DA NANG UNIVERSITY OF SCIENCE AND TECHNOLOGY PBL 4: Design of mechatronic systems(20.05B) TOPIC: Automated Bottle Filling and Capping System Lectures : DR. LE HOAI NAM Members : DANG ANH HUY TRAN VAN DUNG Class : 20CDTCLC1 Da Nang, December 2023 0 PREFACE Currently, industrial automation is pivotal for the development of a nation. Developed countries like the United States, Japan, and Russia are well-versed in automation. In these nations, manual labor has been largely replaced, significantly reducing the number of factory workers.
Skilled labor, engineers proficient in technical skills, now oversee and control the production process directly through computers. One such monitoring application is WinCC, enabling remote control and supervision of the entire production process without the need for physical presence at the manufacturing site. These aspects underscore the significance of employing WinCC in the automation industry. In a developing country like Vietnam, industrial modernization is of paramount importance for economic growth and the nation's modernization needs.
As students majoring in 'Electro-Mechanics,' we recognize the pressing real-world application needs of our country's industrial sector. To serve the community and gain practical knowledge, we delve into exploring and understanding recent scientific advancements. This pursuit allows us to contribute to the community and gain deeper insights into practical knowledge, reinforcing the theoretical understanding acquired over the years. For these reasons, our team has chosen the project: 'Automated Bottle Filling and Capping System.' Throughout our work, we anticipate mistakes and welcome feedback from our instructor and peers to enhance our project We sincerely thank you! Writer Dang Anh Huy 1 CHAPTER 1.1 SETTING THE PROBLEM Starting from the visits to various manufacturing enterprises equipped with production lines, our team has observed numerous automated production lines in conjunction with the current trend of automation in our country's manufacturing sector.
Furthermore, these systems aim to address time constraints, reduce the workforce, increase output, and streamline costs for the company. Your team's chosen topic translates to: "Automatic Bottle Filling and Capping Extraction System," utilizing the PLC S7-1200 1214 DC/DC/DC.2 THE INITIAL TECHNICAL REQUIREMENTS OF THE SYSTTEM ARE - Minimum production capacity of 450 bottles per hour. - Bottle type: Nuti Food milk bottle, 297ml. - Tight sealing and capping of the bottle neck.
- Accurate filling of water with low margin of error. - Ensuring occupational safety during operation.3 DESIGN REQUIREMENTS - Voltage used: 12V and 24V. Depending on the capacity of the motor and other peripheral devices, it is usually less than 5A. - Electrical safety measures: The system is designed to prevent shock throughout the system and other electrical equipment meets CE standards.
Emergency shutdown button when an incident occurs. - Frame: Designed with shaped aluminum and box steel, resistant to vibration. - Water pipes: High pressure pipes, guaranteed to be hygienic, no residue.4 RESEARCH CONTENT Content 1: Learn and refer to documents, textbooks, research related topics and content and come up with methods to implement the topic Content 2: Mechanical design, 3D drawings, kinematic diagrams, technical plans, calculations and engine selection Content 3: Circuit design, circuit drawings, calculation and selection of electronic components. Content 4: Programming PLC, designing monitoring interface on Wincc Content 5: Test and adjust the software and hardware for the system to the most optimal level.
Content 6: Write an explanatory report Content 7: Project Report 1.5 OVERVIEW OF THE FILLING LINE 1.1 Introduction To be able to build a system as required, we need to learn some concepts and basics related to the system. Filling concepts, ways to communicate between the 2 PLC and peripheral devices, and supported software are all presented in this program. It can be seen that today's consumer products are mostly contained in bottle- shaped packaging, especially in the food industry, for example: beer, wine, soft drinks, milk, etc. with many outstanding advantages such as Low cost, sturdy, highly aesthetic, easy to produce.
