Design And Development Of Automated Counting Machine For Industrial Application.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN AND DEVELOPMENT OF AUTOMATED COUNTING
MACHINE FOR INDUSTRIAL APPLICATION
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours.
by
MUHAMMAD FARIS B MD YUSUF
FACULTY OF MANUFACTURING ENGINEERING
2009
ABSTRACT
This project describes and reviews various sensor technologies, particularly through
beam sensor and retro reflective sensor, which is applicable to counting an object in
industrial applications. Aspects of review include technical requirement, design and
fabrication, and instrumentation procedures for the sensors. A comparative between two
sensors on the relative merit and selection criteria is carried out through an analysis of
advantage and disadvantage on real applications of sensors in counting method. Hence, a
details drawing for each part components were prepared and will be check to fabricate
and develop. Electrical component to control a machine were determined with its
function. Some of analysis will be taken as consideration to achieve a target objective of
project such as time productivity counting and type of product been used.
i
ABSTRAK
Projek ini dijalankan untuk membincangkan dan mengulas tentang kepelbagaian teknologi
sensor khususnya sensor sinar penembus dan sensor pemantulan sinar, dimana ia boleh
digunakan dalam membilang objek didalam aplikasi industri. Aspek yang dibincangkan
adalah termasuk rekaan dan fabrikasi pembangunan mesin serta prosedur yang diperlukan
semasa pemasangan sensor dan keperluan teknikal sensor tersebut. Perbandingan di antara
dengan kelebihan setiap sensor dan kriteria yang diperlukan semasa membuat pemilihan
sensor dibuat berpandukan kelebihan dan kekurangan dalam aplikasi sebenar penggunaan
sensor dalam kaedah membilang objek. Justeru itu, gambarajah terperinci di lakukan seblum
proses membangunkan di jalankan. Beberapa analisis dijalankan terhadap projek
membangunkan mesin kira ini untuk mencapai objektif projek dari segi masa yang di ambil
terhadap productivity dan jenis-jenis bahan yang sesuai digunakan untuk applikasi dalam
projek ini.
ii
DEDICATION
Special Dedicated to My Beloved Family
Md Yusuf Mahmud
Jawizah Mamat
Yusrizan Md Yusuf
Nor Fathilah Md Yusuf
Khairul Azli Md Yusuf
Al-Yani Md Yusuf
Nur Ashikin Md Yusuf
Ahmad Mokhzani Md Yusuf
Muhammad Asraf Md Yusuf
And
All my Friends
iii
ACKNOWLEDGEMENT
I wish to thank my supervisor, Mr. Lokman Abdullah for his valuable advice,
constructive criticisms, stimulating discussions and valuable suggestions during the
preparation of this project report. I would like to express my thanks to all colleagues
who are always ready to give their helping hands. Last but not least, no words can be
used to express my deepest gratitude to my parent and family for their encouragement
and love, which are forever indebted.
iv
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
ix
List of Figures
x
1. INTRODUCTION
1.1
Background Study
1
1
1.2
Problem Statement
2
1.3
Objective of Project
3
1.4
Scope of Project
3
2. LITERATURE REVIEW
2.1
4
Historical Development of Counting Machine
For Industrial Application
4
2.1.1
What is counting?
