................27

Automatic condiment delivery system

MEHS-SEPM3

6.1.4 Delimitations:............................................................................................ 27 6.1.5.Choice of model and method procedure...................................................28 6.1.6 Time schedule ..........................................................29

6.2 Process Report................................................................................................ 31 6.2.1 Reflections through the project making process.......................................31 6.2.2 Initial project description...........................................................................31 6.2.2.1. Initial project start:.............................................................................31 6.2.2.2. Teamwork:......................................................................................... 31 6.2.2.3. The result: ......................................................................................... 32 6.2.3. Daily log: ................................................................................................. 32 6.2.4. Meetings with supervisors........................................................................33 6.3 Calculations..................................................................................................... 33 6.3.1 Preliminary calculations ...........................................................................33 6.3.2 Conveyor and container ...........................................................................35 6.3.3 Lifting mechanism .................................................................................... 37 6.3.4 Driving the trolley mechanism .................................................................38 6.3.5 Cutting machine ....................................................................................... 39 6.3.6 Air pressure for the suction cups ..............................................................40 6.4 Choice of materials.......................................................................................... 41 6.5 Control box...................................................................................................... 44 6.5.1 Control box operation sequence ..............................................................44 6.5.2 Control box diagrams................................................................................46

Automatic condiment delivery system

MEHS-SEPM3

6.5.2.1. Conveyor motor diagram:..................................................................46 .......................................................................................................................... 46 6.5.2.2. Cutting blades diagram:.....................................................................47 6.5.2.3. Driving trolley diagram:.....................................................................48 6.5.2.4. Lifting device diagram:.......................................................................49 6.6 Cost calculation............................................................................................... 50 6.7 Data sheets..................................................................................................... 51 6.7.1 Spur gears................................................................................................. 51 6.7.2 Bevel gears............................................................................................... 52 6.7.3 Aluminum type 6....................................................................................... 52 6.7.4 Stainless steel........................................................................................... 53 6.7.5 Air compressor.......................................................................................... 53 6.7.6 Laser beam trip sensor..............................................................................54 6.7.7 Ultrasonic sensor....................................................................................... 55 6.7.8 Suction system Anver parts.......................................................................56 6.8 Design drawings.............................................................................................. 57

List of figures and tables

Figure 1 Idea 1....................................................................................................... 12 Figure 2 idea 2........................................................................................................ 13 Figure 3 idea 3........................................................................................................ 14 Figure 4 idea 4........................................................................................................ 15 Figure 5 idea 5........................................................................................................ 16

Automatic condiment delivery system

MEHS-SEPM3

Figure 6 idea 6........................................................................................................ 17 Figure 7 decision matrix......................................................................................... 19 Figure 8 Summary of calculations..........................................................................20 Figure 9 task allocation table.................................................................................22 Figure 10 task allocation chart...............................................................................22 Figure 11 time schedule diagram...........................................................................29 Figure 12 Time schedule Gantt chart.....................................................................30 Figure 13 Conveyor and container calculations......................................................37 Figure 14 Lifting device calculations......................................................................37 Figure 15 Driving mechanism calculations.............................................................38 Figure 16 Cutting machine calculations..................................................................39 Figure 17 Pressure for suction cups calculations....................................................40 Figure 18 Cost calculations..................................................................................... 50 Figure 19 Drawings structure................................................................................. 57

Executive summary
We decided to design a system / machine that will replace the Coax manufactured vacuum pumps because they are slow, unreliable and they need constant refilling and supervision. By doing that we intend to save the company time, money and to eliminate another risk of occurring errors. An automated system will eliminate the human factor and will add reliability to the whole line. We are positive that after studying our report you will find in it a real and consistent idea that will later on, become a sure replacement of the existing machine used by Danpo. In the executive summary, we will guide you through our means and purpose of the present project. We will be doing that by answering 3 main questions:

Automatic condiment delivery system

MEHS-SEPM3

1. What are the primary problems and purpose?

At the moment, the main drawback of the existing machine is that it needs refilling at rather short intervals of time, in some cases less than 5 minutes. That means time, effort and constant supervision given by the worker responsible for the production line. The line has a length of about 50 meters and uses around 6 different machines that have to be operated and supervised by the worker. It is very often the case when the line will need 2 or even 3 of these vacuum machines at a time. Sometimes, when 2 or 3 of these machines are used on the same line, the worker has to literally run between machines along the production line because the time that is spent at one machine can be also the time that one of this vacuum pump machines empties up, and there can be 3 of those emptying up at the same time. Translating all this in man-hours it means that, only because of this machine, the line needs another worker that has to fill them up and get new bag every time the cart empties.

