design and manufacture of an automatic pet bottle supplying machine for water bottling production lines

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING DESIGN AND MANUFACTURE OF AN AUTOMATIC PET BOTTLE SUPPLYING

MINISTRY OF EDUCATION AND TRAINING

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING

DESIGN AND MANUFACTURE OF AN AUTOMATIC PET BOTTLE SUPPLYING MACHINE FOR WATER

BOTTLING PRODUCTIO LINES

LECTURER: TUONG PHUC THO STUDENT: DAM HOANG THONG HUYNH PHAM DUY TRI

S K L 0 1 2 6 4 2

GRADUATION PROJECT

MECHATRONICS ENGINEERING TECHNOLOGY

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION

GRADUATION THESIS

Advisor: M.E TƯỞNG PHƯỚC THỌ

Student: ĐÀM HOÀNG THÔNG 19146077

Major: MECHATRONICS Course: 2019-2023

Design and manufacture of an automatic PET bottle supplying machine for water bottling production lines

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

-

Ho Chi Minh City, March …, 2024

GRADUATION PROJECT ASSIGNMENT

Student name: Đàm Hoàng Thông Student ID: 19146077 Student name: Huỳnh Phạm Duy Trí Student ID: 19146133 Major: Mechatronics Class: 19146CLA Advisor: M.E Tưởng Phước Thọ Phone number:

Date of assignment: 05/09/2023 Date of submission: …/…/2024 1 Project title: Design and manufacture of an automatic PET bottle supplying machine for water bottling production lines

2 Applying the knowledge acquired through education along with the insights gained through group research and study, we have surveyed, researched, and constructed an automatic PET bottle machine Through the process of real-world observation and our own experiences in design and machine processing, the automatic bottle machine facilitates easy bottle arrangement and achieves high efficiency, making it user-friendly

3 Content of the project:

- Calculation and design proposal - Selecting motor and detail

- Electrical circuit design and 3D modeling - Manufacture product

- Testing

4 Final product:

- An automatic PET bottle supplying machine for water bottling production lines has an efficiency of about 1500 bottles per hour

CHAIR OF THE PROGRAM

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ADVISOR

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THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

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Ho Chi Minh City, March … , 2024

ADVISOR’S EVALUATION SHEET

Student name: Đàm Hoàng Thông Student ID: 19146077 Student name: Huỳnh Phạm Duy Trí Student ID: 19146133 Major: Mechatronics

Project tittle: Design and manufacture of an automatic PET bottle supplying machine for water bottling production lines

Advisor: M.E Tưởng Phước Thọ

EVALUATION

1 Content of the project

………

2.Strengths

……… ……… ……… 3.Weekness

……… ……… ……… 4 Overall evaluation: (Excellent, Good, Fair, Poor)

……… 5 Mark: ……… (in word……….)

Ho Chi Minh City, month day, year

ADVISOR

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THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

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Ho Chi Minh City, March …, 2024

PRE-DEFENSE EVALUATION SHEET

Student name: Đàm Hoàng Thông Student ID: 19146077 Student name: Huỳnh Phạm Duy Trí Student ID: 19146133 Major: Mechatronics

Project title: Design and manufacture of an automatic PET bottle supplying machine for water bottling production lines

Name of Reviewer: M.E Lê Thanh Tùng

EVALUATION

1 Content and workload of the project

……… 2 Strengths:

……… 3 Weaknesses:

……… 4 Approval for oral defense? (Approved or denied)

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Ho Chi Minh City, month day, year

REVIEWER

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-EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER

Student name: Đàm Hoàng Thông Student ID: 19146077 Student name: Huỳnh Phạm Duy Trí Student ID: 19146133 Major: Mechatronics

Project title: Design and manufacture of automatic supply PET bottle machine for water bottling production line

Name of Defense Committee Member: -

- - - -

EVALUATION

1 Content and workload of the project

……… 2 Strengths:

……… 3 Weaknesses:

