Automatic t shirt folding machine

AUTOMATIC T-SHIRT FOLDING MACHINE GANPAT UNIVERSITY U V Patel College of Engineering Ganpat University, Kherva-382711 Ta & Dist.: Mehsana (North Gujarat) Ph.: 02762-286805, 286081 Fax (D): 286080 E-mail: info@uvpce.ac.in Web: www.uvpce.ac.in AUTOMATIC T-SHIRT FOLDING MACHINE Project Report DEEPAK SHROFF (09MC116) ABHAY ODHPAL (09MC127) PARESH SOMANI (0MC130) AUTOMATIC T-SHIRT FOLDING MACHINE CERTIFICATE Towards partial fulfillment of requirement for the award of Degree of “Bachelor of MECHATRONICS ENGINEERING” of “GANPAT UNIVERSITY” This is the record of candidates own work carried out by them under our supervision & guidance In our opinion the work submitted has reached a level required for being accepted for exam The matter embodied in this project has not been submitted to any other university or institute Project Report on “ AUTOMATIC T-SHIRT FOLDING MACHINE” Submitted By: DEEPAK SHROFF (09MC116) ABHAY ODHPAL (09MC127) PARESH SOMANI (09MC130) GUIDE: COUNTERSIGNED: Prof S.G.PATEL Prof J P PATEL Assistant Professor, Head of Department, Mechatronics Engineering Department, Mechatronics Engineering Department, AUTOMATIC T-SHIRT FOLDING MACHINE U.V Patel College of Engineering, U.V Patel College of Engineering, Kherva, Mehsana Kherva, Mehsana 1.1.1 Index INTRODUCTION INTRODUCTION TO AUTOMATION DEFINITION OF PROJECT BACKGROUND OF PROJECT 2.CONCEPT 3.DESIGN AND CONSTRUCTION 3.1 HOW DID WE START MAKING THIS PROJECT 3.2 CONSTRUCTION AND FABRICATION 3.3 DESIGN OF ELECTRONIC CIRCUIT 3.4 PNEUMATIC CIRCUIT DESIGN AND CONSTRUCTION WORKING AND RESULTS PROBLEM FACED DURING CONSTRUCTION AND DESIGN DESIGN CALCULATIONS CONCLUSIVE REMARKS FURURE SCOPES REFERENCES AUTOMATIC T-SHIRT FOLDING MACHINE 1.1.2 Acknowledgments Our project has been a result of our own hard work but this project could not have become a reality without the support and help of many of our friends and faculty members We take this opportunity to acknowledge their help and thank them for their goodwill We would like to thank our Principal and Head of Department Shri J.P.PATEL for his unwavering support and kind co-operation He has been a great teacher and true mentor to us throughout our degree We would also like to thank our project guide Shri S.G.PATEL for his support and conceptual help at various technical problems We’ve had the opportunity of being his students during three semesters and have learnt a great deal from him The very concept of the project as well as its realization would not have been possible without him We would also like to acknowledge and thank the efforts of Shri D.K.SONI for helping us during making of this project Lastly we would like to thank all the faculty members of Mechatronics department for their support throughout the year Apart from our faculty members we’ve also gained a lot of experience and expertise from interacting with our classmates and friends We would like to thank them all for being with us in this journey and making it memorable DEEPAK SHROFF (09MC116) ABHAY ODHPAL (09MC127) PARESH SOMANI (09MC130) AUTOMATIC T-SHIRT FOLDING MACHINE ABSTRACT Our project ”AUTOMATIC T-SHIRT FOLDING MACHINE ” , the idea came into our mind by viewing the t.v serial ‘BIG BANG THEORY’ in which one scientist name Sheldon Cooper used such kind of t-shirt folding flaps to fold his t-shirts We thought of making this machine by operating it automatically Then we searched for existence of such kind of machines, and we found that there is a company in Greece that makes automatic T-shirt folding machine and the name of the company is ‘THERMOTRON’ Initially we thought of making the project related to automatic car parking but the problem related to Image Processing was faced by us So we thought of making the T-Shirt folding machine T-shirt folding machine aims at substantially contributing to increasing high-quality output of textile products and especially ready-made clothes such as t-shirts, jeans, trousers, shirts, Punjabi suits etc., to cater the needs of manufacturing units which have a capacity of producing 3000040000 t-shirts per day AUTOMATIC T-SHIRT FOLDING MACHINE INTRODUCTION • Automation is the use of machines, control systems and information technologies to optimize productivity in the production of goods and delivery of services The correct incentive for applying automation is to increase productivity, and/or quality beyond that possible with current human labor levels so as to realize economies of scale, and/or realize predictable quality levels In the scope of industrialisation, automation is a step beyond mechanization Whereas mechanization provides