Smart Bottle Packing System.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Smart Bottle Packing System
Thesis submitted in accordance with the partial requirements of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Robotics and Automation)
Wan Mohd Salihin Bin Wan Mustafa
Faculty of Manufacturing Engineering
April 2008
UTeM Library (Pind.112007)
dllk
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
5
'~sn
JUDUL:
SMART BOlTLE PACKING SYSTEM
SESl PENGAJIAN:
SEMESTER 2 200712008
Saya WAN MOHD SALIHIN BIN WAN MUSTAFA
mengaku membenarkan laporan PSM I tesis (SarjanalDoktor Falsafah) ini disimpan
di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kqunaan seperti berikut:
I. Laporan PSM I tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM I tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4.
*Sila tandakan (4)
SULlT
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA
RASMl 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan oleh
organisasilbadandi mana penyelidikan dijalankan)
TIDAK TERHAD
&&JL;+
(TANDATANGAN PENULIS)
Alamat Tetap:
33, Jln PI 1113,
Taman Pulai Indah,
Cop Rasmi:
SMRIMAN BIN AROULLAH
81110 Johor Bahru,
Johor.
Tarikh:
oyoy/mg
I
Pens ,or&:
Fakultr Kaluruteraan Pemwatan
tln~versltiTekntkal Matdvcl* ~*rlaka
Kanrng Berkuncl 1300 Aye! keroh
75450 bl+bldha
Tarikh:
I
/ b f lD
L
I
!?
* Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULlT atau TERHAD.
DECLARATION
I hereby declare that this report entitled "SMART BOTTLE PACKING
SYSTEMn is the result of my own research except as cited in the references.
Signature
WAN MOHD SALIHIN BIN WAN
Author's Name
Date
MUSTAFA
:
04 APRIL 2008
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Robotics and Automation). The members of the supervisory committee
are as follow:
SHARlM6& 8W A~DULLAH
Pevvimh
'dkulti vquruteraan Pemouatan
Universiri Tertnital Malaysia Metaka
B @ * u ~ c ~1200, Ayer Keroh
75450 klaka
ABSTRACT
This report is about smart bottle packing system. The main focus of this thesis is to study
the application of the packing system with producing a machine that can use in industry
to pack bottle into carton. This project is also to optimize the usage of the machine for
the industry purpose.
The system can perform very quickly and to improve their production. In the production
this packaging machinery, must have some tools will help calculate bottle number to be
segregated by grouping. In the packing industry, several different types of packages
have been employed in the marketing of bottled products, and widely accepted by users,
particularly, for such products as bottled beverages, which are conveniently arranged in
double row relation and enclosed in a carton or wrapper.
In addition, it is generally loaded by dropping the bottles in the cells fiom the top which
presents an undesirable bottle breaking hazard. There are also certain disadvantages in
its production and subsequent handling.
ABSTRAK
Laporan ini mengenai sistem pembungkusan botol yang kemaslteratur. Fokus utarna
tentang tesis ini adalah untuk mempelajari aplikasi sistem pembungkusan dengan
membina mesin yang boleh digunakan di dalam industri untuk memasukkan botol ke
dalam kotak. Projek ini juga turut mengoptimiskan penggunaan mesin untuk kegunaan
industri.
Sistem ini boleh beroperasi dengan cepat dan dapat meningkatkan produksi. Dalam
penghasilan mesin pembungkusan hi, perlu ada beberapa alat yang akan membantu
menghitung bilangan botol untuk diasingkan secara berkumpulan. Dalam industri
pernbungkusan, beberapa perbezaan jenis bungkusan yang telah digunakan dalam
pemasaran produk-produk pembotolan, dan diterima dengan meluas oleh penggunapengguna, terutamanya, untuk produk-produk minuman yang dibotolkan kerana, yang
wujud dengan mudah disusun dalam hubungan dua baris dan dilampirkan dalam satu
karton atau pembungkus.
