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
Introduction
Introduction about project
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.
• Lightweight: PET plastic bottles are very lightweight, making them convenient for transportation and everyday use.PET is often transparent, allowing consumers to
12 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:
Introduction about 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
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
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
• Electrical circuit design and 3D modeling
Subject and scope of the research
In this project, the focus is on designing bottle dispensing system using PLC as the control device, while also enabling system monitoring via an HMI To achieve the research objectives, the study includes:
• Variable frequency drive for three phase motor
The scope of this research project is defined as follows:
• 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 positioning of the bottles at the end of this process
• 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 three-phase motor: Variable frequency drive for three- phase motors is used to adjust the speed and rotational frequency of the motor to match the production process of the machine
• User interface:The user interface is simple, easy to operate, and allows for system monitoring
• Limited to PET bottles of specified dimensions that are not deformed by impact
• Design and manufacture aimed at achieving over 80% of the target set by the advisor, which is 1500 bottles.
Research method
The research method employs a technical and experimental approach to implement the design of an automated bottle dispensing system It assesses the feasibility and effectiveness of the system design, utilizing methods such as analysis and comparison as well as data analysis to evaluate the system's performance, features, and scalability compared to other technical approaches
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.
Graduation project structures
The graduation project consists of 8 parts, of which the specific contents are as follows: Chapter 1: Introduction
THEORETICAL BASIS
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.
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
• High initial investment cost, difficult maintenance, and repairs
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
• 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.
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
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 anti- jamming mechanism in the turntable
Motor 4 24VDC 60W + Rotate the bottle anti- jamming mechanism at the exit
+ 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
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
• When there is no obstruction: sensor 1 emits light, sensor 2 receives light The continuous transmission and reception result in an ON state signal
• When there is an obstruction: sensor 1 emits light, sensor 2 does NOT receive light The light obstructed by the blocking object triggers sensor 2 to switch from ON to OFF state
• Not affected by the surface of the obstructing object
• Can be used for objects of various colors
• Long working distance of up to 100m
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
• Easy installation with only one sensor head for both transmission and reception
• Detects transparent, blurry, and thin objects
• Long working distance of up to 20m
• Saves on wiring and installation costs
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
• 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
• Advantages: Capable of transporting heavy loads, high durability, good temperature resistance
• Disadvantages: Complex manufacturing process, high cost
• 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
Design and calculation
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
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
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 3.7: Actual tank and conveyor 1
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, the bottle falls down and stand of it bottom The hook is designed for specific bottle, the
33 condition is that the hook size is smaller than the bottom so that the bottle got push through without any changes Yet the hook is just a bit bigger than the bottle neck, hooking the bottle and flipping it to the right direction The rolling wheel is placed just before the hook to introduce a lever Later on, we decided to use a motor to increase friction between the bottle and the conveyor belt
One more problem that we ran into was the processing speed of the conveyor is always to slow compare to the turn table Therefore, we put a small rubber wheel at the exit to slow down the bottles, ensuring the hook has enough time to recover to it start position and ready for the next one