……… 4 Overall evaluation: (Excellent, Good, Fair, Poor)

Ho Chi Minh City, month day, year

COMMITTEE MEMBER

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Disclaimer

Project title: Design and manufacture of an automatic PET bottle supplying machine

for water bottling production lines

Advisor: M.E Tưởng Phước Thọ

Student: DAM HOANG THONG – Student ID: 19146077

Student: HUYNH PHAM DUY TRI – Student ID: 19146133

 Dam Hoang Thong

Acknowledgements

Throughout the process of completing our graduation project, our team has received a tremendous amount of help and enthusiastic support We were guided and encouraged to overcome all difficulties and complete this meaningful period

Firstly, we would like to express our gratitude to Ho Chi Minh City University of Technology and Education and the Faculty of International Education for providing favorable conditions for us to carry out our graduation project

Secondly, we sincerely thank Mr Tuong Phuoc Tho, our advisor, who provided valuable guidance and advice to our team, helping us complete our graduation project From his advice, we overcame challenges during the project and gained further insights into the design and implementation process

Additionally, we would like to express our gratitude and respect to Mr Le Thanh Tung, who provided many suggestions for our report He also helped us improve the quality of our presentation before our actual presentation

In conclusion, we sincerely thank everyone who has helped us complete the graduation project report as well as the machine we have created

Abstract

The design and manufacture of an automatic PET bottle supplying machine for water bottling production lines The objective is to optimize and enhance the efficiency of the bottle packaging process by integrating automatic mechanisms for bottle supply The machine is designed to handle PET bottles smoothly, ensuring continuous and accurate bottle supply to the water bottling production line

The design includes key features such as conveyor systems, bottle sorting, and controlled output mechanisms, all integrated to support continuous and accurate bottle supplying processes The system is equipped with sensors and controllers to detect and respond to variations in bottle quantity, ensuring flexibility to meet different production requirements

Additionally, the automatic PET bottle supplying machine is designed with friendly controls, enabling operators to easily monitor and adjust machine settings The integration of safety features ensures a safe working environment

user-This research contributes to the field of industrial automation by presenting an innovative solution to optimize the efficiency and accuracy of the bottle supplying process in water bottling production lines The proposed machine offers a reliable and flexible solution for businesses looking to optimize their production processes in the bottling