Tambahan pula, ia biasanya dimasukkan dengan menurunkan botol-botol ke dalam selsel dari atas yang di mana akan mengakibatkan botol-botol yang pecah. Terdapat juga
keburukan-keburukan tertentu dalam pengeluarannya dan pengendalian yang berturutan.
DEDICATION
For M y Parents and Friends.
ACKNOWLEDGEMENT
First of all, I would like to express my thanks to the thesis supervisor, Encik Shariman
Bin Abdullah for unwavering support, guidance and advice, time and thoughtful
contribution throughout this project.
With all the difficulty that I have been through while doing this thesis, I feel very
grateful that I manage to finish the report at last. Hopefully this report could help those
who are interested in this field and contribute something valuables to education field.
Finally, I would like to express my gratitude to all my fiends who has given me ideas
and comments on my thesis. And not forget to my mother and father. Thank you.
TABLE OF CONTENTS
Abstract ............................................................................................... i
Abstrak ...............................................................................................
. .
..
-11
...
Dedication.. ..........................................................................................111
Acknowledgement................................................................................... iv
Table of contents..................................................................................... v
List of Figures.......................................................................................ix
List of Tables...................................................................................... ..xi
.............................................................................. 1
.
1 INTRODUCTION
1.1. General Introduction.....................................................................1
1.2 Problem statement........................................................................2
1.3 Objectives ..........................................................................................................2
.......................................................................................-3
1.4 Scope o f Project
.................................................................... 4
LITERATURE REVIEW
2.1. Introduction ................................................................................ -4
2.2. Current Design ............................................................................-4
2.2.1. The Plastic Bottles in Drinking Water Packaging.............................4
2.3 .Material selection............................................................................6
2.3.1. Motor Classification...............................................................6
2.3.1.1.DC
brush motor..............................................................
6
66
99
2.3.1.2.DC brushless motor ........................................................... 7
2.3.1 3.Stepper Motor ..................................................................9
2.3.1.4.Servo Motor ................................................................... 15
2.4. Sensor classification....................................................................... 18
2.4.1. Photoelectric sensor.............................................................. -19
2.4.1.1 .Visible Light versus Invisible Infrared Light ............................19
. .
2.4.1 2.0perating Pnnc~ples
......................................................... 20
2.4.1 3.Through Beam Type Sensors..............................................20
2.4.1.4.Diffise Type Sensors.......................................................21
2.4.1.5.Fiber Optic Type Sensors...................................................21
2.4.1.6.Polarizing Filters ............................................................ 22
2.4.2. Inductive Proximity Sensor.....................................................22
2.4.2.1 .Inductive Proximity Sensor Control Technology........................22
2.4.2.2.AppIications for Inductive Proximity Sensors...........................28
2.4.3. Capacitive Sensor................................................................ 31
2.4.3.1 .Sensitivity Adjustment ...................................................... 33
2.4.3.2.Differences between Capacitive & Inductive Sensors..................34
2.4.3.3 .Correction Factor ............................................................34
2.4.3.4.Current Source and Current Sink..........................................35
.....................................................................36
2.4.4. Limit Switch...................................................................... 37
2.4.4.1 .Working of a limit switch...................................................37
2.4.4.2.Selection of a limit switch..................................................38
2.4.3.5.Mounting
2.4.4.3.Applications ..................................................................38
2.5. Special features or techniques.......................................................... 39
.
...................................................................................................
