CHAPTER 1: INTRODUCTION 1.

1 INTRODUCTION

Automation is become more important nowadays. The definition of automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the industry, automation is very important as it help increase productivity rate and greatly reduce operating time and also work handling time significantly. Automation always has been use for replacing human operator in a job or tasks that very dangerous or required monotonous work. Automation machine usually consists the combination of mechanical part and electrical part. Since automation system is a synergetic combination of electronic, mechanical design and computer software, our group would be responsible for the redesign the filling system for automation upgrading and dealing with the conceptual design. We will develop the mechanical part and the housing for the system and covers all the mechanical aspect in our machine.

Mechanical Engineering is an engineering discipline that involves the application of principles of physics and chemistry for analysis, design, manufacturing and maintenance of various systems. Our mechanical system consists of following component:

Structure that consist of several straight and bent strips of selected material such as iron that have different sizes welded together for the assembly of our machine.

Screw that will be to hold objects together and to position objects. Conveyer

Nozzle directed the flow of the sauce into the bottle. Pneumatic cylinder to generate pressure for the sauce to flow smoothly into the bottle.

Tank that use to store the sauce.

Our project is based on industrial visit to Perniagaan Rohaya & Abu Bakar factory that was located at Bukit Mertajam, Seberang Perai Tengah, and P. Pinang during the semester break. It is a factory that well known in north region of Malaysia in producing sauce such as chili sauce, ketchup sauce and soy sauce for the market in in Kedah, Penang and Perlis. The reason of our visit to their factory is to know in more detail how the process of bottled up the sauce is done at the factory.

Based on current condition, the process of bottling the sauce is done manually. The empty bottle will be hold by the worker and then the nozzle will be open to allow the sauce to flow into the bottle. When the bottle is almost been filled up by the sauce, the worker will close the nozzle to stop the process. The bottle then will go to capping station. In other word, the process of filling the sauce into the bottle is done manually but thus based on our researched, it will encounter a few problems. With the process is done manually, the productivity level is fully depends on mental and physical state of the worker. When the worker is at his/her best condition, the process will be smooth and fast but when the workers get tired, he/she need to rest and this slow down the productivity rate. Thus, the number of bottle that has been filling up with sauce is not consistent.

Next, another problem is the possibilities of the worker to do mistake when he/she tired are high. When the worker is exhausted, he/she may wrongly fill the amount of volume of the sauce into the bottle. Furthermore, the worker only use they eyes to observe the volume of sauce been bottled up and this will make the possibilities of the volume of sauce not consistent is high. This also will make the volume of the sauce that been fill into the bottle not accurate to the desired standard volume wanted by the company. Moreover, each worker can only filling up one bottle at a one time. So the amount of sauce can be bottled up at certain time is limited. Automation machine is found as the best solution to solve the entire above problem. Therefore, based on the problem that been faced by the Perniagaan Rohaya & Abu Bakar factory, we decided to build an automated sauce filling machine as our final year project. This machine is intended to improve their productivity rates and implement the use of automation in real industry. 1.2
I.

OBJECTIVE OF THE PROJECT

To redesign the mechanical structure in automated filling machine system for automation upgrading

II.

To applied our knowledge and technical skills in making an automated machine for the use in real industry

III. IV.

To redesign the filling machine that low in cost but still efficient in produce product. To minimize the human error and increase the production rate in the Perniagaan Rohaya & Abu Bakar factory.

1.3

SCOPE OF THE PROJECT Our scope is to covers the mechanical component that will be used, selecting

material and design the concept of the automated filling machine. Our aim is to develop the conceptual design of the automated filling machine that meet the requirement of our objectives.

1.4

LIMITATION OF PROJECT Our main focus for Automated Sauce Filling Machine project is to build and

produce the machine that will exactly have the same function with other filling machine in market but with lower budget in order to help SMI (Small Medium Industry) by making their work process become easier and slowly increase their production rate.

CHAPTER 2: LITERATURE REVIEW 2.1 Project

Requirement

Component review of the project Pneumatic cylinder NO 1 2 3 4 5 6 3/2 Valve 5/2 Valve Air unit Air regulator Single acting cylinder Double acting cylinder ITEM PURPOSE To control cylinder To control cylinder To supply air source To filter the air from water To move parts To move parts

Mechanical part NO 1 2 3 4 5 6 7 8 ITEM Stainless steel Zink/ Plate Aluminium profile Aluminium pipes Stainless steel blade Roller Bushing Flexible hose Plastic To make the tank To make the frame of the machine To transfer the sauce To stir the sauce in tank To support station To smooth the movement To guide the sauce in filler line To seal the cap PURPOSE

PROJECT SPECIFICATIONS
Machine Name Product Number of station Operating mode Incoming supply Incoming air pressure Operating voltage Controller Alarm Indicator Automated Sauce Filling Machine Sauce Bottling 1 station Fully automated and manual mode Single phase 220~240 Vac, 50/60 Hz 5~6 bar 24Vdc PLC Omron Buzzer Red Stop Yellow Error Green - Run

SAFETY FEATURES Machine is required to have safety features in order to protect the machine and the operator from damage and harm.

The standard safety features for the machine: 1. EMERGENCY STOP BUTTON SWITCH

2.

3.

4.

5.

