End of Line Automation

End of line automation? is an applied reasearch and industry based high end control automation project. Aimed towards designing and fabrication of an automated, efficient and cost-effective solution of stacking at industrial scale. It is a system controlled by Programmable Logic Controller (PLC), in

Project Title

End of Line Automation

Project Area of Specialization

Robotics

Project Summary

End of line automation” is an applied reasearch and industry based high end control automation project. Aimed towards designing and fabrication of an automated, efficient and cost-effective solution of stacking at industrial scale. It is a system controlled by Programmable Logic Controller (PLC), incorporating sensors and pneumatic pushers to actuate certain push motion when certain conditions are met. This system is particularly designed for stacking of soap bundles but can be customized for any other object or product of that manner.
This Invention relates primarily to an efficient, cost effective and sustainable solution of the problems faced due to the manual stacking of soap bundles at the end of line of a production plant.

Project Objectives

Automation holds a very important role in industries. Manufacturing would be nothing without automation, factory robots, and industrial motion control. Stacking procedures most commonly employed by industries involve using labor force which not only reduces packing efficiency but also increases the risk of error. Most common problems suffered due to such procedures include:

1. Slower Packaging
2. Increased cost
3. Increased Labor
4. More prone to human error

Our project “End of Line Automation” basically is the automation of the end of line product stacking and boxing using purpose built assembly. The project aims to replace the manual work done by hand with an automatic machine which offers the following benefits:

1. Reduces Cost
2. Improves Quality
3. Improves efficiency
4. Enables Faster packaging
5. Increases human safety

Project Implementation Method

Soap bundles are arriving on the conveyor at a speed of 50 bundles a minute. The bundles of soap will be pushed by a pneumatic pusher (Pusher 1) on to a platform perpendicular to the conveyer. The movement of bundles on the conveyor before being is stopped by a blocker. Each push will be actuated, once two bundles arrive in front of the pusher 1, this condition is checked by a capacitive proximity sensor controlled by a programmable logic controller (not shown in the figure). A second pusher (Pusher 2) will push the bundles in the carton placed on the lifting platform. A capacitive proximity sensor will detect the placement of carton otherwise the whole process will be stopped if carton is not placed in time. The arrival of both the bundles across 2nd pusher is checked using inductive proximity sensor (not shown in the figure). Once 4 the bundles are on platform (i.e. pusher 1 working twice), pusher 2 will actuate the 4 bundles into the carton placed on another platform (platform 2). Adjustable wall will keep the face of the carton open till all bundles are placed inside. After placement of each layer of 4 bundles the lifting platform will move downward a single. This motion of the lifting platform is attached to the third pneumatic sensor (Lifter 1). Each layer will be detected by the number of pushes counted by programmable logic controller. Initially the carton is placed on the box holder (platform 2) in vertical position. Another pneumatic cylinder (Rotator 1) will rotate the carton and the box holder to horizontal position such that the open end of the carton faces the pusher 2. Pusher 1, Pusher2, Lifter1 and Rotator1 are pneumatic pushers based on piston cylinder assembly working on compressed air. Pusher 1, Pusher2 and Rotator1 are controlled by single coil electric solenoid, whereas lifter 1 in connected to double coil solenoid that enables the step by step movement of Lifter1. Adjustable wall can be manually adjusted according to the varying size of the soap bundle and according to the varying size of carton.

Benefits of the Project

Our project “End of Line Automation” basically is the automation of the end of line product stacking and boxing using purpose built assembly. The project aims to replace the manual work done by hand with an automatic machine which offers the following benefits:

1. Reduces Cost
2. Improves Quality
3. Improves efficiency
4. Enables Faster packaging
5. Increases human safety

Introduction of automation industry in Pakistan at undergrad level, creating a better job market for skilled and qualified individuals. Gradually taking the industry towards  better more efficient and cost effective methods of automation. A thriving efficient industry will lead to stable economic growth in Pakistan.

Technical Details of Final Deliverable

Sensors:

Capacitive Proximity Sensor

•CM 30-15/CM12-4

•Number of sensors used: 02

•Working principle: Electrical Field Distortion

•One sensor is used to count number of bundles arriving on conveyor

•The other detects the placement of box on the carrying platform.

Inductive Proximity Sensor

•LM 18-30-05 NA

•Number of sensors used: 01

•Working Principle: Electric Field Distortion

•Inductive sensor counts the number of soaps pushed on the second platform

•Also, it triggers the second pusher after counting 02.

PNEUMATIC

1.It is easier to control and integrate as compared to Hydraulic and Electrical pushing systems.

2.It is Budget Friendly

3.It is faster

4.Electrical and Hydraulic systems are meant for heavy load in contrast to pneumatic systems.

•We are using a total of 4 Pneumatic pushers

•Stroke length of P1 is 6 inch

•Stoke length of P2 & P3 is 10 inches

•Stroke length of P4 is 8 inch

•Stroke time of P1, P2, P3 and P4 are 0.45 sec, 0.95 sec, 1 sec and 1.1 sec respectively.

SOLENOID

•A total of 04 solenoids are used, 03 single coil solenoids and 01 Double coil solenoid, to control the pneumatic pushers

•Single coil Solenoid:

a.At any point of time, one valve would always stay open

b.Works only for full strokes

c.Has two states

•Double coil Solenoid:

a.It has three states

b.Has the ability to stop mid stroke

c.Both the valves are locked in the beginning

PROGRAMMABLE LOGIC CONTROLLER

PLC S7 300 – CPU 314 IFM

•24V Digital Input Ports: 4 Sink type (NPN)

•24V Digital Output Ports: 5

•Programming Language used: Ladder Diagram

•Programming Software used: Simatic Manager

Using Siemens S7 was a requirement set forth by the industry

Final Deliverable of the Project

Hardware System

Type of Industry

Manufacturing

Technologies

Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure

Required Resources

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