34 Figure 3.9: 3D in front of Conveyor 2
Calculation and selection of motor for conveyor belt 1
3.2.1 Motor selectiom for conveyor belt 1
Maximum load mass: 3 kg ( when bottles on the conveyor belt simultaneously)
The total of mass: 5 kg
The diameter of the roller as 0,050 m
The displacement per motor revolution is: a = 𝑑 × 𝜋 = 0,050×3.14 = 0,157 (m) (1)
Required motor revolutions per minute: n = 𝑣
Torque on the motor shaft:
We have: T is the toruqe load on the motor shaft (N.m)
R is the roller radius(m) u is the friction coefficient of conveyor belt
=>T1 = 0,15 × 50 × 0,025 × 5 = 0,9375 N.m Torque required for the motor to operate 8h / day
T = k × 𝑇 1 as K is the load factor ( working condition factor) (4)
After using a gear reducer with a ratio of 1:20
Vđc = 1250/20 = 62.5 RPM Based on the motor power and shaft speed, we choose the following motor :
• Brand name: Jiangsu oubang motor manufacture
Figure 3.12: Motor single phase 4IK25GN-C
3.2.2 Calculation of chain transmission ratio
Chain drive transmission, a type of indirect drive mechanism, is used to transmit motion between distant shafts, and can be employed for speed reduction or increase Compared to belt drives, chain drives offer higher load capacity and efficiency They can simultaneously transmit motion to multiple shafts However, chain drives require more complex manufacturing and maintenance, particularly susceptible to impact and wear, especially when lubrication is inadequate and in dusty environments
There are three types of chains: roller chains, bush chains, and tooth chains After careful consideration and evaluation, the authors have decided to choose roller chains due
38 to their structural similarity to bush chains The difference lies in the addition of rollers on the outer surface, allowing the replacement of sliding friction between the bush and sprocket with rolling friction between the roller and sprocket Roller chains exhibit higher wear resistance than bush chains and are less complex to manufacture than tooth chains, hence they are widely used
Figure 3.13: Roller chains Determine parameters:
Base on velocity of roller chains is low so we choose the number of teeth for the frist sprocket from 13-15 So we choose the first sprocket Z1 = 15
Because the target weight – weight of PET bottles is very light, there is no need to increase torque of the transmission so we choose the transmission rate: u = 1
With u= 1 choose the number of teeth for the second sprocket
Z2 = u ×Z1 = 1 × 15 = 15 The conditions to ensure the durability requirement for the chain drive transmission: The calculate power:
Pt = P k kz kn ( equation 5.3 [1]) (6) With the conveyor shaft speed n0= 61 (RPM), with:
K=K0 Ka Kđc Kc Kbt Kđ ( equation 5.4 [1] ) (7) K=1.1,25.1.1,25.1,3.1.35 = 2,74
K0=1: center distance of the sprockets is at an angle < 40 0
Kđc=1: adjustment with one or two sprockets
Kbt=1.3: lubricated working environment meets requirements
Kđ=1,35: working with light impacts
According to Table 5.5 on page 181 of the textbook " Tính toán thiết kế hệ dẫn động cơ khí tập một ”n0 = 61(RPM), choose a single-strand chain transmission with a chain pitch p = 12,7 (mm) The distance of: a p = 10 12,7 = 127 (mm) (8) Base on the parameter table for Z1 and Z2 we have d1 and d2 are 67 mm amin = 0,5 × (d1+d2) + 30 = 0,5 × (67 + 67) + 30 = 97 (mm) (9)
Figure 3.14: Dimension of chain links
According to the formula for the number of chain links: (equation 5.12 [1]) (10)
= 35 Take an even number of chain links: X = 34 chain links
Calculate the center distance: equation ( 5.13 [1]) (11) a = 0,25.p.[X - 0,5(z2+z1)+√[𝑋 − 0,5(𝑧 2 + 𝑧 1 )] 2 − 2( 𝑧 2 −𝑧 1
To avoid excessive tension on the chain, reduce a by an amount equal to (12)
→ a = 128 mm The number of sprocket impacts with in one second according to (equation 5.14 [1])
Parameters of the sprocket: (equation 5.17 [1]) (14) Pitch diameter of the sprocket:
𝑆𝑖𝑛 30 𝜋 = 61 (mm) Outside diameter of the sprocket:
15) = 66,1(mm) Table 5.2 𝑑 1 = 7,75 mm with r = 0,5025𝑑 1 + 0,05 = 0,5025 7,75 + 0,05 = 3,944 (mm)
Calculation and Selection of Motor for Rotary Table
3.3.1 Motor Selection for Rotary Table
Table 1: Diameter: 1m and weight: 10kg
Table 2: Diameter: 0.8m and weight: 8kg shaft: diameter 20mm, weight 3.5kg friction: 0.15
Rotational speed of table and shaft: 55 RPM
Pulley : diameter: 70mm and weight:1kg
Time for the rotary table from maximum speed to complete stop is 11s
We have: Rotational speed of table is 55 RPM → f= 55
T = 𝐼 𝛼 𝑆𝐹 = 1,89 0,52 5 = 4,914 𝑁 𝑚 (19) Required torque for the motor to operate under 8h / day
T = k × 𝑇 1 as k is the load factot (20)
After using a gear reducer with a ratio of 1:25
25 = 60 RPM Based on the motor power and speed, we choose the following motor:
• Motor name: Motor 3 phases BHI62SMT – G2
Figure 3.16: Motor 3 phases BHI62SMT – G2
3.3.2 Calculation of belt transmission ratio
Calculate the toothed belt transmission:
6000 = 2.01 m /s = 2010 mm/s (page 54 [1] ) (22) Actual transmission ratio ut = 𝑑 2
1 = 0.02= 2 % < 4% (24) as= (1,5÷2) ( d1+ d2 ) = 210÷ 280 take as = 250 mm (equation 4.3 [1 ]) (25)
Addition of 100 to 400mm depending on belt joint method
Requirement for minimum lifespan Lmin ≤ 𝑖 max
As: i – bending cycles of the belt per second:
Calculation and motor selection for conveyor belt 2
The total of mass : ≈ 0.4 kg
Calculation of electric motor parameters
The displacement per motor revolution is : a = 𝑑 × 𝜋 = 0,028×3.14 = 0,0879 (m) (28) Required revolutions per minute on the working shaft: n = 𝑣
Torque on the motor shaft:
T: is the torque load (N.m) W: is the total mass (N) R: is the roller radius (m) SF: is the safety factor u: friction coefficient
T1 = 0.15 × 0.4 × 10 × 0.014 × 5 = 0,042 N.m Torque required for the motor operate 8h/ day
T = k × 𝑇 1 as k is the load factor (31)
Using a pulley transmission with a ratio 4:1
Based on the motor power and shaft speed, we choose the following motor
• Motor name: DCM50-775 45 VDC rpm
Belt drive is used to transmit power between distant shafts The belt is mounted on two pulleys with initial tension, creating frictional force on the contact surface between the belt and the pulley, which allows the load to be transmitted Due to the flexibility of the belt, the transmission system operates smoothly, quieter, and is more suitable for high speeds
Calculation for toothed belt drive
6000 = 0.039 m /s = 39mm/s (page 54 [1] ) (32) Actual transmission ratio: ut = 𝑑 2
0.2424 = 0.0198 = 1.98 % < 4% (34) as= (1,5÷2) ( d1+ d2 ) = 93.75÷ 125 take as = 125 mm (equation 4.3 [1]) (35)
4.125 = 351.13(equation 4.4 [1] ) (36) Adding from 100 to 400 mm depending on the belt connection method
Requirement for minimum lifespan Lmin ≤ i_max Where: i is the number of belt flexes per second:
Calculation and durability test
Calculation and testing of shaft durability:
Axle control according to fatigue durability for wheel shafts: Axis diameter is determined by formula: d ≥ ∛(𝑇 ∕ (0,2[𝜏])
Fatigue testing at dangerous cross section:
According to formula 10.19 in the reference document (document [1], page 195):
In which: [s]: permissible safety coefficient, [s] = 1,5…2,5 According to formula 10.20 and 10.21 (document [1], page 195):
According to formula 10.20 and 10.21 (document [1], page 195):
𝜎 −1 and 𝜏 −1 are the limit of bending and twisting fatigue
For bending stress rotation axis changes cyclically, therefore: 𝜎𝑚𝑗 = 0 According to formula 10.22 (document [1], page 196):
According to table 10.6 (document [1], page 196) with axis with round area:
When the axis rotates one way, the torsional stress changes with the arterial cycle:
In table 10.6 (document [1], page 196) with axis with round area:
According to formulas in 10.25 and 10.26 (document [1], page 197):
𝑘 𝜏𝑑 = (𝑘 𝜏 ∕ 𝜀 𝜏 + 𝑘 𝑥+1 ) ∕ 𝑘 𝑦 (50) k x : stress concentration coefficient, by table 10.8 (document [1], page 197) k x = 1.1 k y : shaft surface endurance coefficient, according to table 10.9 (document [1], page 197) k y = 1.6
𝜀𝜎 and 𝜀𝜏: size coefficient refers to the effect of axis size on fatigue limits
𝑘𝜎 and 𝑘𝜏: actual stress concentration coefficient when bending and twisting
So that, 𝑠 𝑗 : the safety coefficient is considered only with stress and the safety coefficient are only considered with the next stress at the table level
⟹ Satisfied with the endurance conditions
Control System Design
Electrical System Design
4.1.1 Requirements for the Electrical System
The electrical system of the machine must be installed to ensure absolute safety for users The wiring must be securely installed to avoid vibration, insulated, and equipped with conduits if necessary In case of connections, use electrical connectors such as Domino and ensure firm connections on the pins of the Domino The electrical system needs to be waterproof and dustproof Therefore, the devices will be installed in an electrical cabinet Inside the electrical cabinet, the system needs to be assembled securely The wires must be placed in cable clamps and avoid excessive bending or cutting of wires within the clamps The clamps should be neatly arranged, aesthetically pleasing, and easily accessible for maintenance and replacement The devices in the cabinet must be arranged neatly, separated, with a clear distinction between high-voltage devices and low-voltage devices (220V and 24V)
CB (Circuit Breaker) is connected to the 220V power supply to protect the electrical system
The 24V power supply, Inverter, and 220V Relay are connected downstream from the CB
The 24V power supply provides power to the PLC, 24V Relay, sensor 1, sensor 2, and HMI
The PLC receives signals from sensor 1, sensor 2, and HMI to control the entire system
The PLC is programmed to control the inverter for motor 2 (3-phase motor), open/close the 24V relay, and control the 220V relay to operate motor 1, 3, 4, 5, 6, and the blower.
