PACKING LINE CONTROL

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA

IN MECHANICAL ENGINEERING {FOUNDRY}

SUBMITTED BY:

1. R. VINOTH KUMAR
2. L. PRAMOSH
3. C. N. SHANKARAN

4. S. SOLOMAN RAJ
5. K. NEDUMARAN
6. S. SARAVANAN

Under guidance of
Mr. V.K.RAJENDRAN, M.E

OCTOBER 2007.
DEPARTMENT OF MECHANICAL ENGINEERING{FOUNDRY}

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 602 103

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 602 103

BONAFIDE CERTIFICATE
This is to certify that this Project work on

PACKING LINE CONTROL

submitted by . Reg. No.

in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING{FOUNDRY}
This is the bonafide record of work carried out by him under our supervision
during the year 2007
Submitted for the Viva-voce exam held on ..

HEAD OF THE DEPARTMENT

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMEN
T

ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement
and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., for presenting his felicitations on us.
We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.,
for guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Engineering (FOUNDRY) Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS

Chapter No.

TITLE

1.

INTRODUCTION

2.

SYNOPSIS

3.

CONSTRUCTION

4.

WORKING PRINCIPLE

5.

MECHANICAL ASSEMBLY DIAGRAM

6.

ELECTRICAL CIRCUIT DETAILS

7.

ELECTRICAL WIRING DIAGRAM

8.

COST ESTIMATION

9.

CONCLUSION

10.

BIBILOGRAPHY

INTRODUCTION

INTRODUCTION

In our technical education the project work plays a major role. Every
students is put in to simulated life particularly where the student required to
bring his knowledge, skill and experience of the project work.

It helps how to evolve specifications under given constrains by

systematic approach to the problem a construct a work device. Project work
thus integrates various skills and knowledge attainment during study and
gives orientation towards application.

As the students solve the various problems exposed by the project

work, the students get the confidence to overcome such problems in the
future life. It helps in expanding the thinking and alternatives for future
applications.

SYNOPSIS

SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select this project work is to acquire practical knowledge in the
field of automation using Microcontroller.
We selected MATERIAL CONVEYING & COUNTING CONTROL
SYSTEM as our project work and we used principles of Mechatronics in

developing this project. This project consist of two conveyors, the first
conveyor (feeding conveyor) is used to feed the job and it is

mounted

above the second conveyor(packing conveyor) .The packing conveyor

feeds the packing box .The jobs are feeded from the feeding conveyor to
the packing conveyor through the IR sensor which is used to count the job
while feeding to the packing box.
When the switch is pressed, the packing box slides on the packing
conveyor and the packing conveyor is stopped by the magnetic sensor at
packing station. The jobs are fed by the feeding conveyor to the packing
box through the IR sensor which sends the signal to the Microcontroller. The
Microcontroller stops the feeding conveyor after the counter reaches the
preset value and the same process is repeated again.
.

CONSTRUCTION

CONSTRUCTION DETAILS
This project consists of following units
1.Controller System
2.Job feeding conveyor unit
3.Packing box feeding conveyor unit
4.IR sensor unit
5.magnetic sensor
1. MICRO CONTROLLER SYSTEM:
This system monitors the engine condition by using PIC 16F870 (28
pin IC Package) micro controller. The pin details of micro controller are
shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

the LDR sensor is connected to PORTA (i.e)pin no 2&5.The pin no 1 is

RESET switch..The bulbs are connected to port B .

2.JOB FEEDING CONVEYOR;

This conveyor is used to feed the jobs continuously towards the packing
conveyor through the IR sensor.The jobs are conveyed through the belt
conveyor .The conveyor belt is rotated between the driving and driven
pulley by the A.C .Synchronous motor.The A.C .Synchronous motor and the
conveyor belt assembly is mounted

separately on a wooden board .The

height of the job feeding conveyor unit is arranged slightly above the
packing conveyor unit.The job feeding conveyor is shown in fig.

ASSEMBLY DIAGRAM OF BELT CONVEYOR MECHANISM

3.PACKING BOX FEEDING CONVEYOR UNIT;

This conveyor feeds the packing box. The packing boxes are conveyed
through the belt conveyor. The conveyor belt is rotated between the driving
and driven pulley by the A.C. Synchronous motor. A wooden stage is
arranged below the nylon belt in order to avoid the slack. A plastic channel is
arranged on the stage to guide the packingbox.A magnetic sensor is fitted at
the side of the plastic channel.The whole arrangement is shown in figure.

PACKING BOX FEEDING CONVEYOR

STAGE

1. Pulley and Belt

Here there are two Pulleys, called as driving Pulley and driven Pulley is
rotated freely on the shaft which is held in bracket.
The belt is made of nylon materials, which is red in color. The width and
length of the belt is cut from the main sheet and its ends are pasted.