human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements while increasing load capacity, speed, and repeatability Automation plays an increasingly important role in the world economy and in daily experience Automation has had a notable impact in a wide range of industries beyond manufacturing (where it began) Once-ubiquitous telephone operators have been replaced largely by automated telephone switchboards and answering machines Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions In general, automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries The main advantages of automation are: • • • • • Increased throughput or productivity Improved quality or increased predictability of quality Improved robustness (consistency), of processes or product Increased consistency of output Reduced direct human labor costs and expenses The following methods are often employed to improve productivity, quality, or robustness • • • • • • • Install automation in operations to reduce cycle time Install automation where a high degree of accuracy is required Replacing human operators in tasks that involve hard physical or monotonous work.[3] Replacing humans in tasks done in dangerous environments (i.e fire, space, volcanoes, nuclear facilities, underwater, etc.) Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc Economic improvement: Automation may improve in economy of enterprises, society or most of humanity For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century Reduces operation time and work handling time significantly AUTOMATIC T-SHIRT FOLDING MACHINE • • Frees up workers to take on other roles Provides higher level jobs in the development, deployment, maintenance and running of the automated processes In garment industries, we already have screen printers, knitting machines, automatic looms, packing machines to easy the work intensity of industries, reduce the labours, and hence increase the overall production rate of the industry But what if folding of clothes is also possible automatically? Driven by such curiosity, we start our adventure trying to find a more scientific & technological way to get easier folding of clothes T-shirt folding machine aims at substantially contributing to increasing high-quality output of textile products and especially ready-made clothes such as t-shirts, jeans, trousers, shirts, Punjabi suits etc., to cater the needs of manufacturing units which have a capacity of producing 30000-40000 t-shirts per day Besides designing the machine, it also aims at improving price per performance ratio Our project i.e AUTOMATIC T-SHIRT FOLDING MACHINE , is to develop a more efficient and easy cloth folding method by trying different methodologies and advanced tools to completely eliminate the size variation of a fold, to substantially reduce the number of labours needed and to reduce the time consumed to fold the t-shirts to a great extent AUTOMATIC T-SHIRT FOLDING MACHINE CONCEPT Manual t-shirt folding flaps were already available in the market as shown in figure below AUTOMATIC T-SHIRT FOLDING MACHINE Here also, we can completely eliminate the variations in the fold of a t-shirt, but since it is manual, so time consumed was not reduced much Also as many labours were required as much required by the simple traditional t-shirt folding process That is why, we decided to automate the process of t-shirt folding by using concepts mentioned below We used electronic circuit to signal the pneumatic valves, which controlled the actuation of pneumatic cylinder These pneumatic cylinders were used to actuate the flaps Also, not any proper positioning of this manual folding flaps was possible, but in automatic t-shirt folding machine we have made a dedicated table with base considering the ergonomics of the average human height We have made the base detachable so, that only the base is needed to change for changing the variation in the sizes and the variety of clothes (for example:- shirts, pants, jackets, ladies suit etc.) Only thing we need to change is to change the mode of machine i.e to change the mode from t-shirt folding to shirt folding or pant folding and so on DESIGN AND CONSTRUCTION How did we start making this project !!! First stage experiment:After absorbing the critical experience of the first experiment by folding the t-shirt with the help of bare hands, we come to a conclusion that the T-shirt which has lines made by folding will leads to unrealistic and false appearance It also took too long to to get folded and all the t-shirts were having some variation in their sizes as were observed when stack of ten t-shirts were made Second stage experiment :The designed