For this reason, automatic bottle filling and capping systems are widely used with many different types. Automatic bottle capping lines come in a variety of sizes and are used in conjunction with liquid filling lines. It is used not only in large companies but also in small private production facilities.2 Options - Quantification Methods + Quantification by standardization: Accurate quantification of liquids by pre- standardizing them before pouring into bottles. + Quantification by fixed-volume extraction: Liquids extracted to a fixed level in the bottle by filling up, then subtracting the displaced volume.
+ Quantification by time-based extraction: Pouring liquid into bottles within a specified time frame for quantification. Choose a quantification by time-based extraction: Figure 1.1: Time-based filling machine - Bottle caps supply: + The robot arm is positioned after the completion of the filling process + Sliding friction allows the cap to automatically wipe in as the bottle finishes filling when the cap is rotated. +The cylinder will push the bottle cap down to the mouth of the bottle 3 The selected option for sliding friction Figure 1.2: Sliding friction solution - Filling: + Conventional filling option: liquid flows into the bottle due to the difference in glass height. The flow rate is slow so it is only suitable for less viscous liquids.
+ Vacuum filling method: Attaching the bottle to a vacuum system, the liquid flows into the bottle due to the pressure difference between the storage container and the pressure inside the bottle. +Pressure pushing method: Applied for products with gases such as beer, soft drinks. Choose the regular pressure pouring option Figure 1.3: Conventional pressure pouring plan The filling mechanisms can be arranged in a linear setup, operating simultaneously (linear filling machine), or positioned on a turntable, working sequentially (rotary filling machine). Choose turntable extraction machine structure 4 Figure 1.4: Structure of rotary table extractor 5 CHAPTER 2.
CALCULATION AND MECHANICAL DESIGN 2.1 DESIGN REQUIREMENTS Title: "Automatic Bottle Filling and Capping System using PLC S7-1200" with the following requirements: + The system must have stable and robust hardware. + Minimum production capacity of 450 bottles per hour. + Turntable dimensions must match the bottle specifications. + Precise water filling with low margin of error.
+ The turntable mechanism must position accurately and rotate precisely by 90 degrees. + Accurate lid wiping and sealing. + Accurate product counting.2 SYSTEM DECRIPTION: System dimensions: 100x100x50(cm) The hardware framework comprises two conveyor belts positioned perpendicular to each other, incorporating a rotary turntable mechanism with four corners equally spaced at 90 degree intervals to perform distinct tasks.3 KINEMATIC DIAGRAM Figure 2.4 TECHNICAL PLAN AND 2D DRAWING Figure 2.1 Conveyor motor The capacity of a motor for a conveyor belt is primarily determined by several key components: + Power necessary during idle phases. + Power required to propel objects along the conveyor belt.
+ Power essential for overcoming friction. + Conveyor belt specifications such as: Length: 60cm Width: 7cm Height: 10cm The combination of the first two components is the capacity needed to run the conveyor Calculate engine power : In there : Nct: is the power required for the enginev(W). N: capacity on the conveyor belt(W) n: general efficiency of the conveyor Determine the capacity N : N=(P. -Select roller diameter Select roller diameter v: D=30 mm Engine speed : N= V/D.
π =104( Vòng/p) - Engine torque : 8 T= mgD/2= 4.3: JGP37 545 DC24V 100RPM gear reduction 2.2 Bottle cap screwing motor Calculate engine power: Determine the capacity N : N=F.3: Gear reduction motor DCM555 DC24V 600RPM 9 2.3 The water pump motor * Water pump engine : - This capacity is based on traffic P(kW)= [Q(m3/s)*H(m)* proportion H2O(1000kg/m3)]/[102* pump efficiency (0,8-0,9)] = (0,0033.4 Calculate cylinder selection F= 0,5 kg = 5N P= 8 bar = 8kgf/cm2 t= 0,5s √ F 4 0,89 ( Chọn D = 1,5 cm ) D= x = √ Pπ 10 π D 2 3,14. 1,76= 14,08 N Choose a safety factor of 2 F = 2.14,08= 28,16 N Selecting a cylinder length of 5cm, pressure at 8 bar resulting in a thrust of 28.5 Select conveyor belt Figure 2.6: Conveyor belt - The model was made for research purposes, so the team chose a conveyor belt with small dimensions: 60cm long, 7cm wide, 8cm high, just right for bottles to run in a straight line. - Number of conveyor belts: 2 conveyor belts 11 2.6 Select frame material Figure 2.7: Shaped aluminum - The frame is made of 3x3 (cm) shaped aluminum material. With compact size, sturdy structure, easy to disassemble and transport, and reasonable price.