industry

Contents

Chapter 1: Introduction 11

1.1 Introduction about project 11

1.1.1 Introduction about PET bottles 11

1.2 Introduction about machine 13

1.2.1 Benefit of the machine 13

1.5.2 Specific research methods 15

1.6 Graduation project structures 16

Chapter 2: THEORETICAL BASIS 17

2.1 The demand for the automatic bottle supplying machine 17

2.2 The current status of the automatic bottle supplying machine 17

2.3 Analysis and Selection of Design Options 19

2.3.1 Overview analysis of the automatic bottle supplying machine 19

2.3.2 Choosing the bottle detection sensor 23

2.3.3 Bottle Conveying System 26

Chapter 3: Design and calculation 28

3.1 Main parts of the machine 28

3.2 Calculation and selection of motor for conveyor belt 1 35

3.2.1 Motor selectiom for conveyor belt 1 35

3.2.2 Calculation of chain transmission ratio 37

3.3 Calculation and Selection of Motor for Rotary Table 41

3.3.1 Motor Selection for Rotary Table 41

3.3.2 Calculation of belt transmission ratio 43

3.4 Calculation and motor selection for conveyor belt 2 44

3.4.1 Selection motor 44

3.4.2 Calculation of transmission ratio 46

3.5 Calculation and durability test 47

Chapter 4: Control System Design 51

4.1 Electrical System Design 51

4.1.1 Requirements for the Electrical System 51

4.1.2 Preliminary Electrical System Design 51

4.2 Components Used 52

4.2.1 CB 2P 32A PS45N/C2032 Sino : 52

4.2.2 The power supply 24V 5A 53

4.2.3 Variable Frequency Drive VFD-M 0.4KW Delta 54

4.4.2 Turningtable control algorithm flowchart 69

4.4.3 System operating diagram 70

4.5.1 Scope of Study 71

4.5.2 Introduction 71

4.5.4 Communication standard 79

4.5.6 Wiring connect 80

4.5.8 Registers of the Devices 83

4.6 Designing the User Interface HMI 84

4.6.1 User Interface Design for the Project 84

Chapter 5 Experiments and analysis 88

5.1 Analysis the machine 88

5.2 Preparation of samples and experimental methods 92

5.3 Evaluation 97

5.4 Development 97

LIST OF FIGURES

Figure 1 1: History of PET 11

Figure 1 2: Dimension of bottle 12

Figure 1 3: Bottles are using 12

Figure 1 4: Picture of supply machine 13

Figure 2.1: Bottle supplying machines utilizing Delta robot arms 17

Figure 2.2: Bottle supplying machines utilizing centrifugal method 18

Figure 2.3: Bottle unscrambler using a hook mechanism 19

Figure 2 4: The structure of the tank 20

Figure 2 5: The structure of the turning table 20

Figure 2 6: The structure of the flipping mechanism 21

Figure 2.7: General diagram of the machine 21

Figure 2.8: Different types of optical sensors 24

Figure 2.9: Through-beam sensors 24

Figure 2.10: Retro-reflective sensors 25

Figure 2.11: Diffuse reflective optical sensor 25

Figure 2.12: Roller Conveyor 26

Figure 2.13: PVC Conveyor Belt 27

Figure 3.1: 3D Design of turning table 28

Figure 3.2: Transmission of turning table 29

Figure 3.3: 3D of turning table 30

Figure 3.4: Actual turning table 30

Figure 3.5: 3D Design tank and conveyor 1 31

Figure 3.6: Chain links transmission 32

Figure 3.7: Actual tank and conveyor 1 32

Figure 3.8: 3D Design of Conveyor 2 33

Figure 3.9: 3D in front of Conveyor 2 34

Figure 3.10: Actual conveyor 2 34

Figure 3.11: 3D Design of machine 35

Figure 3.13: Motor single phase 4IK25GN-C 37

Figure 3.15: Dimension of chain links 39

Figure 4.1: Electrical System Design 51

Figure 4.2: Circuit breaker 52

Figure 4.3: Power supply 24V 5A 54

Figure 4.4: Variable Frequency Drive VFD-M 0.4KW Delta 54

Figure 4.11: Control circuit diagram 64

Figure 4.12: Motor circuit diagram 64

Figure 4.13: An overview image of the electrical cabinet 65

Figure 4.14: The front face of the electrical cabinet 66

Figure 4.15: Images of the components inside the electrical cabinet 66

Figure 4.16: Behind HMI 67

Figure 4.17: General flowchart 68

Figure 4.18: Turningtable control algorithm flowchart 70

Figure 4.19: System operating diagram 71

Figure 4.20:Introduce Modbus communication mode 72

Figure 4.21:Communication frames according to Modbus RTU standard 73

Figure 4.22:Communication frames according to Modbus RTU standard 73

Figure 4.23:Structure of Modbus RTU frame 73

Figure 4.24:Structure of Modbus RTU frame 74

Figure 4.25:An example of a TCP/IP model 75

Figure 4.26:The hybrid TCP/IP RTU model 76

Figure 4.27:The basic structure of Modbus RTU communication 76

Figure 4.28:Modbus TCP/IP communication structure 77

Figure 4.29:Modbus TCP/IP communication 77

Figure 4.30:Binary to hexadecimal conversion table 77

Figure 4.31: The communication frame structure of the Modbus ASCII protocol 78

Figure 4.32:The communication wiring diagram 79

Figure 4.33:Connection diagram for RS485 to PLC DVP40ES2 80

Figure 4.34: Configuration of connection ports for different cable standards for Samkoon 102HS HMI 80