Automatic condiment delivery system

MEHS-SEPM3

The primary purpose was to see if this idea can actually be made and used in real-life situations. So we thought of a real-life problematic situation, that has a strong practical influence on the productivity of a line. Our project will relive the worker of that line of the stress of loading the condiments every 5 minutes or even less. And most of all, we found a problem, that had to involve our knowledge of our last semester courses, including mechanics, machine elements ,machine dimensioning , dynamics , material science and electrics.

2. What is the solution?

The main idea of the solution is to make a combination of processes that reduce time consumption in loading the needed condiment in the production line. Also, the idea had to be full-proofed in different factors so that it would be useful and productive. Our device is intended to resolve the problem of loading the bags of condiment in the machine, without stress and without constant human interference. We intend to make the process automatic by installing an automated arm that is loading, cutting and discharging the bags of condiments. A robot arm will be designed by us to load the condiments automatically to the line of production. It will also discard the empty bag.

Automatic condiment delivery system

MEHS-SEPM3

All the worker has to do is bring a cart with bags every hour or more, instead of cutting and loading each bag every 4, 5 minutes.

3. What actions have been taken?

In order to find the correct and the best solution, we first had to make multiple choices, which mostly differed in the design of the construction. The principal of the mechanical part for each choice differed but we had to choose one that would get the job done in any circumstances. Of course our solution had to comply with the needs given by the problem and the criteria given by the actual present situation so researching had to be done to find out how the device would be useful in mechanics, production, environment and logistics, which later turned out to be a problem, because each solution had advantages and disadvantages We were lucky because we didnt have to define a user group and so on, because we focused on a real problem that a factory actually has and therefore the user group is restricted to that factory and maybe some others that use that same layout for production.

Automatic condiment delivery system

MEHS-SEPM3

1. Introduction
At the moment the meat processing factory, Danpo, in Farre is using 3 lines of production where they use different machines, including some that spread condiments on the meat products. These condiment powdering machines have to be fed condiments by other machines that are placed beside the main production lines. Now, Danpo is using some vacuum machines from COAX, that from the ergonomics and production point of view tend to be slow and not reliable. A machine like that basically consists of a stainless steel bowl and a vacuum pump that sucks the condiment, which is in a powder shape, from the bowl, into a plastic tube and inside the machine that spreads it on the meat. The bowl is designed to be at a level that will allow the worker to fill it up manually.

Automatic condiment delivery system

MEHS-SEPM3

The main disadvantage is that they have to be filled up every 5 to 10 minutes, depending on the type of the condiment used. For example when using bread crumbs the bowl will empty in 5 minutes. That means that the worker has to be there every 5 minutes to cut a bag of condiments, empty it in the machine and discard the empty bag. We decided to design a system / machine that will replace the Coax manufactured vacuum pumps because they are slow, unreliable and they need constant refilling and supervision. An automated system will eliminate the human factor and will add reliability to the whole line. We are positive that after studying our report you will find in it a real and consistent idea that will later on, become a sure replacement of the existing machine used by Danpo.

2. Solution
2. 1 Brainstorms
We designed several solutions to the problem, using the camp fire procedure, all of whom seemed reliable enough, so we started going into detail of each of them individually so that we could see which one is the most suitable. We each studied the actual problem and tried to come up with the best solution for fixing it .We tried to take in consideration the costs, the manufacturing difficulty, the installation ways, and the actual benefit of the end result for each idea.

2.1.1 Idea 1
The condiment bag will be pushed out of the pile by a hydraulic arm, the narrowing sides will make sure that the bag doesnt miss the conveyor and the horizontal rod will correct the position of the bag. Knife will slice the bag on top and it will be flipped over by a hydraulic mechanism. After the bag is emptied it will be blown away to the garbage box.

Automatic condiment delivery system

MEHS-SEPM3

Figure 1 Idea 1

2.1.2 Idea 2
The main idea is to use a simple , one axis robotic arm that is supported and guided by a straight I beam .the cart will be placed longitudinally so the bags are just in one line aligned with the beam. The beam is about 2 meters high so the arm can come on top of the bags, select one, pierce it with the 4 side claws, lift it and deliver it to the cutter. After that the arm is delivering the empty bag in the garbage bin that is situated near the cart.

