Design and development of an automated can filling machine

Project Title

Design and development of an automated can filling machine

Project Area of Specialization RoboticsProject Summary

Automation is one of the main techniques by which industries increase productivity, decrease costs, and maintain overall productivity. Automated systems incorporate a variety of mechanical components, controlled through control systems, such as Programmable Logic Controllers (PLCs). Our project is one such example of industrial automation. We will design and manufacture an industrial automation system that will fill empty cans with multiple fluids, such as paint (viscous), and ether. The cans will be filled to an equal weight, using an arrangement of load cells, which will be used to monitor the weight of the can as it is being filled. In addition, the system will be controlled using available industrial PLCs, and an HMI interface will also be designed for effective human control and monitoring of the system. The machine will also include a can rejection system which will identify the placement of the cans beneath the filling nozzle and reject cans which do not fall within the filling region, thereby preventing any spillage of the fluid. The machine will be fed empty cans using a transport conveyor, and full cans will be taken away from the machine by another transport conveyor.

Project Objectives

The objectives of the project are as follows:

1. A working paint can filling machine to fill 1 Liter paint cans.
2. A transport conveyor system to bring empty cans to the machine and take full cans away from the machine.
3. A weighing and filling system to ensure that all cans are filled to the same weight.
4. A CAD model of the system
5. A project thesis.
6. ANSYS analysis of the filling system.
7. The filling system should be capable of filling three different (viscosity) fluids.
8. A can rejection system
9. A simulation of the system.

Project Implementation Method

First of all, the objectives, deliverables and schedule of the project were finalized. Then, using these as constraints work on the design of the hardware was begun, as this is a hardware intensive project. The system has been divided into three main sub systems:

1. The conveyors: This subsystem includes:
   1. The transport conveyor which will bring empty cans to the filling machine.
   2. The weighing conveyor, which is located underneath the filling machine and will communicate with the filling machine to ensure all cans are filled to an equal weight.
   3. The output conveyor: This will transport full cans away from the filling machine. 
2. The filling machine and ancilliaries: This includes all the storage tanks for the various fluids, cleaning fluids, distribution systems and piping, pumps, and sensors, nozzles, and valves pertaining to the filling of cans. 
3. The control and monitoring system: This includes the control panel for the whole machine, where the user can observe the state of the machine and alter its operation. All buttons, switches, indicators, and safety systems are part of this.

Once this was done, detailed CAD desiging was initiated starting with the first module. As of know, the physical fabrication of the conveyor system has begun, while the filling system has been designed. Once the conveyor system's fabrication completes, the filling system will be manufactured, and the control and monitoring system will be designed using CAD, after which it will also be manufactured. Once all three subsystems are manufactured, they will be integrated and the machine will be tested for a variety of test cases, so that we can ascertain its performance, which will allow us to determine the OEE - Overall Equipment Efficiency, following which will be the literature and documentation phase where we will document our methods. 

Benefits of the Project

This project will result in the following benefits:

1. This prototype can be used in local small industries, to easily and quickly package their products for distibution. Filling machines affordable for such industries, in the market at the moment are too labor intensive, and thus not as productive. 
2. The machine can be generalized from paint filling to filling viscous fluids, such as honey, tomato puree etc. This will allow small farmers to manufacture and package their own products, and sell them directly in the market reducing reliance on middlemen thereby providing better prices to consumers and better profits for themselves. 
3. This project is also beneficial to us, the executors of the project, as it provides us an opportunity to practically design and manufacture a machine based on a certain problem definition. The experience gained especially regarding physical manufacturing and prototyping is invaluable in our professional development. 

Technical Details of Final Deliverable

In the final deliverable prototype, the first transport conveyor will consist of a conveyor belt supported on two pulleys, one head pulley and one tail pulley. The head pulley will be driven by a motor connected to the pulley by means of a synchronous belt. The same motor will be used to drive the conveyor of the filling machine. The dimensions of the first transport conveyor will be 1.2 metres (length) by 0.18m (width). The filling conveyor will be of the same width, but will only have a length of 0.3m. The filling conveyor's pulleys will be supported by a sheet metal part with a C shaped crossection, which will be bolted onto four cantilevered load cells supported by a rigid base plate. There will be a large 10 Liter tank on the ground which will feed the paint to a smaller, 5 Liter overhead tank by means of an AODD (Air Operated Double Diaphragm) positive displacement pump. The actual filling will be controlled by motorized valves, and the flow will be due to gravity, with the pump being activated only if the liquid level in the overhead tank falls below a threshold value. In addition, there will be smaller tanks for water, and a solvent, which will be pumped directly using electric pumps (as these fluids are less viscous than paint). In addition, there will be nozzles placed inside the overhead tank, so that solvent can be run through the entire system to clean it after paint filling has been done. This is necessary to prevent the paint from drying out and clogging the pipes (based on a paint manufacturing company's recommendation). Finally, the filled cans will roll down a 0.7m long by 0.18m wide idler conveyor to the termination point, from where they can be removed. 

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Others Core Technology RoboticsOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	31681
Conveyor belts	Equipment	2	2000	4000
Iron shaft for machining	Equipment	6	144	806
Mild Steel sheets	Equipment	15	140	2100
Fasteners	Equipment	50	10	500
Machining work (including welding, plating, sheet bending etc).	Equipment	1	3000	3000
Drill bits	Equipment	7	40	280
Threading tools	Equipment	2	150	300
Scrap metal aluminium	Equipment	3	225	675
Load cells 20 Kg	Equipment	4	550	2200
Ball bearings	Equipment	21	80	1680
Suction hose	Equipment	12	40	480
pneumatic fittings	Equipment	2	180	360
Transport and Petrol	Miscellaneous	1	3500	3500
HX711 modules	Equipment	4	175	700
Electrical items (such as wiring, switches, LEDs etc.)	Equipment	1	4000	4000
Printing of logbook	Miscellaneous	1	1100	1100
Printing and binding of reports (estimated)	Miscellaneous	2	1000	2000
Camera module	Equipment	1	4000	4000