4
2.1.2
Historical counting device
4
2.1.3
Historical counting machine
5
2.1.3.1
Cremer Company
5
2.1.3.2
Cremer’s Method
6
2.2
Feeder Mechanism in Counting Machine
7
2.2.1
Type of Feeder Mechanism
7
2.3
Counter Detector in Counting Machine
11
2.3.1
Photoelectric Sensor
11
2.3.2
Principle of Photoelectric Sensor
12
2.3.3
Detection Object by Using Photoelectric Sensor
15
2.4
General Counting Machine
17
2.4.1
Method of Sorting and Counting Cans
17
v
2.4.2
Discrete Tablet Counting Machine
18
2.4.3
Counting Method in a Leaves Counting Machine
19
2.4.4
Apparatus and Method for Counting Fruits and Other Object
22
2.5
Counting by using Programmable Logic Circuit
21
3. METHODOLOGY
22
3.1
Description Project Procedure
24
3.2
Counting Method Process
25
3.2.1
Description of Counting Method Process
26
3.3
Application Automated Counter by OMRON Industrial Automation
27
3.3.1
Step for Counting Procedure
28
3.3.2
Description of the Timing Chart
29
3.4
Design Detail of Photoelectric Sensor
30
3.4.1
Technique Used in Photoelectric Sensor
31
3.4.1.1
Through Beam Sensor
31
3.4.1.2
Sensing Method of through Beam Sensor
31
3.4.2
Retro Reflective Sensor
32
3.4.2.1
Retro Reflective Sensor Method
32
3.4.2.2
Retro-reflective Sensors with Polarization Filter
33
3.4.2.3
Limited-reflective Sensors
33
3.4.3
Advantages and Disadvantage Type Sensor
34
3.4.3.1
Through Beam Sensor
34
3.4.3.2
Retro Reflective Sensor
35
3.4.4
Comparison between Through Beam Sensor and
3.5
Retro Reflective Sensor
35
Reason Choosing Through Beam Sensor for Counting
36
vi
4. DESIGN AND DEVELOPMENT PLANNING COUNTING
DEVICE
39
4.1
Design Procedure
39
4.2
Working Process Counting Device
40
4.3
Simulation of Working Process
41
4.4
Process Sequence of Simulation
42
4.5
An Electrical of Hardwiring Process
43
4.6
Development Counting Device Planning
44
4.6.1
Description Development Procedure.
45
5. DESIGN AND DEVELOPMENT OF AUTOMATED
COUNTING MACHINE
5.1
Design of Automated Counting Machine Component by Using
46
Solid Work
46
5.1.1
Design a Component of Automated Counting Machine
46
5.1.2
Step of Designing of Automated Counting Machine
47
5.2
Automated Counting Machine Circuit
52
5.2.1
Component Electrical of Automated Counting System
52
5.3
Development Process of Automated Counting Machine System
55
5.3.1
Developing conveyor
56
5.3.1.1
Part of conveyor
56
5.3.2
Control panel
57
5.3.2.1
Step developing control panel
58
5.3.3
Laser beam
59
5.3.4
Sensor Receiver
59
6. RESULT
60
6.1
Result of Development Automated Counting Machine System
60
6.2
Automated Counting Machine Testing
61
6.2.1
Manually Counting Testing
61
6.2.2
Automatically Counting Testing
64
6.2.2.1 Description of Automatic Counting Testing
vii
66
7. DISCUSSION
69
7.1
Discussion of Automated Counting Machine
69
7.2
Analysis of Counting Machine
72
7.3
Limitation of Counting Machine
78
8. CONCLUSION
79
8.1
Summary of Project
79
8.2
Conclusion
80
8.3
Recommendations
80
REFERENCES
81
APPENDICIES
A-Design Counting Machine
viii
LIST OF TABLES
1.1
Gantt Chart of PSM
3
3.1
Advantages and Disadvantages of Through Beam Sensors
34
3.2
Advantages and Disadvantages Retro Reflective of Sensors
34
3.3
Comparison between Sensors
35
7.1
Comparison between Manually and Automatically Counting Operation
69
7.2
Counting Time for One Object for Variable
Width Size of Object
74
7.3
Sample with Different Width Size Object
75
7.4
Time Taken to Count with Different Width
75
7.5
Time Cycle for Five Objects
75
7.6
Object Sensed by Sensor Detector
76
ix
LIST OF FIGURES
2.1
A Roman Abacus
5
2.2
First Counting Machine
6
2.3
Cremer’s Counting Principle
6
2.4
Tumbling Barrel Hopper
7
2.5
Bladed Wheel Hopper and Tumbling Barrel Hopper for Feeding of
Durable Cylindrical Parts
7
2.6
Rotating Drum for Orientating Plastic Bottles
8
2.7
Rotary Centerboard Hopper
9
2.8
Feeding of bottle caps in correct orientation.
9
2.9
Creating a single file of washer in a vibratory.
2.10
Orientating Headed Screws or Rivets at the Top Discharge
10
Potion of Vibratory Bowl
10
2.11
Through-beam Sensor
11
2.12
Retro-reflective Sensors
11
2.13
Diffuse-reflective Sensors
12
2.14
Mode Reflectivity Table
13
2.15
Diffused Mode with Mechanical Background Suppression.
13
2.16
Diffused Mode with Electronic Background Suppression.
14
2.17
Variation the Bottle Moves Through The Light Beam.