Automatic condiment delivery system

MEHS-SEPM3

Figure 2 idea 2

2.1.3 Idea 3

The condiment bags are lifted up by grip arm. The arm drives the bag to the conveyor and cuts the bag on the way. Arms height is adjusted by a hydraulic mechanism. The condiment is spilled on the conveyor and is taken away to the needed place. The empty bag is taken away by the arm

Automatic condiment delivery system

MEHS-SEPM3

Figure 3 idea 3

2.1.4 Idea 4
The worker will load up a big stack of condiment bags before the lines starts working; they will be stacked in 4-5 rows. Then with the help of the hydraulic hammer the top layer will be pushed so that the first bag from the batch is pushed in the spring activated holders. The knife will slice the bottom part of the bag so that the condiments will fall on the conveyor which will take them to the spreading machine

Automatic condiment delivery system

MEHS-SEPM3

Figure 4 idea 4

2.1.5 Idea 5
This idea had a very good impact on us, just by the fact that it has a reduced cost and a simple principle. The condiment bags will be pushed out of the pile by a hydraulic arm. The bags that get on the 2 sided conveyors will get cut in the middle and all of the content will just drain on the second conveyor and from there, to the collector. The bags will not go further than the mini conveyor, witch, after a few seconds, after the bag is completely empty; will move in the side, throwing the bag away.

Automatic condiment delivery system

MEHS-SEPM3

Figure 5 idea 5

2.1.6 Idea 6
The main idea is to use a simple , one axis robotic arm that is supported and guided by a straight I beam .the cart will be placed longitudinally so the bags are just in one line aliened with the beam. The beam is about 2 meters high so the arm can come on top of the bags, select one, get the bag with 4 suction coups on the sides, lift it and deliver it to the cutter. The advantage of this idea comparing to the idea #2 is that the suction coups will not pierce the bag so there is no risk of the bag breaking before it is on top of the cutting blades. After that the arm is delivering the empty bag in the garbage bin that is situated near the cart.

Automatic condiment delivery system

MEHS-SEPM3

Figure 6 idea 6

2.2 Criteria
1. Technical requirements show whether the machine element parts are complex and whether its easy or not to put them together in the assembly. Meaning that we were looking for such kind of design, where the parts are simple and can be easily modified individually for our particular design. 2. Load capacity shows how much and where the load can become a problem for the respective solution 3. Costs show us how expensive the device will be. As we wanted to make it as less expensive as possible, we had to define simple designs with cheap materials and at the same point maintain the strength of the system.

Automatic condiment delivery system

MEHS-SEPM3

4. Reliability shows more or less if the device is capable enough to satisfy our requirements as well as defining if it has a large probability to fail. 5. Installation difficulty shows how complex is the installment of the device to the car. It depended whether it had to involve more than one person and whether the customer needs help from a professional. 6. Cleanliness tells whether or not the device is leaving a lot of dirt and materials during use or after use. 7. Usage difficulty tells whether or not it is difficult to use the device, if it requires some extra knowledge or just careful using of the device. We used a marking system from 0 to 5 , 0 meaning that the respective criteria is not met .5 means that the criteria is met in a very good manner so the solution is the best concerning that particular criteria.

2.3 Decision matrix

Idea 1 Selection Criteria Weig ht 15% 10% 15% 20% 20% 10% 10% Rati ng 3 1 4 3 4 0 4 2 No

Idea 2 Weight Weighte Rati ed d score ng score 0.45 0.1 0.6 0.6 0.8 0 0.4 2.95 3 No 2 2 2 2 3 5 4 0.3 0.2 0.3 0.4 0.6 0.5 0.4 2.7

Idea 3 Rati ng 2 1 2 2 2 3 3 6 No Weighte d score 0.3 0.1 0.3 0.4 0.4 0.3 0.3 2.1

Idea 4 Weight Ratin ed g score 3 1 3 2 3 1 3 5 No 0.45 0.1 0.45 0.4 0.6 0.1 0.3 2.4

Idea 5 Weight Ratin ed g score 2 4 4 2 2 2 2 4 No 0.3 0.4 0.6 0.4 0.4 0.2 0.2 2.5