Figure 4.35:Wiring diagram for communication devices 80

Figure 4.36: Communication roles of devices 81

Figure 4.37: Configuring the connection port of the PLC 82

Figure 4.38:PLC communication configuration 82

Figure 4.39: HMI connection port configuration 83

Figure 4.40: The main interface sheet of the group's HMI 85

Figure 4.41: The manual mode sheet of the group's HMI interface 85

Figure 4.42: The auto mode sheet of the group's HMI interface 87

Figure 5 1: Actual of our Machine 88

Figure 5 2: Conveyor 1’s working 89

Figure 5 3: Turning table's working 90

Figure 5 4: Conveyor 2 's working 91

Figure 5 5: Our team and machine 92

Figure 5 6: The result of case 1 93

Figure 5 7: The problem at the output of turn table 94

Figure 5 8: The result of case 2 95

Figure 5 9: The result of case 3 96

LIST OF TABLES

Table 2 1: Explain for diagram 22

Table 4.1: Specific of Blower 61

Table 4.2: the advantages and disadvantages of the Modbus 78

Table 4 3: Parameter of VFD 81

Table 4.4: Configuration of the HMI connection port 84

Table 5 1: Specific of machine 88

Table 5 2: The result of case 1 93

Table 5 3: The result of case 2 94

Table 5 4: The result of case 3 96

LIST OF ABBREVIATION

TCP/IP Transmission Control Protocol/ Internet Protocol

Chapter 1: Introduction

1.1 Introduction about project

1.1.1 Introduction about PET bottles

Chemists at DuPont company first created Polyethylene Terephthalate (PET) in 1941 while experimenting with polymers By the late 1950s, researchers had figured out how to stretch a thin sheet of PET resin to create PET film, which is widely used today in applications such as video and photographic film, X-rays, and more In the early 1970s, this technology was further developed to allow for the blow molding of PET bottles, resulting in rigid, lightweight, and shatter-resistant containers In 1973, a DuPont scientist named Nathaniel Wyeth patented the first finished PET plastic bottle, which quickly gained market acceptance In 1977, the first PET bottle was recycled Perrier and Evian were among the first companies to capitalize on the bottled water trend, followed by PepsiCo with its Aquafina brand in 1994 Coke and Dasani followed suit in 1999, both using purified tap water From 1994 to 2017, the revenue from bottled water in the United States increased by 284%, according to data from the Beverage Marketing Corp

Polyethylene Terephthalate (PET) plastic bottles are a type of polyester resin commonlyused to produce containers for water, beverages, oils, and many other products.

Figure 1 1: History of PET

Properties of PET bottles:

• Lightweight: PET plastic bottles are very lightweight, making them convenient for transportation and everyday use.PET is often transparent, allowing consumers to

see the contents inside, which helps promote brand visibility and facilitates product identification

• Heat Resistance: PET has relatively high heat resistance, making it suitable for storing hot liquids such as hot water or beverages with high temperatures

• Chemical Resistance: PET typically exhibits resistance to corrosion and the effects of many chemicals

• Durability: PET is durable and rigid, helping to protect the contents inside from external factors

• Recyclability: PET is one of the most recyclable plastics Recycling PET bottles helps reduce plastic waste and alleviates pressure on natural resources

PET plastic bottles are a popular choice for packaging water, soft drinks, and other beverages

Dimension of bottle we used in this machine:

Figure 1.2: Dimension of bottle

Figure 1.3: Bottles are using

1.2 Introduction about machine 1.2.1 Benefit of the machine

The automatic bottle supplying machine is designed to connect various stages in the filling and capping system, serving industries such as soft drink and beverage production, bottled water production, pharmaceuticals, etc

The system integrates the processes of filling, capping, and automatic box packing A central control unit typically utilizes a Programmable Logic Controller (PLC) Each stage operates automatically, with labor only involved in some control, input, and output stages without the need to manually arrange bottles The automatic bottle supplying machine arranges bottles efficiently through conveyor belts and flipping mechanisms The results bring several advantages:

• Increasing Productivity and reducing Cost: The overall output achieves higher productivity compared to manual operations The system can fill thousands of bottles per hour, depending on the bottle's capacity

• Reduced Labor Costs: The automated filling system requires fewer and simpler tasks, leading to a reduced need for labor, depending on the bottle's capacity • Safety: Automating operations and shifting operators from active participation to

supervisory roles make the work environment safer

• Improved Product Quality: The filling system not only operates faster than manual methods but also produces more consistently and accurately according to strict product requirements

Application Scope:

This system is applicable to manufacturing facilities producing dishwashing liquid, soft drinks, purified water, beer, etc It is suitable for liquid or dense liquid products with high requirements for hygiene and sterilization

Figure 1.4: Picture of supply machine

1.3 Research target

Through surveys and practical experiences, along with personal practical experience in creating a reliable and efficient bottle supply system, ensuring that the output bottles are positioned correctly, maintaining a stable bottle count, and eliminating bottle jams

Several key steps:

• Calculation and design proposal • Selecting motor and detail

• Electrical circuit design and 3D modeling • Prototype creation

objectives, the study includes:

• Mechanical structures and systems • PLC programming

• Modbus ASCII communication protocol

• Variable frequency drive for three phase motor • User interface

• PET bottles

1.4.2 Research Scope

The scope of this research project is defined as follows:

Mechanical Part:

• Utilizing Solidworks software for design and calculations

• Researching and designing the bottle dispensing system, including the bottle storage container and conveyor system This research includes aspects related to design and fabrication, ensuring dimensions are suitable for the type of bottles Turn table: Investigating and rectifying any issues causing the system to jam Research includes understanding and repairing the rotary table system to eliminate jams while ensuring the rotation speed of the table

• Bottle flipping system: Researching and, through experimentation, designing a flipping mechanism suitable for the bottles, ensuring accurate flipping and proper

Electrical and Control Part:

• PLC: Research focuses on using PLC to control the entire system, including motors, monitoring screens, and sensors to ensure precise and stable process execution • ASCII communication protocol: Research focuses on using communication

protocols to control the variable frequency drive

• Variable frequency drive for phase motor: Variable frequency drive for phase motors is used to adjust the speed and rotational frequency of the motor to match the production process of the machine

three-• User interface:The user interface is simple, easy to operate, and allows for system monitoring

compared to other technical approaches

1.5.2 Specific research methods

The specific research method for this topic includes the following steps:

Literature review: Evaluate literature to explore concepts related to bottles and automatic bottle dispensing machines, PLC control systems, variable frequency drives, control interfaces (HMI), and communication protocols Review previous studies, technologies, and methods applied in this field to gain an overview of current research and identify unexplored aspects

Define the research objectives: Clearly define the research objectives and questions of the topic The research objectives are related to the development of an automatic bottle dispensing system, improving performance, addressing bottle jamming issues, achieving efficient motor control, and implementing a simple user interface

Research design: Determine the methodology and research plan to achieve the set objectives This includes designing both the mechanical-electrical components as well as programming the control system to achieve optimal performance

Implementation: Execute the system according to the research design and carry out the research steps This involves assembling mechanical components, electrical panels, programming the control system, and designing the interface These steps will be conducted according to the research plan to ensure integrity and reliability

Evaluation and results analysis: Perform evaluation and analysis of the results obtained through the system's experimental process This assessment includes performance measurements, data analysis, and comparison with predetermined criteria The analysis will provide conclusions regarding the system's performance, features, and reliability, as well as provide information to propose improvements and developments for the future

This chapter is applied to carry out the research steps systematically and scientifically, defining objectives, designing, implementing, and analyzing the evaluation of the system's results

1.6 Graduation project structures

The graduation project consists of 8 parts, of which the specific contents are as follows: Chapter 1: Introduction