To shut-down the power supply to the machine whenever faulty occurs To ensure the safety of the whole system from damage and prevent any serious personnel injury BUZZER - It will produce siren or warning sound to alert the operator if the machine had failure while its operation EARTHLING - To connect of the exposed conductive part of an installation to the main earth terminal of the installation CIRCUIT BREAKER - Device such as Electric Circuit Breaker (ELCB) and Miniature Circuit Breaker (MCB) are used to give the protection to the machine system if any short circuit and current leakage occur suddenly. TOWER LAMP RED indicates the machine STOP GREEN indicates the machine is RUNNING mode YELLOW indicates the EMERGENCY and follower by the BUZZER

CHAPTER 3: RESEARCH METHODOLOGY 3.1 3.2 FLOW CHART DESIGN OF THE PROJECT

Phases, tasks, methods, techniques and tools CHAPTER 4: PROTOTYPE/PRODUCT DEVELOPMENT 4.1 STAGE 1: PROJECT RESEARCH We do some research study, for every combination method proposed such as approach used, technical skills, method used, equipment used and the general materials used. We also provide equations for calculating the reliability parameters that will be presented along with components reliability estimates. We will be analyzing the accuracy of our machine components and we will also perform it to investigate their effect on the overall system reliability levels. In order to validate the results obtained from the proposed methods, comparisons will be made to the results

from the existing available systems reliability estimation methods such as from the commercial reliability estimation filling machine and the results obtained from the field data measurement technique. This study also will review various type of filling machine that later will be used as case studies to test and validate the proposed method. In order to get the best result, comparison will be made between our machine and other filling machine in term of cost, system and others. Accurate analysis techniques will be proposed and conducted to improve the critical areas of our machine process systems reliability. Cost and benefit analysis that considers the cost of outage and the cost of Automated Sauce Filling Machine will also be performed to ensure that the user or company will satisfies the performance of our machine at a right cost. Our research study will conclude with recommendations on the benefits of our machine in terms of systems topology, configuration and lastly the cost with respect to load criticality and applications.

4.2

STAGE 2: COMPONENT AND MATERIAL SELECTION The second stage is one of the important stages after project research. This is because in this stage I have to select the component and material very specifically. After doing my project research, I was selecting the component that will used to build the line follower robot.

4.3

STAGE 3: SURVEY PRICE OF COMPONENT

In order to purchase any components from suppliers, we practiced the auditing method, as follow: Determined the basic requirement for each part in the project design. Listed down all the required component

Contact a few vendors for information and specification on the required parts. Obtain the quotation from suppliers. Compare specifications, prices, reliability of the parts and the delivery periods when purchasing parts and equipment. Discuss with group members, supervisor and the suppliers on the part to be purchased.

4.4

STAGE 4: DESIGN AND SKETCH

This stage is the most important part because this will show all the components that is needed or not for the project. The design is always change based on the target budget. I have to sketch the design concept on a plane paper. The design is based on the actual filling machine but I reduce the dimension into smaller size. The design need to be simple to reduce the cost for fabrication. The idea of the design was referring from the internet and the final year project senior students. After I have finished the design, I need to do some calculation to find the suitable pneumatic cylinder diameter. This is because I need to find the suitable force for the pneumatic cylinder to move the conveyor belt correctly. Calculation for the design: 4.5 4.6 4.7 STAGE 5: FINAL ASSEMBLY STAGE 6: FINAL TEST LIMITATION AND PROBLEM OF MECHANICAL DESIGN OF FILLING

MACHINE PROJECT
Any project will have a certain amount of problems, so we need a plan that should be made as a backup countermeasure. Many of the problems that we have expected from the machine are listed together with the appropriate solution.

No. 1

Instrument/station Filling process using pump

Silo for sauce Storage

Problem Expensive due to the specification for food use The sauce might get clocked

Solution Can be replaced with the injection type of filling Add additional heating element even there is stir in the silo

Stage 1: Project Research Stage 2: Component and Material Selection Stage 3: Survey Price of Component Stage 4: Design and Sketch Stage 5: Final Assembly Stage 6: Final Test

CHAPTER 5: TESTING AND RESULTS 5.1 TESTING

Testing the pressure Testing the movement precision Testing the movement of component Testing the filling of nozzle to bottle

5.2

RESULT

Hardware

CHAPTER 6: CONCLUSION AND RECOMMENDATION 6.1 CONCLUSION

Briefly, this project includes pneumatic, programmable logic controller, electrical wiring, electrical motor and even mechanical installation & alignments. For that, we could gain knowledge in these areas as we practice and learnt with it. Moreover, it gives a foresight view on the automation used in the industries. Student could also bring up with new ideas to overcome ways which are not appropriately used in this Sauce Filing Machine. As a consequence, it motivated the student to design something which will be useful in the automation area or in any fields in future.

Also, this project teaches us that even the simplest thing could be hard to handle and runs according to the desires such as when the filling station occur error and failed to operate smoothly. This project could give the desired requirements and ability to the student based on how this project has been done and completed.

6.2

RECOMMENDATION

Redesign with more simple design Upgrade the design with more suitable component for full functionality 6.3 BENEFIT FOR THE FUTURE DEVELOPMENT AND RESEARCH

This project will create an automated filling machine that will greatly help the small medium industry by applying the machine into real industry. The main benefits of this project can be stated briefly as follows:
I. This machine offer the similar performance like others filling machine at market but the cost is cheaper thus it suitable for the use of small industry. II. III. Reduces operation time and work handling time significantly. It increase the production rate and the output generate is consistent. The volume of sauce that can be bottled up also is consistent. IV. The design of the machine is user friendly.

REFERENCES APPENDIX
- Picture - Design - Gant chart - Calculation