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Hệ thống chiết rót đóng nắp tự động là hệ thống giúp chiết rót định lượng chất lỏng như nước có hoặc không có gas. Hệ thống chiết rót đóng nắp tự động phải đảm bảo vệ sinh, năng suất cao, định lượng sản phẩm chính xác Hệ thống này thường được dùng trong các ngành nghề sản xuất.
DA NANG UNIVERSITY OF SCIENCE AND TECHNOLOGY PBL 4: Design of mechatronic systems(20.05B) TOPIC: Automated Bottle Filling and Capping System Lectures Members : : Class : DR LE HOAI NAM DANG ANH HUY TRAN VAN DUNG 20CDTCLC1 Da Nang, December 2023 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 CHAPTER OVERVIEW 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 1.2 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 1.3 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 1.4 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 1.5.1 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 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 bottleshaped 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 1.5.2 Options - Quantification Methods + Quantification by standardization: Accurate quantification of liquids by prestandardizing 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 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 Figure 1.4: Structure of rotary table extractor CHAPTER 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 2.2 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 2.3 KINEMATIC DIAGRAM Figure 2.1: Kinetic diagram 2.4 TECHNICAL PLAN AND 2D DRAWING Figure 2.2 Figure 2.2.1 2.5 CACULATE 2.5.1 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.v)/1000 = (mgv)/1000 (W) N= ( 4.9,8.0,5 ) =0,0196 ( kw ) =19,6 (W ) 1000 =19,6 / 1= 19,6 (W) Choose the safety coefficient for the engine : 1,5 Engine capacity : P= 19,6*1,5= 29,4 (W) General system efficiency : - Required engine power : N ct = 29,4 =31,57(W )[1] 0.931 According to [1], we choose a motor suitable for the system: Choose a DC geared motor with capacity : N = 40(W) -Select roller diameter Select roller diameter v: D=30 mm Engine speed : N= V/D π =1000/30 π =104( Vòng/p) - Engine torque : T= mgD/2= 4.9,8.30/2= 588mN.m Figure 2.3: JGP37 545 DC24V 100RPM gear reduction 2.5.2 Bottle cap screwing motor Calculate engine power: Determine the capacity N : N=F.v (W) In there : F: rotation force to close the cap(N) v: Maximum speed of the bottle cap screwing motor (m/s) F=m k g f =0,3.5 10 0,34=5,1(N ) Inferred : N=F v=5,1 =17(W ) 0,3 General system performance - Required engine power : N ct = 17 =18,25(W )[2] 0.931 According to [2], we choose a motor suitable for the system: Choose a DC geared motor with capacity : N = 20(W)