Idea 6 Ratin g 3 3 3 3 3 5 3 1 Develop Weighte d score 0.45 0.3 0.45 0.6 0.6 0.5 0.3 3.2

Technical requirements Load capacity Costs Reliability Installation difficulty Cleanliness Usage difficulty
Total Score Rank Continue?
Figure 7 decision matrix

2.4 Summary of calculations 2.5 Suitable solution

We chose the arm that can move on a vertical axis and it can be transported longitudinally along a beam that is situated on top of the whole assembly. The arm is hovering on top of the cart that is filled with bags of condiment, it picks up the bag using the suction cup and then it goes in the position to cut the bag .There the arm is lowering to reach the cutting blades. After that the arm is just going on top of the garbage bin and releasing the empty bag. By doing that we managed to come up with a very good solution that will fix the problems that Danpo has now. Our solution is quite cheap and easy to assemble and we think that it would bring a lot of plus in the production line and by doing that, also in the economics of the company. All the calculations that we made led us to results that permitted us to choose cheap materials and permitted us to design it easy to assemble and maintain.

3. Conclusion
The overall project result is supposed to give a valid solution to our chosen problem. It also had to show what kind of problem are we solving, who is the beneficiary, and what was our process in reaching the final goal of the project. During the project period, we were going into detail of the problem as well as the solution itself, so that we could understand it and assess it. You will be able to see in the report that the group has tried their best to solve the problem, as during the period we have faced some design problems that had to be reviewed. The project itself should help you understand what kind of problem did we think of, where did we look for necessary information, how the solution helps with solving the problem and so on. The appendix should help You understand the details of our solution, including the calculations, materials and the drawings with some detailed explanations of how the whole device is built and how its working. All in all, the project period this semester was found quite difficult as when going more and more into detail, more and more problems have arisen.

Figure 8 Summary of calculations

We think that we were true to the lines of the time schedule and that we did manage to finish the report on time with all the sufficient information that we could find and all the explanations needed in order to assess whether or not we accomplished our task.

4. Task allocation:
Zoly: He has been working mostly on the design. Zoly has great skills in Autodesk so we let him to use it. So we can choose him as implementerof the group: he is constructing all our group ideas in 3D and we can choose the best option. Dmitrij: Dmitrij has been working with the calculations the most. Also he has been doing 3D modeling, teamwork, had great ideas. We can call him as specialistof our group: he can start calculating and try to find the best solution by himself. Edgars: We can choose him like a group leader or coordinator. Edgars is always trying to chose the best solution and divide all the works, which should do what. He is self-confident and he can make the final decision if something is not clear. Marius: He is the team worker of the group. Marius made helped with writing the project, made sketches, some 3D modeling and research. He is diplomatic: listens and do what is necessary for the team and project. Bogdan: Bogdan is team worker of the group too. He made most part of writing and research, made some sketches and 3D modeling too. Bogdan listens what is necessary to do and he works for the team to make the project as good as possible.

We think that our group is quite good team workers. Everybody knows what they need to do; everybody helps to each other and tries to find the best solutions. Everyone had some ideas which were developed or not. Our group is diplomatic, nobody makes the solution before talking and voting which solution is the best.

Writing Bogdan Zoly Marius Edgars Dima Total 40 15 20 15 10 100

Calculation s 10 15 10 30 35 100

3D Modeling 15 30 15 20 20 100

Drawings 10 30 25 15 20 100

Research 25 10 30 20 15 100

Total 100 100 100 100 100 Complet e

Figure 9 task allocation table

Figure 10 task allocation chart

5. List of references

1. Prices for cost calculations, and information on various products: http://www.alibaba.com/ 2. Information on motors http://www.electricmotorwarehouse.com/ http://www.inverterdrive.com/ 3. Gears, V-Pulleys, V-Belts: http://www.hpcgears.com/ , http://www.qtcgears.com/ 4. Bearings: http://www.skf.com/ 5. Air pump, suction coups, hoses, : http://www.anver.com/ 6. Formulas, beam profiles and values from: Mechanical and metal trades handbook. 7. Pictures and general information about various things: http://en.wikipedia.org/ 8. Information about various coefficients of friction: http://www.roymech.co.uk/Useful_Tables/Tribology/co_of_frict.htm 9. Online calculator : http://www.tribology-abc.com