Chapter 2: Theoretical background Chapter 3: Mechanical design

Chapter 4: Control system design Chapter 5: Results and experiments References

Chapter 2: THEORETICAL BASIS

2.1 The demand for the automatic bottle supplying machine

In industries such as dishwashing detergent manufacturing, soft drink production, purified water, and beer production, there is a significant demand for automatic PET bottle dispensing machines for bottling systems to save time, labor, and operational costs Therefore, the fabrication and machining of automatic PET bottle dispensing machines to help businesses save costs are essential

2.2 The current status of the automatic bottle supplying machine

There have been several types of machines serving the automatic bottle dispensing process In general, these machines come in two forms utilizing the following methods:

Type 1: Bottle supplying machines utilizing Delta robot arms

When bottles are placed into the container, the bottle conveyor operates to bring the bottles to the Delta robot arm Thanks to image processing technology, the bottles are rearranged efficiently

Figure 2.1: Bottle supplying machines utilizing Delta robot arms Advantages:

• High precision Disadvantages:

• High initial investment cost, difficult maintenance, and repairs • Machine speed: 3600 bottles/1 hour

Type 2: Bottle supplying machines utilizing centrifugal method

Similar to the bottle dispensing machine using the Delta robot arm, bottles are placed into the bottle supply container and then transferred to a rotating table via a conveyor belt At the rotating table, bottles are oriented using centrifugal force Before entering the bottling process, bottles are arranged efficiently to ensure the system operates smoothly

Figure 2.2: Bottle supplying machines utilizing centrifugal method Advantages:

• Low initial investment cost • Easy maintenance and repairs • User-friendly interface

• Machine speed: 12,000 bottles/hour Disadvantages:

• Bottles are susceptible to deformation due to mechanical impacts Type 3: Bottle unscrambler using a hook mechanism:

This mechanism is almost the same to the centrifugal method since it also has a hopper to store scramble bottle and a conveyor belt to transport them onto the turning table Moreover, both uses centrifugal force as part of its core mechanism However, the turning table of the hook mechanism machine is parallel to the ground, pushing the bottle to the rim of the tank The different in height of the 2 plates create a slot, in which the bottle is trapped, and transported to another conveyor in the direction of the turning table

Figure 2.3: Bottle unscrambler using a hook mechanism

At this stage, there can only be 2 possible outcomes, the bottle head is leading or the bottle is leading Bottle with its bottle leading is the right direction, because we want to stand the bottle up right so that it can be filled later on The hook mechanism works as a filter, when the bottom is leading, the hook would not be able to change the direction due to the bottom is wider than the hook parameter, whereas it will change the direction of the bottles with its head leading As a result, only bottom leading bottle are transported to a sideway clamp conveyor where it got raised up straight and ready for next stages

Through comparison, the authors have chosen the design option of an automatic bottle supplying machine utilizing the centrifugal method This method is suitable for current businesses in Vietnam, offering low initial investment costs, high efficiency, ease of use, and maintenance

2.3 Analysis and Selection of Design Options

2.3.1 Overview analysis of the automatic bottle supplying machine

The entire process of an automatic bottle supplying machine includes: power supply, E-cabinet, tank, turning table, flipping mechanism, and bottle filling machine, conveyor 1, conveyor 2, bottle anti jamming mechanism 1 andbottle anti jamming mechanism 1 At the end of the journey, the bottles will be stood up and fed into the filling machine

Firstly, the power supply will be connected stably to ensure continuous operation Next is the e-cabinet, which is the central component of the machine, managing and controlling various parts of the automation process, including adjusting the speed and sequence of the production steps

Figure 2 4: The structure of the tank

Secondly, workers will pour bottles into the tank, typically around 30 bottles The tank is where bottles are provided and prepared for the next process A conveyor belt is placed inside the tank to transfer bottles from the tank to the subsequent stages of the production line

Figure 2 5: The structure of the turning table

Then, the turning table will take on the task of feeding the bottles one by one, reducing bottle jamming by the bottle anti jamming mechanism at the exit The turning table helps shape the bottles and positions them correctly for the next steps of the process Moreover, to ensure that they do not overlap so we use the bottle anti jamming mechanism in the turntable to prevent two bottles from entering the exit hole simultaneously