Components Used
A circuit breaker (CB) is a device used in electrical systems to protect electrical equipment and users from the risks of overloads or short circuits in the power network Its main function is to cut off or interrupt the electrical circuit when a fault occurs, such as overload, short circuit, or imbalance in the electrical system
Circuit breakers play a crucial role in maintaining the safety and stability of the electrical system and are often integrated into electrical control panels or other electrical devices
Here are the specifications of the CB 2P 32A PS45N/C2032 Sino :
• Number of poles: 2 poles in, 2 poles out
CB has several important applications in the electrical system, including:
Equipment and circuit protection: CB disconnects the electrical circuit when it detects overload or short circuit, protecting electrical equipment, components, and conductors from damage and explosions caused by heat generation
Human protection: CB helps prevent electrical accidents caused by overload or short circuits, minimizing the risk of injury or death to humans when in contact with electrical equipment
Fire prevention: Disconnecting the electrical circuit in case of overload or short circuit helps limit the risk of explosions due to increased heat in electrical devices and conductors
Easy restoration: After the cause of overload or short circuit is rectified, CB can be easily reset to restore the operation of the circuit without replacing components
Time and cost-saving: CB saves time and costs compared to using traditional electrical protection devices like fuses because they can be reset after interrupting the electrical circuit without replacement
Monitoring and controlling current: CB also allows monitoring and controlling the current flow in the circuit, ensuring safe and efficient operation of the electrical system
The power supply 24V 5A is a power converter from AC to DC with small dimensions, easy to move, and stable output suitable for powering modules using 24V electricity, such as cameras, LED lights, DC water pumps, electromagnetic locks, electromagnets, solenoid valves, relay modules, sensors, etc
This power supply has input protection against overvoltage, short circuit, and overcurrent, making it suitable for medium-duty applications
Specifications of the power supply:
• Input voltage range: AC110/220VAC ± 15%
• Output voltage: 24VDC adjustable within 5%
• Overload protection : >25% of rated power
4.2.3 Variable Frequency Drive VFD-M 0.4KW Delta
Figure 4.4: Variable Frequency Drive VFD-M 0.4KW Delta
Delta Variable Frequency Drive (VFD) is one of the widely used electronic control devices in electrical control systems It is utilized to regulate the speed and power output of generators The Delta VFD is manufactured by Delta Electronics, a Taiwan-based power company established in 1971, specializing in the production of electrical control devices, including variable frequency drives The company has achieved significant milestones in this field and has become one of the leading VFD manufacturers globally Currently, Delta VFDs are employed in a wide range of electrical control applications, from small-scale to large-scale systems
Applications of the VFD include:
Soft start: The VFD helps reduce the starting current, ensuring a smooth transition from high starting current to low starting current This ensures the safety of the motor, avoiding excessive loads VFDs are often used to reduce starting currents, minimize component failures, and increase the durability and lifespan of motors
Speed control and motor reversal: Only VFDs can change motor speed quickly and easily in automated systems Moreover, they facilitate motor reversal when connected to a
DC power source and current, converting it into AC current The advantages of VFDs make them stand out and are used more frequently compared to traditional starting methods
Electrical system safety protection: In traditional starting methods, the starting current is higher than the rated current With VFD starting, the starting current is much lower than the rated current
Energy saving: VFDs save energy by adjusting the motor's starting speed During operation, when the motor runs at a specific speed, unused power loads cause waste When a VFD is installed, the motor speed adjusts according to the load, saving 20% - 30% of energy consumption In terms of cost, it can save a significant amount for users
Safe monitoring and control: Installing VFDs in electrical systems enhances process monitoring and safer operation, allowing parallel devices to operate stably This improves production efficiency and meets user needs, particularly in terms of safety
In this article, the authors use this VFD to control a three-phase motor with the following specifications:
• Cooling method: Integrated cooling fan
• Equipped with braking unit and DC choke
• Protection functions: Overvoltage protection, overcurrent protection, overload protection, overheat protection, external fault, thermal protection, ground fault protection, self-diagnosis