DRIVEN PULLEY

DRIVE PULLEY

MOUNTING BRACKETS FOR MOTOR AND PULLEYS:

The motor and Pulley mounting brackets are made from 2 mm M.S.
sheet .The sheet is cut and bend to the required shape and drilled as per the
dimensions given in the sketch, the brackets can be placed and screwed on
the novopan The sheet is cut and bends to the required to shape as shown in
fig.

MOTOR MOUNTING BRACKET

DRIVEN PULLEY MOUNTING BRACKET

BELT TIGHTENING MECHANISM:

The driving Pulley is mounted in fixed position and the driven pulley
is mounted at a distance so that the belt can be stretched enough by using
tension mechanism. Here two nuts are used. One is used for adjusting the
tension and the other is used as a lock nut.

BELT TENSION MECHANISM

4.IR SENSOR UNIT;

To count the jobs for the packing an I.R. sensor is used..The I.R. sensor is
fixed at the side of the cross rail which is held in taper between the two
conveyors. The jobs are passed through the IR transmitter &receiver and is
shown in fig.

TRANSMITTER AND RECEIVER

RECEIVER
TRANSMITTER

4.MAGNETIC SENSOR;
The magnetic sensor is fixed at the side of the plastic channel and it is used
to stop the packing box at the packing station. The magnetic sensor is shown
in fig.

MAGNETIC SENSOR

WORKING
PRINCIPLE

WORKING PRINCIPLE
This project consists of two sections.
1. Component feeding section (upper rail)
2. Packing box feeding section (lower rail)

ASSEMBLY DIAGRAM OF BELT CONVEYOR MECHANISM

1.Component feeding section:

TO start the operation press the ON switch in the switch box and the
components are fed on the job feeding conveyor. These jobs are conveyed
from the job feeding conveyor to the packing box conveyor through the
cross rail. When the jobs are passed through the IR sensor which send the
signal to the input of the Microcontroller. The counter in the Microcontroller
counted the IR signal and gives output when the counted value reached the
preset number in the Controller counter.

PACKING BOX FEEDING CONVEYOR

STAGE

2.Packing box feeding section:

When the components are counted up to the setting limit, Microcontroller
stops the upper rail motor to OFF position and switch ON the lower rail
motor. Hence the component filled packing box shifted, and the next empty
packing box is comes to the packing station. A magnetic sensor is fixed in
the plastic channel at the packing station. The magnetic sensor sends signal
to the Microcontroller input by the magnet which is fitted on the packing
box. The Micro controller switched OFF the supply the lower rail motor
when the magnet sends the signal to Microcontroller input. Again the same
process is repeated and packing boxes are filled and shifted with required
components.

MECHANICAL
ASSEMBLY AND
SPARE PARTS
DRAWINGS

MECHANICAL ASSEMBLY AND SPARE PARTS

DRAWINGS

1. CONVEYOR ASSEMBLY UNIT

2. DC MOTOR MOUNTING PLATE

3. DRIVEN PULLEY MOUNTING PLATE

4. DRIVEN PULLEY HOLDING BRACKET

5. DRIVING AND DRIVEN PULLEY

6. BELT TIGHTENING MECHANISM

7. IR SENSOR HOLDING BRACKET

ASSEMBLY DIAGRAM OF BELT CONVEYOR MECHANISM

PACKING BOX FEEDING CONVEYOR

STAGE

DRIVEN PULLEY

DRIVE PULLEY

MOTOR MOUNTING BRACKET

DRIVEN PULLEY MOUNTING BRACKET

BELT TENSION MECHANISM

ELECTRICAL
CIRCUIT DETAILS

ELECTRICAL CIRCUIT DETAIL

1. Micro controller system

2. Interface Circuit
3. Power supply (230V A.C. to 12 V and 5V DC)
MICRO CONTROLLER SYSTEM:
This system monitors the engine condition by using PIC 16F870 (28
pin IC Package) micro controller. The pin details of micro controller are
shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

the LDR sensor is connected to PORTA (i.e)pin no 2&5.The pin no 1 is

RESET switch..The bulbs are connected to port B .

POWER SUPPLY UNIT

INTRODUCTION:
All the electronic components starting from diode to Intel ICs only
work with a DC supply ranging from +5V to +12V. We are utilizing for the
same, the cheapest and commonly available energy source of 230V-50Hz
and stepping down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer,
it can either be stepped down or stepped up depending on the value of DC
needed. In our circuit the transformer of 230V/15-0-15V is used to perform
the step down operation where a 230V AC appears as 15V AC across the
secondary winding. Apart from stepping down voltages, it gives isolation
between the power source and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a
solid state diode. Diode has the property that will let the electron flow easily
in one direction at proper biasing condition. As AC is applied to the diode,
electrons only flow when the anode and cathode is negative. Reversing the
polarity of voltage will not permit electron flow. A commonly used circuit