6. Appendix

Created by :
Edgars Sala Stefan Bogdan Zoltan Balint Dmitrij Lukjanec Marius Barbieru

6.1 Project description

6.1.1 Background
At the moment the meat processing factory, Danpo, in Farre is using 3 lines of production where they use different machines, including some that spread condiments on the meat products. These condiment powdering machines have to be fed condiments by other machines that are placed beside the main production lines. Now, Danpo is using some vacuum machines from COAX, that from the ergonomics and production point of view tend to be slow and not reliable. A machine like that basically consists of a stainless steel bowl and a vacuum pump that sucks the condiment, with is in a powder shape, from the bowl, into a plastic tube and inside the machine that spreads it on the meat. The bowl is designed to be at a level that will allow the worker to fill it up manually. The main disadvantage is that they have to be filled up every 5 to 10 minutes, depending on the type of the condiment used. For example when using bread crumbs the bowl will empty in 5 minutes. That means that the worker has to be there every 5 minutes to cut a bag of condiments, empty it in the machine and discard the empty bag.

6.1.2 Purpose
We decided to design a system / machine that will replace the Coax manufactured vacuum pumps because they are slow, unreliable and they need constant refilling and supervision. By doing that we intend to save the company time, money and to eliminate another risk of occurring errors. An automated system will eliminate the human factor and will add reliability to the whole line. We are positive that after studying our report you will find in it a real and consistent idea that will later on, become a sure replacement of the existing machine used by Danpo.

6.1.3 Problem formulation.

As mentioned before, the main drawback of the existing machine is that it needs refilling at rather short intervals of time, in some cases less then 5 minutes. That means time, effort and constant supervision given by the worker responsible for the production line. The line has a length of about 50 meters and uses around 6 different machines that have to be operated and supervised by the worker. It is very often the case when the line will need 2 or even 3 of these vacuum machines at a time. Sometimes, when 2 or 3 of these machines are used on the same line, the worker has to literally run between machines along the production line because the time that is spent at one machine can be also the time that one of this vacuum pump machines empties up, and there can be 3 of those emptying up at the same time. Translating all this in man-hours it means that, only because of this machine, the line needs another worker that has to fill them up and get new bag every time the cart empties.

6.1.4 Delimitations:
First of all we need to mention that we only plan on presenting a design of the system and not an actual prototype or scale model. Due to the lack of founds, time and limited support from the company we can only take measurements, sketch and later on design the new system. The project report will not contain a market research or any consistent information regarding value chain management, means of marketing and so on because this will be somewhat out of our syllabus at the moment. Because we plan to design a machine that s supposed to work automatically we are aware that there will be need for some sensors , and CNC programming and off course an IT infrastructure covering the automated response of the machine. We will provide a basic control box concerning the engine starting diagrams and sensor connection but we will not provide the CNC program. We will add as appendices some part drawings and layouts of the machine but we will not focus on presenting every part, instead we will show the most important assemblies and most important parts , concerning the ability to function and reliability of the machine. We also did not focus on calculating the lifetime, cycle of oil changes, cleaning periods. Also we did not focus too much on the effect on the environment that the machine will have.

The belt that we use will be a purchased one and we used a simple representation of it to do the calculations. We did not do any experiments and tried to give more importance to the arm of the machine.

6.1.5.Choice of model and method procedure

We will go to Danpo, Farre and take measurements of the production line .We basically need just the height and position where the condiments have to be fed to the machine. Plus we may need to measure the maximum area that we can occupy with the new system. We will use decision matrixes concerning the whole design and some of the main functions of the machine .This way every member of the group will be involved and we will get the best result using a grading system closely linked to the desired criteria.

What: automatic cutting and emptying of bags. Why: It covers our field of study and is a real life situation. Who: Edgars Sioning and Sala is responsible for finding a suitable solution.
Automatic condiment delivery system.

When: The deadline is 16.12.2011

Which: We cover the mechanical Engineering related problems. How: Measurements from factory, machine dimensioning and design.