experiments which introduce tools were conducted During this phase we tried folding the t-shirt using cardboard flaps AUTOMATIC T-SHIRT FOLDING MACHINE But then we decided to make flaps of machine with little modification using the concept of cardboard flaps The only difference in the new design was that every flap was hinged individually and flap B can also be moved to place the folded t-shirts on to the stacker FINALLY, we decided to automate the whole process by using electronic circuit made using a microcontroller (AT 89 C 51) and pneumatic cylinders Pictures of initial work are shown below We tried to make t-shirt folding flaps with the help of waste cardboard pieces and we were succeded in folding the t-shirt 10 AUTOMATIC T-SHIRT FOLDING MACHINE Circuit diagram 33 AUTOMATIC T-SHIRT FOLDING MACHINE Hardware description The components are connect on a Printed Circuit Board as per the given connection details in the circuit diagram The functioning of the circuit can be explained with respect to the action format that occurs in the circuit As the supply is switched ON and both the switches are open the switching supplies ideally 5V is given to the microcontroller Suppose if the any of the switch is closed the supply gets directly shorted with the ground This indicates the microcontroller about the switch positions and thus generates the signal as per the given program for the respective switches position The transistor used allows current to conduct through it when ever a positive pulse is given at its base that is given by the microcontroller in accordance with the program As the transistor is forward biased the supply that is used to actuate the Solenoid Valve gets connected with the Valve terminal and valve start actuating As soon as the voltage is encountered the NPN transistor used goes into reverse bias and stops its conduction so the valve terminal supply gets disconnected till the base current is volts By this we can deduce that the actuation of the valve is directly dependent on the supply given by microcontroller to the base which indeed depends on the program written So the speed of working of the circuit depends on the number of switches used, for instance in the above circuit two switches are used so the X number of speed levels are = So the number of speed levels for X switches will be 34 AUTOMATIC T-SHIRT FOLDING MACHINE Working of Circuit Fig 1-4 shows the working of circuit Here in real circuit instead of LED’S Solenoid Valve are connected Fig-1 35 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-2 36 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-3 37 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-4 38 AUTOMATIC T-SHIRT FOLDING MACHINE • When the switch1 is closed and switch is open in this position the supply from the switch1 is shorted into the ground terminal so microcontroller get voltage so the switch is considered as • When switch1 is closed then it produce signal to pins p2.0 to p2.3 and between each signal delay is provided • When the switch2 is closed and switch is open in this position the supply from the switch1 is shorted into the ground terminal so microcontroller get voltage so the switch is considered as • When switch2 is closed then it produce signal to pins p2.0 to p2.3 and between each signal delay is provided and this procedure will repeat upto 10 times • For stoping the program the reset circuitry is incorporated which is explained below: Reset circuit: Reset pin is an input and is active high Upon applying a high pulse to this pin the microcontroller will reset and terminates all activities Component list 39 AUTOMATIC T-SHIRT FOLDING MACHINE Name of component AT89C51 Microcontroller Resistor Capacitor Switch Crystal oscillator ULN2003A Relay Solenoid Valve IC 7895 Make Value ATMEL R1 C1,C2,C3 S1,S2 X1 ATMEL HC Jelpc LM Number 10KΩ 33pF,33pF,10µF 11.0592MHZ 6V 12V 9-12V 1 1 4 Pneumatic circuit design and construction Pneumatic circuit is as shown Cylinders used are of 250 mm stroke length and 20 mm bore We have used 5/2 solenoid operated spring return valves These valves are configured with electronic circuit to operate cylinders in a proper sequence WORKING AND RESULTS 40 AUTOMATIC T-SHIRT FOLDING MACHINE • There are two modes of working (1) For single t-shirt When button is pressed , the single t.shirt placed over the flaps gets folded (2) For 10 t-shirts When button is pressed, 10 t-shirts in one go can be folded All u need to is to just place t-shirts onto the flaps and no need to press button again and again Between two t-shirts, the second delay is given for placing another t-shirt after one gets folded PROBLEMS FACED DURING