- Iron size: 1m/bar - Length: 3m 2.7 Select the turntable Figure 2.8: Drawing of turntable 12 - In order for the turntable to perform three tasks at the same time: pumping water, provide bottle caps, and crewing bottle caps, the team must design the turntable so that the actuators can be arranged appropriately. - Cutting 4 holes d=8mm 90 degrees apart is reasonable -The hole in the middle will connect to a d=8mm bar attached to 2 ball bearings combined with the frame to fix the tray to ensure it does not vibrate and has good strength.8 3D drawings on solidworks Figure 2.9: 3D drawing on solidworks 2.9 Actual model Figure 2.10: Actual model 13 PART 3. ELECTRICAL - ELECTRONIC SYSTEM DESIGN 3.1 ELECTRICAL SYSTEM DESIGN For the mechanical part to operate, the electrical system plays a decisive role for the entire system. From the mechanical model as designed and completed, create an overall design plan for the control parts.
Identify blocks including: Power block, central processing block, conveyor block, button block, sensor block, bottle cap supply block, bottle cap crew block, rotary block, interface screen block.1 Block diagram of the system Figure 3.1: System block diagram Functions of blocks: + Power block: provides power to the system. + Button block: controls the system. + Sensor block: identifies bottle positions and counts products. + Conveyor belt block: moves bottles in and out.
14 + Water filling block: supplies water to the bottles. + Bottle cap supply block: supply caps to the bottles. + Bottle cap screw block: seals the bottle. + Rotary block: holds and moves bottles at a 90-degree angle.
+ Central processing block: receives, processes information, and controls other blocks. + Interface screen block: Displays the system's operating process on the screen, we can monitor and customize system parameters there.2 System procedures + Empty 330ml bottles are placed onto conveyor belt 1 to the water filling position. + After 2 seconds, the system pumps and fills the 330ml bottles within 6 seconds. + After completion, the system halts for 1 second before rotating the turntable to prevent water spillage while in motion.
Then, the turntable rotates the bottle to the capping position. + At the capping position (capping process takes 3 seconds). + Bottles are then moved out onto the conveyor belt.2: System process Figure 3.3: Steps of the implementation process 15 * Water extraction process 7s The tray rotates 90 degrees in 1 second Take the 1s cap Unscrew the cap for 2 s Take out conveyor belt 1s => 1 hour is approximately 450 bottles 3.3 Select system equipment 3.1 PLC control block S7-1200 The group chose PLC S7-1200 1214C DC/DC/DC from Siemens. The group's system has a total of 11 DI inputs and 8 DO outputs.
While the S7-1200 1214C DC/DC/DC has 14DI, the 10DO can be said to meet the group's requirements, and with its compact design, easy-to-use Tia Protal programming software along with IO expandability. , a SCADA design interface with a rich library, so this is the best choice.4: PLC S7-1200 1214C DC/DC/DC Function CPU 1214C DC/DC/DC Locally integrated I/O: Number type 14 inputs/10 outputs Similar style 2 inputs/2 outputs Work memory 100KB Woad memory 4MB Expansion of signal modules 8 Communication modules 3 (expand to the left) High speed counters: 6 Single phase 3 at 100 kHz, 3 at 30 kHz Square phase 3 at 80 kHz, 3 at 20 kHz Pulse outputs 2 PROFINET 2 Ethernet transmission ports Figure 3.5: Catalog S7-1200 1214C DC/DC/DC 16 3.