Around 1968, automobile manufacturers introduced the initial technical requirements for programmable logic controllers (PLCs) The primary purpose was to replace cumbersome control panels, which consumed a lot of energy and often required frequent replacement of faulty coils or broken contactors The secondary goal was to create a control device with flexibility in changing control programs These technical requirements laid the foundation for industrial computers, with the advantage of easy programming by technicians and manufacturing engineers With programmable control devices, downtime in production can be reduced, production system flexibility can be enhanced, and adaptation to changes in production can be achieved Some computer-based control device manufacturers have produced programmable control devices called PLCs
Figure 4.5: PLC DVP40ES2 The first PLCs used in the automotive industry in 1969 offered significant advantages over relay-based control systems These devices were easy to program,
57 occupied less space in manufacturing workshops, and had higher reliability than relay systems PLC applications quickly expanded to all other manufacturing industries
Today, we can see PLCs in thousands of industrial applications They are used in oil processing, food processing, gas processing, waste treatment, pharmaceuticals, and more PLCs can be connected to computers to transmit, collect, and store data, including control processes, diagnose faults, and remotely change control programs
In this article, the authors use the Delta DVP-ES2 PLC to control the entire electrical system The Delta DVP-ES2 PLC is a large-sized PLC from Delta, an upgraded version of the previous DVP-ES version with many improvements such as processing speed, program memory capacity, and pulse output speed
• Power supply voltage: Single-phase 220VAC
• Communication interface: RS232/RS485 in MODBUS ASCII/RTU
• High-speed pulse output: max = 100 KHZ
Figure 4.6:HMI SAMKOON SK-102HS HMI, short for Human Machine Interface, is a device integrated into various machinery or equipment that allows users to interact with the machine or device through a
58 touchscreen or buttons In a more general sense, any machinery that allows us to adjust, communicate, command, and control through a single screen is referred to as HMI
HMI is an essential device that contributes to speeding up the automation process of stages and complex production processes that require high precision Therefore, HMI is applied in most manufacturing stages across various industries
• In industries such as oil and gas, electronics, steel manufacturing, textile, electricity, water industry, automotive, and motorcycle manufacturing…
• In electronic or digital devices such as disc players, TVs, speakers, amplifiers, etc., through integrated buttons on the device
• Smart devices such as smartphones, iPads, tablets, laptops, etc., through keyboards and touch screens
• HMI is used in devices such as microwave ovens and microwave ovens to adjust temperature and time
• In this article, the author's team uses the SAMKOON SK-102HS HMI to communicate with machinery
• Com1: RS232/422/485 ( Modbus, Free protocol)
In this article, the author's team utilizes the BJ300-DDT-NPN optical sensor
The BJ series optical sensors are compact, high-performance sensors with excellent anti-interference capabilities, enabling accurate and reliable object detection The BJ series integrates sensitivity adjustment and Light On/Dark On modes, making it convenient for device setup It also includes built-in protection circuits for reverse power polarity, output short-circuit, and overcurrent protection, enhancing anti-interference capabilities and minimizing the impact of light
Figure 4.7:Sensor BJ300-DDT- NPN
In this article, the author's team utilizes the BJ300-DDT-NPN optical sensor
Electrical system installation
The electrical system is constructed based on the complete electrical drawings and circuit diagrams During operation, vibrations can cause electrical connections to loosen, resulting in incorrect signals sent back to the controller Therefore, all wires entering the electrical cabinet or control devices to peripheral devices must be carefully insulated with insulated conduit The main purpose is to prevent collisions, vibrations during machine operation, and to enhance the aesthetics of the electrical system The layout of the contents of the electrical cabinet plays a crucial role in ensuring the performance and ease of maintenance of the electrical system Long wires that cannot be shortened will be securely fastened with tie-wires This helps to keep the system neat and orderly The electrical cabinet is placed on the machine frame supports and will be securely attached to the picture chamber, with the machine's wiring routed underneath the cabinet All electrical connections are crimped to avoid loose connections causing electrical leakage and short circuits
All electrical wires must be tightly tied to the machine, avoiding the wires from touching the ground, which can lead to unwanted electrical leakage as well as physical external factors that may cause electrical leakage
The electrical cabinet drawing plays an important role in the design and construction of the electrical cabinet It serves as a communication bridge between the designer and the installer and maintainer of the electrical cabinet Therefore, the drawing table requires clear