CONSTRUCTION • During linkage design During fabrication, the main problem faced by us was how to design a link which can fold the flaps to desired angle and what mechanism to use while doing so We had two options to choose from namely, (1) To use pneumatic cylinders (2) To use motors With pneumatic cylinders, we had to a lot of work related to the issues like what kind of linkage to use for converting translator motion of the pneumatic cylinder to rotary motion With motors, we had to use stepper motor but operation of that was quite slow To fold tshirt we need fast swapping motion of the flaps (otherwise the t-shirt may get slipped down over the flap), therefore we didn’t choose stepper motor Then we decided to use permanent magnet d.c motor (p.m.d.c.m), but again, its movement was not accurate plus one another circuit was needed to control the motion of the motor and also motors were bit costly The motors were not getting fitted properly onto the base plate and they were creating hinderance to the home position of the flaps Also, if we would have used the motors, the channel joint (the joint used to connect flaps with the base plate ) would have been designed accordingly to accommodate the shaft of the motor This again would have added a lot to the cost 41 AUTOMATIC T-SHIRT FOLDING MACHINE THAT IS WHY, we diverted our minds towards using pneumatic cylinders and atlast, we got an idea of the mechanism as mentioned in the construction above • During fabrication During fabrication, there wasn’t any such problem except the mounting of cylinders We had to cut the cylinder mounting base of the table and reweld it as cylinders were not getting adjusted Cutting those welded joints was big task Due to unavailability of resources , we had to cut it with manual saw Then we rewelded it to a proper position as per new calculations • During electronic circuit design Relay’s coil was not able to operate with outputs from controller pin so we had used ULN2003A (relay driver IC) to operate the relay’s When supply is given to Microcontroller then output pins of controller sets to higher state ,so to overcome this problem we had done certain changes in program CALCULATIONS Ideal condition Flap weight=300grams Force =m*g =0.3*9.81 =2.943N Area of Cylinder = /4*d² =π/4*(20)² =314.16mm² 42 AUTOMATIC T-SHIRT FOLDING MACHINE =314.16*10^-6m² Pressure =F/A =2.943/(314.16*10^-6) =9367.84N/m² 0.1bar But for quick operation we will take value of pressure to be p = 0.5bar ……… (1) Moment of hinge M(h)=F*(20/100) =2.943*(20/100) =0.59 0.6N-m Under loading condition Weight will be approximately=300+100grams =400grams Flap Force =0.4*9.81 =3.924N Pressure =F/A =3.924/(314.16/1000000) =12490.45N/m² Assuming P=0.5bar……… (2) From & 2, we get, P=0.5bar so in ideal or in loading condition pressure will remain almost constant 43 AUTOMATIC T-SHIRT FOLDING MACHINE So, P = 0.5 bar Moment when loading M(h)=3.924*(20/100) =0.7848N-m As we need to take the constant pressure for every flap, so we will take the maximum pressure i.e the pressure required by flap A i.e P = 0.5 bar 44 AUTOMATIC T-SHIRT FOLDING MACHINE CONCLUSIVE REMARKS During this wonderful project I have came across many difficulties but I have tackled them successfully During this, I have gained knowledge about various machines used in industries, the ideas and tricks that are used in industry The project facilitate much more improved functions related with weight loss , simplifying operation, and other aspects And more over it will not add cost but we tried to minimize the cost also Even then we want to say that there is much space to improvement in the machine The experience will be very useful for our future During completing this project, we came to know the various problems that occur in any process And if you want to success you have to manage each and every part of any task or project Now we are more confident that we can also something new and are interested to start a new career in mechatronics engineering 45 AUTOMATIC T-SHIRT FOLDING MACHINE FUTURE SCOPES Folding & Packing Machine Multi-steam Press Thermal Press Printing Machine • All processes shown above can be embedded in a single a machine 46 AUTOMATIC T-SHIRT FOLDING MACHINE REFERENCES • Books on Microcontroller: The 8051 microcontroller and embedded systems by JANICE GILLISPIE MAZIDI & Kenneth J Ayala • www.pearsoned.co.in/muhammadalimazidi • www.MicroDigitalEd.com • www.8051.com • MagicPrints, Ahmedabad • Thermotron, Bangaluru • Pneumatic Systems By: P Majumdar • Machine Design By:- V B Bhandari 47 [...]