for supplying large amounts of DCpower is the bridge rectifier. A bridge

rectifier of four diodes (4 x IN4007) are used to achieve full wave
rectification. Two diodes will conduct during the negative cycle and the
other two will conduct during the positive half cycle, and only one diode
conducts. At the same time one of the other two diodes conducts for the
negative voltage that is applied from the bottom winding due to the forward
bias for that diode. In this circuit due to positive half cycle D1 & D2 will
conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of
100Hz. Since each alteration produces a resulting output pulse, frequency =
2 x 50 Hz. The output obtained is not a pure DC and therefore filtration has
to be done.
The DC voltage appearing across the output terminals of the bridge
rectifier will be somewhat less than 90% of the applied rms value. Normally
one alteration of the input voltage will reverse the polarities. Opposite ends
of the transformer will therefore always be 180 degree out of phase with
each other. For a positive cycle, two diodes are connected to the positive
voltage at the top winding.

FILTERING CIRCUIT:

Filter circuits which is usually capacitor acting as a surge arrester

always follow the rectifier unit. This capacitor is also called as a decoupling
capacitor or a bypassing capacitor, is used not only to short the ripple with
frequency of 120Hz to ground but also to leave the frequency of the DC to
appear at the output. A load resistor R1 is connected so that a reference to
the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as
a low pass filter, i.e. it passes only low frequency signals and bypasses high
frequency signals. The load resistor should be 1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V

: for maintaining the stability of the voltage at the load side.

0.1f

: for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR POWER SUPPLY

STEP DOWN

TRANSFORMER

BRIDGE

POSITIVE

RECTIFIER

CHARGE
CAPACITOR

5V
REGULATOR

MOTHER
BOARD

VOLTAGE REGULATOR:

DISPLAY
BOARD

12V
REGULATOR

RELAY

The voltage regulators play an important role in any power supply

unit. The primary purpose of a regulator is to aid the rectifier and filter
circuit in providing a constant DC voltage to the device. Power supplies
without regulators have an inherent problem of changing DC voltage values
due to variations in the load or due to fluctuations in the AC linear voltage.
With a regulator connected to the DC output, the voltage can be maintained
within a close tolerant region of the desired output. IC7812 and 7912 is
used in this project for providing +12V and 12V DC supply.
SPECIFICATION:
Resistors R1 and R2 maintain line load regulation.
At the secondary side of the transformer, applied vlltage = 15V
Conducting drop across the diodes = 2 * 0.6 = 1.2V
Without capacitor:
Vavg = (15-1.2)V = 13.8c pulsating DC
Frequency = 100Hz
With capacitor:
V = Vavg * 1.414 (form factor) = 19.51V
Frequency = 0 Hz
with 7812 voltage regulator:
V0 = +12V

with 7912 voltage regulator: V0 = -12V

c) 5 to 12V interface circuit:

Here we have to drive the 12V DC load. The 5V signal from the PIC
16F870 micro-controller is fed into the input of interface circuit. TIP 120
Darlington transistor is used here for high speed switching purpose and the
Diode IN 4007 is for the safety of TIP 120 transistor during the collapsing of
magnetic field from the 12 DC motor coil. This interface circuit is shown in
fig.

5V TO 12V INTERFACE CIRCUIT

COST ESTIMATION

COST ESTIMATION

1. Microprocessor control Board ----------------------

2000.00

2. DC. Motor (2 Nos)--------------------

1500.00

3. Belt (2 No)---------------------------------------------

200.00

4. Motor & pulley mounting Brackets----------------

100.00

5. Driver & Driven Pulley------------------------------

300.00

6. Novo pan plywood-----------------------------------

200.00

7. Magnetic sensor--------------------------------------

100.00

8. IR sensor -----------------------------------------------

300.00

9. Push button, Wires, & Jack Connectors------------

200.00

10.Belt supporting guides (Plastic) ---------------------

300.00

11.Project Report work----------------------------------

700.00
_______________

Total

5900.00
_______________

CONCLUSION

CONCLUSION

We make this project entirely different from other projects. Since

concepts involved in our project is entirely different that a single unit is used
to various purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of pneumatic system

and how automation can be effectively done with the help of pneumatic
system.
It is concluded that any automation system can be done with the help
of micro controller & pneumatic system.
We have successfully completed the project work on using pneumatic
control at our Institute.
By doing this project work, we understood the working principle and
uses of various controls, switches, relays etc.
It will be of no doubt that pneumatic system will be an integrated part
of any automation process in any industry.
Once again we express our sincere thanks to our staff members.

BIBILOGRAPHY

BIBILOGRAPHY

1. Low cost automation with pneumatics

2. Electro pneumatics

FESTO
FESTO

3. Hydraulics & pneumatics for Power Production -

Harry L Stewart

4. Basic pneumatics

- FESTO

5. www.google.com
6. Workshop Technology

- Hajra Chowdry

7. Production Technology

-R.S. Khurmi