63 representation of the position of installation of equipment within the scope of the electrical cabinet, conductor routes, wire marking schemes, as well as the wiring connecting the external actuators to the electrical cabinet
The authoring team has represented these drawings through Autocad Electrical software
This drawing table shows the wiring diagram of control circuits in industrial control systems This drawing table is commonly used in the design, installation, and maintenance of automation and control systems in industrial environments The control circuit diagram is used to represent the structure and connections of control components in the system It provides detailed information on the installation and maintenance of electronic and control elements for the purpose of maintaining and installing control devices
The drawing table adequately and clearly illustrates the wiring diagram from the PLC's IO devices (sensors, push buttons, intermediate relays, etc.) while also showing the relationship between the VFDs, HMIs, and the PLC The circuit also describes the power supply to the main devices accurately
The motor circuit diagram is a graphic document depicting wires and connections, often used to describe and represent the electrical circuit of hydraulic systems, where components such as motors, engines, valves, proximity sensors, and other components are used
The group's drawing clearly presents the wiring diagram from the control devices (PLC, VFD, relay) to the actuators It also accurately depicts the power sources of these devices
Based on the power ratings of the devices, the group has chosen 1mm² cross- sectional area wires for control wiring and 2mm² wires for hydraulic circuit wiring Additionally, to facilitate installation and maintenance, the group has chosen appropriate colors for the wires as follows:
Red for L 220VAC, 24VDC wires
Blue for N 220VAC, 0VDC wires
Yellow for load-bearing wires
All electrical connections are crimped with cable lugs to prevent loosening due to vibration, which can lead to electrical leakage and short circuits
Figure 4.13: An overview image of the electrical cabinet
Figure 4.14: The front face of the electrical cabinet
Images of the devices inside the electrical cabinet
Figure 4.15: Images of the components inside the electrical cabinet
The team has successfully built the electrical cabinet drawing and carried out the installation for industrial purposes The electrical cabinet ensures labor safety by securely crimping cable lug terminals onto the wire ends The electrical wires are neatly routed within insulated conduits The arrangement of relays, terminal ports, and power sources is rational, facilitating easy maintenance and installation The electrical cabinet meets the requirements for operating the electrical system for the project
Building Flowchart and Block Diagram of systems
Figure 4.17: General flowchart Explanation of the flowchart:
In this mode, the operator will pour bottles into the tank If the number of bottles in the tank is less than 40, they will continue pouring bottles in If the quantity of bottles
69 exceeds 40, it switches to Auto mode At this point, conveyor 1 is responsible for supplying bottles to the turning table When the first bottle is detected by sensor 1, the signal returned to the PLC of sensor 1 will activate the turning table to rotate at a speed corresponding to a VFD frequency of 17HZ, and the bottle anti-jamming mechanism motor 3 and motor 4 will operate Simultaneously, the signal from sensor 1 will be recorded in the PLC memory to count the number of bottles supplied to the turning table When the turntable speed exceeds a VFD frequency of 9HZ, motor 5 will be activated to pull the bottle flipping conveyor, and motor 6 will operate When a bottle passes through the anti-jamming mechanism output of the turning table, sensor 2 will count the number of bottles leaving the turntable At this point, an algorithm will subtract the number of bottles input to the turning table from the number of bottles output from the turning table to determine the remaining number of bottles on the turntable If the number of bottles on the turntable is greater than 15, the system will stop conveyor 1 and maintain the remaining mechanisms in the system Once the number of bottles on the turntable drops below 11, conveyor 1 will resume supplying bottles Bottles that have left the turntable will continue through the flipping mechanisms and fall into the detection area of sensor 3 The signal from sensor 3 will activate the blower to blow the bottles into the next system, thereby completing the automatic bottle supply process
When the bottle is loaded into the turning table by conveyor 1 Sensor 1 counts the number of bottles entering the turning table When the bottle comes out of the turning able, sensor 2 will count the number of bottles coming out of the turning able At this time, the PLC will calculate the number of bottles in the turning table by subtracting the number of bottles from the number of bottles entering If the number of bottles in the turning table is
15, then the conveyor 1 will temporarily stop operating until the number of bottles in the barrel is