... T- SHIRT FOLDING MACHINE 15 AUTOMATIC T- SHIRT FOLDING MACHINE 16 AUTOMATIC T- SHIRT FOLDING MACHINE 17 AUTOMATIC T- SHIRT FOLDING MACHINE 5 Some slots were made on the base plate so as to create some space for actuator (pneumatic cylinder) to actuate Holes were also drilled over this plate to attach flaps over it and also to attach this plate to the main base 18 AUTOMATIC T- SHIRT FOLDING MACHINE Complete... alternative path for the current 32 AUTOMATIC T- SHIRT FOLDING MACHINE Circuit diagram 33 AUTOMATIC T- SHIRT FOLDING MACHINE Hardware description The components are connect on a Printed Circuit Board as per the given connection details in the circuit diagram The functioning of the circuit can be explained with respect to the action format that occurs in the circuit As the supply is switched ON and both the.. .AUTOMATIC T- SHIRT FOLDING MACHINE 11 AUTOMATIC T- SHIRT FOLDING MACHINE CONSTRUCTION Fabrication 1 We made one base as shown in figure 2 Drilling of holes on this stand of base to attach it to the main table with the help of nuts and bolts The table is as shown below 12 AUTOMATIC T- SHIRT FOLDING MACHINE 3 Then we started designing the flaps The size of flaps were chosen as per the average size of t- shirt, ... 28 AUTOMATIC T- SHIRT FOLDING MACHINE current limiting which makes the IC very rugged Output currents up to 1A can be drawn from the IC provided that there is a proper heat sink The voltage source in a circuit may have fluctuations and would not give the fixed voltage output The voltage regulator IC maintains the output voltage at a constant value The IC 7805 indicates the fixed output volt Relay 29 AUTOMATIC. .. AUTOMATIC T- SHIRT FOLDING MACHINE Capacitors:- A capacitor is used to stores an electrical charge between the two plates Ceramic capacitors belong to the family of ELECTROSTATIC capacitors They are Non-Polar They dominate the lower range of capacitance values 24 AUTOMATIC T- SHIRT FOLDING MACHINE They are available in both leaded and surface mount styles The vast majority are fixed capacitance value (their... at its base that is given by the microcontroller in accordance with the program As the transistor is forward biased the supply that is used to actuate the Solenoid Valve gets connected with the Valve terminal and valve start actuating As soon as the 0 voltage is encountered the NPN transistor used goes into reverse bias and stops its conduction so the valve terminal supply gets disconnected till the... not user variable) For our application we had used 33pf, 1000µf & 47µf capacitors ULN2003A 25 AUTOMATIC T- SHIRT FOLDING MACHINE 26 AUTOMATIC T- SHIRT FOLDING MACHINE The ULN2003A is high-voltage high-current Darlington transistor arrays Each consists of seven NPN Darlington pairs that feature high-voltage outputs with common-cathode clamp diodes for switching inductive loads The collector-current rating... switches are open the switching supplies ideally 5V is given to the microcontroller Suppose if the any of the switch is closed the supply gets directly shorted with the ground This indicates the microcontroller about the switch positions and thus generates the signal as per the given program for the respective switches position The transistor used allows current to conduct through it when ever a positive... 1Features • 500-mA-Rated Collector Current (Single Output) • High-Voltage Outputs: 50 V • Output Clamp Diodes • Inputs Compatible with Various Types of Logic • Relay-Driver Applications 27 AUTOMATIC T- SHIRT FOLDING MACHINE IC 7805(voltage regulator) 7805 is a 5V fixed three terminal positive voltage regulator IC The IC has features such as safe operating, area protection, thermal shut down, internal... perfect fold of the t- shirt which is sufficient to get a Electronic circuit design and construction • To rotate the flap automatically through Pneumatic cylinder a MICROCONTROLLER or PLC is required • But from them we had used MICROCONTROLLER Because it reduce cost of project • To operate Pneumatic cylinder automatically a Solenoid Valve is required • To operate Solenoid valve, interfacing of controller ... also shown in figure below 14 AUTOMATIC T-SHIRT FOLDING MACHINE 15 AUTOMATIC T-SHIRT FOLDING MACHINE 16 AUTOMATIC T-SHIRT FOLDING MACHINE 17 AUTOMATIC T-SHIRT FOLDING MACHINE Some slots were made... Fig-1 35 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-2 36 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-3 37 AUTOMATIC T-SHIRT FOLDING MACHINE Fig-4 38 AUTOMATIC T-SHIRT FOLDING MACHINE • When the switch1 is closed... tried to make t-shirt folding flaps with the help of waste cardboard pieces and we were succeded in folding the t-shirt 10 AUTOMATIC T-SHIRT FOLDING MACHINE 11 AUTOMATIC T-SHIRT FOLDING MACHINE CONSTRUCTION