6.1.6 Time schedule

Figure 11 time schedule diagram

Figure 12 Time schedule Gantt chart

6.2 Process Report

6.2.1 Reflections through the project making process
Our project started with research and measurements done in Danpo, and then we proceeded to idea generation and decision taking. After that we did calculations and based on the calculation outcome we revised some dimensions and materials. The designing involved finding the correct elements, such as various beams, platforms, cylinders, engines and their material definitions. Every time, calculations were made in order to see which design would be the most suitable and could hold the most load. Facing all the problems, we learned that every step in the design had to be made precise, as it was one of the most important factors of our project. All in all, we were able to find a pretty good solution to a very big problem that Danpo is facing at the moment,

6.2.2 Initial project description

6.2.2.1. Initial project start:

We chose the arm that can move on a vertical axis and it can be transported longitudinally along a beam that is situated on top of the whole assembly. The arm is hovering on top of the cart that is filled with bags of condiment, it picks up the bag using the suction cup and then it goes in the position to cut the bag .There the arm is lowering to reach the cutting blades. After that the arm is just going on top of the garbage bin and releasing the empty bag. By doing that we managed to come up with a very good solution that will fix the problems that Danpo has now.

6.2.2.2. Teamwork:
Each group member felt responsible enough to come for the meetings and each of them tried their best to solve the problem and make the perfect solution . At the beginning, each of us chose what they will do so that we could start going into detail of each section. The group was able to co-operate and debate with each other considering almost each section, so that the work would be at its best. Arguing between the group members was also a good experience, as each time we argued, we found new ideas and some things that we might be missing at that time.

6.2.2.3. The result:

The overall project result was rather good as we believe that we managed to go into detail and solve the problem. Facing some major as well as minor problems, we think that the group was capable enough to progress each day in advancing the final goal of the project. In the end, we had all the information necessary to explain how the device works and to show its benefits in real-life situations.

6.2.3. Daily log:

2011/12/03

This was our first group meeting and most of the time we have dedicated to brainstorming and choosing the best model/method of doing certain crucial things in the project. Idea descriptions with free-hand sketches were made and were evaluated on the selection criteria chart.

2011/12/04

This day was devoted to research and choosing the standard parts. Field research also took place during this day. Particular work fields were divided upon the group members.
2011/12/05

We continued with the sketching and started doing the needed calculations and focused on the choice of material. Some additional brainstorming was made.
2011/12/06

A pre-version of the 3d model has been made. Started research on engines which we will need for our delivery system.
2011/12/07

Adjustments and modifications have been made to the model. Got rid of most of the drawbacks.
2011/12/08

During this day, we decided to finish some drawings and started checking our entire 3D model in order to be sure that everything will work. After making sure that the model will hold everything and will be in operating condition we made some additional stress analysis in Inventor.
2011/12/09

Started putting together appendix and the project description. Started doing drawings of the parts, which we knew for sure would not need any modifications. Continued with the drawings. Additional stress analyses were made.

2011/12/11

This day we were still working with project writing, drawings and layouts .Made corrections to the project: reducing weight, re-modeling some parts.
2011/12/12

Working on drawings. Still putting together the appendix and the project description.
2011/12/13

Making all the required diagrams and tables. Finishing the appendix and the project description
2011/12/14

Making the finishing touches

2011/12/15

Checking everything for the final time and printing all the pages
2011/12/16

Handing in the project

6.2.4. Meetings with supervisors

We had opportunities for meetings with our supervisors, that was really helpful as we had some major problems, which we couldnt solve without our supervisor help. Basically it was enough for us to solve all the problems that were arisen during the period. Peter Olsen and Bo Leander Gylling helped with the calculations while Klaus Bahner and Morten Carter helped us with dynamic calculations and electrical control box concerns.

6.3 Calculations
6.3.1 Preliminary calculations

6.3.2 Conveyor and container

Figure 13 Conveyor and container calculations

6.3.3 Lifting mechanism

Figure 14 Lifting device calculations

6.3.4 Driving the trolley mechanism

Figure 15 Driving mechanism calculations

6.3.5 Cutting machine

Figure 16 Cutting machine calculations

6.3.6 Air pressure for the suction cups

Figure 17 Pressure for suction cups calculations

6.4 Choice of materials

Platform holding the 2 motors.

We decided to simplify the placement of the forces and the supports by placing 4 forces of 200 N that would be corresponding to the weight on each rope and one 200 N force for the weight of the 2 motors .The supports are corresponding to the 6 legs that are connected to the wheels on top that drive the platform. We have the same idea for another platform that holds the cutting device .That platform is the same material and width as this one but the weight of the cutting device is a lot smaller .This is why we decided to skip the stress calculations for that smaller one. We simulated a stress analysis in AutoCAD Inventor and this is what we got: We got a 85 MPa general Von Misses stress so we can chose Aluminum type 6.