3 METHODOLOGY
40
3.1. Introduction............................................................................... -40
3.2. Flow Chart................................................................................ -41
3.3. Tools and Equipment....................................................................42
3.3.1. SolidWorks2007.................................................................. 42
3.3.2. PIC 16F877A Microcontroller..................................................42
3.3.3. SK40B start up kit ............................................................... 43
3.3.4. UICOOA USB ICSP PIC Programmer.........................................44
3.3.5. 10A Motor Driver ................................................................46
Smart Bottle Packing System
Thesis submitted in accordance with the partial requirements of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Robotics and Automation)
Wan Mohd Salihin Bin Wan Mustafa
Faculty of Manufacturing Engineering
April 2008
UTeM Library (Pind.112007)
dllk
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
5
'~sn
JUDUL:
SMART BOlTLE PACKING SYSTEM
SESl PENGAJIAN:
SEMESTER 2 200712008
Saya WAN MOHD SALIHIN BIN WAN MUSTAFA
mengaku membenarkan laporan PSM I tesis (SarjanalDoktor Falsafah) ini disimpan
di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kqunaan seperti berikut:
I. Laporan PSM I tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM I tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4.
*Sila tandakan (4)
SULlT
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA
RASMl 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan oleh
organisasilbadandi mana penyelidikan dijalankan)
TIDAK TERHAD
&&JL;+
(TANDATANGAN PENULIS)
Alamat Tetap:
33, Jln PI 1113,
Taman Pulai Indah,
Cop Rasmi:
SMRIMAN BIN AROULLAH
81110 Johor Bahru,
Johor.
Tarikh:
oyoy/mg
I
Pens ,or&:
Fakultr Kaluruteraan Pemwatan
tln~versltiTekntkal Matdvcl* ~*rlaka
Kanrng Berkuncl 1300 Aye! keroh
75450 bl+bldha
Tarikh:
I
/ b f lD
L
I
!?
* Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULlT atau TERHAD.
DECLARATION
I hereby declare that this report entitled "SMART BOTTLE PACKING
SYSTEMn is the result of my own research except as cited in the references.
Signature
WAN MOHD SALIHIN BIN WAN
Author's Name
Date
MUSTAFA
:
04 APRIL 2008
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Robotics and Automation). The members of the supervisory committee
are as follow:
SHARlM6& 8W A~DULLAH
Pevvimh
'dkulti vquruteraan Pemouatan
Universiri Tertnital Malaysia Metaka
B @ * u ~ c ~1200, Ayer Keroh
75450 klaka
ABSTRACT
This report is about smart bottle packing system. The main focus of this thesis is to study
the application of the packing system with producing a machine that can use in industry
to pack bottle into carton. This project is also to optimize the usage of the machine for
the industry purpose.
The system can perform very quickly and to improve their production. In the production
this packaging machinery, must have some tools will help calculate bottle number to be
segregated by grouping. In the packing industry, several different types of packages
have been employed in the marketing of bottled products, and widely accepted by users,
particularly, for such products as bottled beverages, which are conveniently arranged in
double row relation and enclosed in a carton or wrapper.
In addition, it is generally loaded by dropping the bottles in the cells fiom the top which
presents an undesirable bottle breaking hazard. There are also certain disadvantages in
its production and subsequent handling.
ABSTRAK
Laporan ini mengenai sistem pembungkusan botol yang kemaslteratur. Fokus utarna
tentang tesis ini adalah untuk mempelajari aplikasi sistem pembungkusan dengan
membina mesin yang boleh digunakan di dalam industri untuk memasukkan botol ke
dalam kotak. Projek ini juga turut mengoptimiskan penggunaan mesin untuk kegunaan
industri.
Sistem ini boleh beroperasi dengan cepat dan dapat meningkatkan produksi. Dalam
penghasilan mesin pembungkusan hi, perlu ada beberapa alat yang akan membantu
menghitung bilangan botol untuk diasingkan secara berkumpulan. Dalam industri
pernbungkusan, beberapa perbezaan jenis bungkusan yang telah digunakan dalam
pemasaran produk-produk pembotolan, dan diterima dengan meluas oleh penggunapengguna, terutamanya, untuk produk-produk minuman yang dibotolkan kerana, yang
wujud dengan mudah disusun dalam hubungan dua baris dan dilampirkan dalam satu
karton atau pembungkus.
