Automation for the Production Line of Sand Casted Molds

Project Objectives
• Designing 3D CAD model of the complete conveyor belt system.
• Fabrication of the prototype mechanical model.
• Developing Image processing algorithm on MATLAB to detect pouring
cup center.
a) Detection of Sprue cap and Reference point.
b) Finding the center of Sprue cap.
c) Computing the distance from reference point to Sprue cap center
in pixels.
d) Computing mold height through range sensors.
e) Transforming the pixel distance into the actual distance.
f) Interfacing electronic control unit and sensors.
• Calibrating and testing the complete system.

Project Requirement

• The motive behind this industrial project is to provide a solution for the
automated conveyor system for the induction furnace present in
Manufacturing Resource Center – SMME
• The prototype demonstrates the feasibility of the actual automated
system required in MRC, hence the designing is done keeping in view the
actual equipment location and dimensions.
• The system will be capable of transferring molds from preparation area
to induction furnace, align the mold’s sprue cap with furnace's pour
point and then transfer the finished mold to holding area.
 Project Timeline
S/N Task Name Duration Start Finish
1 Designing 3D CAD model and drawings 15 days October 1, 2013 October 20, 2013
2 Purchase list of mechanical and electronic hardware 11 days October 20, 2013 November 1, 2013
3 Construction of mechanical model 32 days November 1, 2013 December 15, 2013
4 Developing Image processing algorithm on MATLAB 30 days December 15, 2013 January 23, 2014
5 Implementing electronic hardware for complete system 15 days January 23, 2014 February 12, 2014
6 Calibrating and Testing 20 days February 12, 2014 March 11, 2014
7 Completing the thesis/report write up 45 days March 11, 2014 May 12, 2014

Module 1. Designed 3D CAD model of the complete conveyor belt system

Alternate View
 Module 2. Purchase list for base electronic hardware.

S/N Item Seller Price Qty Subtotal(PKR)

1 Arduino MEGA 2560 Robotics.pk 3800 1 3,800
2 Motor Driver Controller Board Digipak.org 1350 2 2,700
3 Pololu 12V, 500 RPM, 5 kg-cm Encoder Robotics.pk 4000 1 4,000
4 Pololu 12V, 350 RPM, 8 kg-cm Encoder Robotics.pk 4000 1 4,000
5 Pololu 12V, 350 RPM, 8 kg-cm, 29:1 Gear Motor Robotics.pk 2350 2 4,700
6 Sharp GP2Y0A21YK Mid Range Sensor Robotics.pk 1500 1 1,500
7 37D mm Metal Gearmotor Bracket Pair Robotics.pk 1200 2 2,400
8 A4Tech PK-910H 1080p WebCam Robotics.pk 2050 1 2,050
Total 25,150
Module 3. Project Process Tree