Figure 2 6: The structure of the flipping mechanism

Thirdly, the next process is the flipping mechanism, where bottles will be moved to the final position before being fed into the filling machine If the neck of bottles is hooked but lacks sufficient contact points between the conveyor belt and the bottle, this mechanism will increase friction between the bottle and the conveyor belt, making it easier for the bottle to flip Finally, the bottles are transported to the filling machine by the blowing machine

Figure 2.7: General diagram of the machine

Table 2 1: Explain for diagram

Device Source Output/Power Application

Sensor 1 12-24VDC PNP 12-24VDC + Count the number of bottles into the turntable + Control the number of optimal bottles in the turntable

Sensor 2 10-30VDC NPN 0VDC + Count the number of bottles coming out of the turntable

+ Control the number of optimal bottles in the turntable

Sensor 3 10-30VDC NPN 0VDC + Activate the blowing machine run

Motor 1 220VAC_2phase 25W + Pull conveyor belt 1.

Motor 2 220VAC_3 phase 200W + Rotate table

Motor 3 220VAC_2Phase 25W + Rotate the bottle jamming mechanism in the turntable

anti-Motor 4 24VDC 60W + Rotate the bottle jamming mechanism at the exit

anti-+ Control the number of bottles coming out of the turntable

Motor 5 24VDC 60W + Pull the conveyor belt 2

Device Source Output/Power Application

Motor 6 24VDC 60 W + Supports the bottle flipping mechanism to operate effectively

Blower 220VAC 200W + Supply bottles to the next link

Source 220VAC 24VDC 5A + Supply the electricity source

Based on existing research in the market and applying the knowledge we have acquired, our team has come up with the idea of designing and fabricating a bottle sorting machine model This will help reduce labor, and enhance the efficiency of the bottling production system

2.3.2 Choosing the bottle detection sensor

The sensor plays a crucial role in the bottle dispensing machine, detecting the position and counting the number of bottles This device notifies the system and users to make adjustments, thereby increasing the accuracy of the machine

For optimal bottle detection based on the knowledge acquired, the author team has decided to use an optical sensor

An optical sensor is a device used to detect obstacles or colors It emits a beam of light, and when there is an obstacle blocking this light beam, the sensor will emit a signal to the control center This product line is widely used in automated assembly lines, where light shining on the semiconductor surface changes the characteristics of the light sensor Optical sensor products are widely applied to count products on conveyor belts, inspect defective products, measure the thickness of object surfaces, and check safety when opening and closing garage doors

There are 3 common types of optical sensors: through-beam sensors, retro-reflective sensors and diffuse reflection sensors

Figure 2.8: Different types of optical sensors

Through-beam sensors:

Figure 2.9: Through-beam sensors

The through-beam sensor requires both transmitter and receiver sensors to be installed facing each other in order to function One sensor emits light while the other sensor receives it When there is an obstruction cutting across the sensor, it switches from the ON state to the OFF state

It is suitable for environments with high light reflection or strong light-absorbing surfaces Common reflective optical sensors may not be suitable

Figure 2.10: Retro-reflective sensors

The retro-reflective optical sensor consists of a transmitter and receiver light on the same sensor unit It is accompanied by a mirror or reflector designed to reflect the light emitted from the sensor head

Operating principle: The sensor continuously emits a beam of light straight ahead When encountering the mirror, the light is reflected back towards the receiver head located on the sensor unit In this case, the sensor will always indicate an ON state When an object passes through, it interrupts the reflected light signal At that moment, the sensor switches from an ON to OFF state

The ON-OFF output signal is determined by the type of sensor used The three commonly used output signal types are PNP, NPN, and Namur

Diffuse reflective optical sensor

Figure 2.11: Diffuse reflective optical sensor

The diffuse reflective optical sensor is a type of sensor that combines a transmitter and receiver in one unit It is widely used in machine components or on production lines to count or classify products