Tambahan pula, ia biasanya dimasukkan dengan menurunkan botol-botol ke dalam selsel dari atas yang di mana akan mengakibatkan botol-botol yang pecah. Terdapat juga
keburukan-keburukan tertentu dalam pengeluarannya dan pengendalian yang berturutan.
DEDICATION
For M y Parents and Friends.
ACKNOWLEDGEMENT
First of all, I would like to express my thanks to the thesis supervisor, Encik Shariman
Bin Abdullah for unwavering support, guidance and advice, time and thoughtful
contribution throughout this project.
With all the difficulty that I have been through while doing this thesis, I feel very
grateful that I manage to finish the report at last. Hopefully this report could help those
who are interested in this field and contribute something valuables to education field.
Finally, I would like to express my gratitude to all my fiends who has given me ideas
and comments on my thesis. And not forget to my mother and father. Thank you.
TABLE OF CONTENTS
Abstract ............................................................................................... i
Abstrak ...............................................................................................
. .
..
-11
...
Dedication.. ..........................................................................................111
Acknowledgement................................................................................... iv
Table of contents..................................................................................... v
List of Figures.......................................................................................ix
List of Tables...................................................................................... ..xi
.............................................................................. 1
.
1 INTRODUCTION
1.1. General Introduction.....................................................................1
1.2 Problem statement........................................................................2
1.3 Objectives ..........................................................................................................2
.......................................................................................-3
1.4 Scope o f Project
.................................................................... 4
LITERATURE REVIEW
2.1. Introduction ................................................................................ -4
2.2. Current Design ............................................................................-4
2.2.1. The Plastic Bottles in Drinking Water Packaging.............................4
2.3 .Material selection............................................................................6
2.3.1. Motor Classification...............................................................6
2.3.1.1.DC
brush motor..............................................................
6
66
99
2.3.1.2.DC brushless motor ........................................................... 7
2.3.1 3.Stepper Motor ..................................................................9
2.3.1.4.Servo Motor ................................................................... 15
2.4. Sensor classification....................................................................... 18
2.4.1. Photoelectric sensor.............................................................. -19
2.4.1.1 .Visible Light versus Invisible Infrared Light ............................19
. .
2.4.1 2.0perating Pnnc~ples
......................................................... 20
2.4.1 3.Through Beam Type Sensors..............................................20
2.4.1.4.Diffise Type Sensors.......................................................21
2.4.1.5.Fiber Optic Type Sensors...................................................21
2.4.1.6.Polarizing Filters ............................................................ 22
2.4.2. Inductive Proximity Sensor.....................................................22
2.4.2.1 .Inductive Proximity Sensor Control Technology........................22
2.4.2.2.AppIications for Inductive Proximity Sensors...........................28
2.4.3. Capacitive Sensor................................................................ 31
2.4.3.1 .Sensitivity Adjustment ...................................................... 33
2.4.3.2.Differences between Capacitive & Inductive Sensors..................34
2.4.3.3 .Correction Factor ............................................................34
2.4.3.4.Current Source and Current Sink..........................................35
.....................................................................36
2.4.4. Limit Switch...................................................................... 37
2.4.4.1 .Working of a limit switch...................................................37
2.4.4.2.Selection of a limit switch..................................................38
2.4.3.5.Mounting
2.4.4.3.Applications ..................................................................38
2.5. Special features or techniques.......................................................... 39
.
...................................................................................................
3 METHODOLOGY
40
3.1. Introduction............................................................................... -40
3.2. Flow Chart................................................................................ -41
3.3. Tools and Equipment....................................................................42
3.3.1. SolidWorks2007.................................................................. 42
3.3.2. PIC 16F877A Microcontroller..................................................42
3.3.3. SK40B start up kit ............................................................... 43
3.3.4. UICOOA USB ICSP PIC Programmer.........................................44
3.3.5. 10A Motor Driver ................................................................46