The displacement of the plate is maximum 0.06 mm which is certainly acceptable.

Support beam for the platform.

We decided to simplify the

placement of the forces and the supports by placing 1 force of 350 N that would be corresponding to the weight of the whole

platform (1000 N) divided by 3 because there are 3 of those beams working in parallel .The supports that we chose is fixed supports on the sides because the beam is welded to the frame. We simulated a stress analysis in AutoCAD Inventor and this is what we got: We got a 44 MPa general Von Misses stress so we can chose Aluminum type 6

The

displacement 0.12

is mm

maximum

which is certainly acceptable.

Beam for driving the platform.

We decided to simplify the placement of the forces and the supports by placing 6 forces of

200 N that would be corresponding to the weight of the whole platform (1200 N) divided by 6 because there are 6 wheels working in parallel .The supports that we chose is fixed supports on the sides because the beam is welded to the supports. We simulated a stress analysis in AutoCAD Inventor and this is what we got: We got a 114 MPa general Von Misses stress so we can chose Aluminum type 6

The which

displacement is

is

maximum 0.125 mm certainly acceptable.

Support for beam.

We decided to simplify the placement of the forces and the supports by placing 6 forces of

200 N that would be corresponding to the weight of the whole platform (1200 N) divided by 6 because there are 6 support legs .The supports that we chose are the bottom of the legs. We simulated a stress analysis in AutoCAD Inventor and this is what we got: We got a 116 MPa general Von Misses stress so we can chose Aluminum type 6

The displacement is maximum 0.86 mm which is certainly acceptable.

6.5 Control box

6.5.1 Control box operation sequence
Conveyor: K1 is a manual NO switch used to load the condiment in the production line manually. K2 is a NO automatic relay switch, which is activated by the sensor placed on the machine when the level of the condiment in the production line is lower than a certain level K3 is a NC automatic relay switch, which is deactivated by the same sensor when the level of the condiment in the production line is over another lever higher than the previous one K4 is a manual NC emergency stop switch. Cutting blades: K5 is a NO automatic relay switch, which is activated by a sensor, when the bag is lowered to a certain height. Following that a CNC will tell the rotation direction and the distance travelled. The cutting machine must make a trip forward and a trip backwards to cut the bag properly. K6 is a NC automatic relay switch, which is activated by a sensor, when there is no bag at a certain height.

K7 is a manual NC emergency switch. Lifting: K8 and K9 will be controlled by a CNC program that will be able to read if the bag is connected or not in the suction cups. The CNC will also be able to reverse the motor rotating direction in order to lower the bag. K10 is a manual NC emergency stop switch. Driving: K11 is a NO automatic relay switch, which is activated by a sensor, when a bag is lifted to a certain level. CNC will take over from now and decide the rotation direction and the distance travelled. K12 is a NC automatic relay switch, which is activated by a sensor, when a bag is dropped in the trash bin The trolley will be stationed at the position of the trash bin until a NO is activated. . K13 is a manual NC emergency stop switch.

6.5.2 Control box diagrams

6.5.2.1. Conveyor motor diagram:

6.5.2.2. Cutting blades diagram:

6.5.2.3. Driving trolley diagram:

6.5.2.4. Lifting device diagram:

6.6 Cost calculation

For cost calculations we had in consideration the materials used and the extra cost for production, buying equipment, man-hour costs, design costs, assembly costs , transportation. For material cost we had to make a compromise by rounding up the density of the material and the price/kg .We did that to simplify the table and make it easy to follow. We chose average density of the materials as 5800 because we use stainless steel, plastic and aluminum and that number is something between these material densities. For the price/kg we followed the same logic so we decided on an average price/kg of 1 Euro/kg.

Figure 18 Cost calculations

6.7 Data sheets

6.7.1 Spur gears

6.7.2 Bevel gears

6.7.3 Aluminum type 6

6.7.4 Stainless steel

6.7.5 Air compressor

6.7.6 Laser beam trip sensor

6.7.7 Ultrasonic sensor

6.7.8 Suction system Anver parts

6.8 Design drawings

Figure 19 Drawings structure