Operating principle:

• When there is no obstruction: light does not reflect back to the receiver position or the object surface does not reflect light to the receiver position The sensor indicates an ON state

• When there is an obstruction: the sensor continuously emits light from the transmitter When encountering an obstruction, the light is reflected back to the receiver position on the sensor

Characteristics: Easily affected by surface, color, and maximum distance is 2m Choice of the author group: Due to the characteristic of bottles being opaque green and easily detected by this type of diffuse reflective optical sensor, the author group has chosen to use this type of sensor to detect and count the number of bottles Additionally, through experimentation, they observed and compared the effectiveness of this type of sensor

2.3.3 Bottle Conveying System

Option 1: Roller Conveyor

Figure 2.12: Roller Conveyor

• Advantages: Capable of transporting heavy loads, high durability, good temperature resistance

• Disadvantages: Complex manufacturing process, high cost Option 2: PVC Conveyor Belt

Figure 2.13: PVC Conveyor Belt • Advantages: Easy to manufacture, low cost

• Disadvantages: Low durability, prone to tearing

Chosen Option: Since the items to be transported are lightweight PET plastic bottles, and the conveying distance is short, using a roller conveyor would be costly and not optimal Therefore, the group decided to opt for the PVC conveyor belt option

Chapter 3: Design and calculation

3.1 Main parts of the machine

The unscrambler mechanism that we choose so most resemble to the hook mechanism The reason for this is that the turning table was past down onto us by senior student working on the same project Since the target of this project is to be simple, we agreed upon dealing with things that our senior has not been able to complete

Turning table

Figure 3.1: 3D Design of turning table

Figure 3.2: Transmission of turning table

The frame of the table is made out of aluminum 40x40 bars These aluminum bars are widely used and easily manipulated Meaning, you could assemble these aluminum bars into the main frame The tray is made out of 2mm thick steel, with the diameter of 1000 mm, 400mm tall This ensure the bottle can freely move within the tank The two plates in side of the tray are levitating so the tray is not withstanding normal force, the only force that the tray has to deal with are the pressure when the bottles are swing off to the wall of the tray due to centrifugal force

Inside of the tray, the plates need to rotate around an axis when the tray stay still Therefore, the axis is allocated by 2 bearing housing, code name UFL204 which are bolted onto a custom-made frame, fabricated out of box iron The motor has it own plate to support it, using hex slotted head bolts and stabilize it on to the aluminum frame through slider, now the motor position can be adjusted to fit the designed belt length

The shaft needs to withstand the weight and the torque of the whole rotating motion The shaft upper head are threaded, so that 2 nuts are inserted to stabilize the rotating plates Furthermore, another thick and smaller in diameter block is stacked on top, these three plates are concentric via 4 bolted and nuts fastening

One face of the tray is cut open, where we insert a leading path for the bottle to exit A problem the occur often are bottle getting struck at the mouth of the exit For that, we design a turning fan, keeping unwanted bottle out of the way

Figure 3.3: 3D of turning table

Figure 3.4: Actual turning table

Supply tank and input conveyor

Figure 3.5: 3D Design tank and conveyor 1

Our first implementation is to create another way to control the input going into the turning table since after a few tests, the turning table wouldn’t be able to process more than 30 bottles at one time The tank is designed to hold up to 100 bottles These are scramble bottle, fresh out of the blowing chamber With the addition of this tank, it is much easier to input more bottles into the turning table The mechanism that we choose to load bottles is a cleated belt conveyor The tank bottom is tilled at a degreed, to ensure the bottle are always rolling the to the cleats and get carry up the conveyor, onto the turning table The transmission method that we use is chain-sprocket, which is very common among conveyors

Figure 3.6: Chain links transmission

Figure 3.7: Actual tank and conveyor 1

Hook conveyor belt

After the turning table output a line of bottle, this stage unites the direction of the bottles When the bottle enters the conveyor which is speed up, it goes through a hook The right direction is the one with it bottom leading The reason being, at the end of the line,