17
3.1
Summary of Project Procedure
23
3.2
Count Method on Counting Machine
26
3.3
Counter Automated in Production Line
27
3.4
The Input, Control and Output Signal Sequence in a Boxing Process
27
3.5
Input Signal
28
3.6
Control Count
28
3.7
Output Control Count
29
3.8
Preset Counter
30
x
3.9
Photoelectric Counter
31
3.10
Sensing Method Through Beam Sensor
32
3.11
Retro Reflective Sensor
32
3.12
Retro-reflective Sensors with Polarization Filter
33
3.13
Sensing Method Reflective Sensors
34
3.14
Structure of a Typical Counter
37
3.15
The Effective Beam of Opposed-Mode Sensors
37
4.1
Step in Design Procedure
39
4.2
Flow Chart Working Process
40
4.3
Electrical Circuit by Using Automation Studio
41
4.4
Hardwiring Process
43
4.5
Development Procedure
44
5.1
Process designing automated counting machine
47
5.2
Shaft’s Conveyor
47
5.3
Conveyor Body
48
5.4
Stand Conveyor
48
5.5
Belt Conveyor
48
5.6
Assembly Component of Conveyor
49
5.7
Box
49
5.8
Digital Counter
49
5.9
Push Button
50
5.10
Indicator light
50
5.11
Control Panel.
50
5.12
Laser Beam
51
5.13
Sensor Receiver
51
5.14
Base
51
5.15
Automated Counting Machine
52
5.16
Schematic Motor Conveyor
54
5.17
Laser Beam Schematic Diagram
54
xi
5.18
Sensor Receiver Circuit
55
5.19
Shaft
57
5.20
Electrical motor
57
5.21
Bearing
57
5.22
Front View Conveyor
57
5.23
Side View Conveyor
57
5.24
Internal View of Control Panel Box
58
5.25
Connector on Control Panel Box
58
5.26
Internal Laser Beam
59
5.27
Laser Beam Position on Conveyor
59
5.28
Sensor Receiver
59
5.29
Sensor Receiver Position
59
6.1
Automated Counting Machine
60
6.2
Flow process manual counting testing
62
6.3
Press push button on orange indicator
63
6.4
Digital counter display
63
6.5
Push button on red indicator
63
6.6
Flow Process of Automatic Counting Testing
65
6.7
Switch Power
67
6.8
The “Dark ON” Operation
67
6.9
Sensor Cannot Receive a Light Beam
68
6.10
Orange Indicator Blinking
68
6.11
Count Up
68
6.12
Count on Preset Value
68
6.13
Red Light
68
7.1
Object Position before Count
70
7.2
Light Beam Blocked
71
7.3
Object through a Light Beam
71
7.4
Position Sensor Detector on Conveyor
72
xii
7.5
Angle of Light Beam to Sensor Receiver
73
7.6
Width Size of Object.
73
7.7
Graph Time Taken for One Object
74
7.8
Graph Time Versus with Width Object
75
7.9
Time Cycle for Five Objects
76
xiii
CHAPTER 1
INTRODUCTION
1.1 Background Study
Development of counting machine in industrial application has been chosen to fulfill PO
and PEO in course Manufacturing Robotic and Automation. Nowadays, there’s much
manufacturing of machine in engineering field. The method and results of measuring the
accuracy of a particle sizing and counting machine are described and compared with the
results obtained when sizing with a microscope. Machine counting appears to be quicker
and more consistent and accurate than counting by eye (Courshee, R. J. 1954).
A counting machine consists of feeding system in electrical and electronic component.
For an example is vibratory bowl where it’s the oldest method and still most common
approach to the automated feeding (orienting) of industrial parts. Part feeders, which
singulate and orient parts prior to packing and insertion are critical components of an
automated assembly line. The oldest and still most common approach to automated
feeding is the vibratory bowl feeder which consists of a bowl filled with parts
surrounded by a helical metal track. An application of vibratory bowls are suitable for
feeding components for subsequent operations on special machines in cosmetic,
electrical, mechanical, pharmaceutical, optical, bearing and many other industries. The
components can be plastic caps, spouts, capsules and electrical connectors, bearings as
well as heavy parts such as anchor bolts, bearing races and metal sockets.
1
Sensing methods based on electrical capacitance, magnetic and eddy-current effects are
extremely sensitive and fasting acting and are suitable in close proximity to the sensor.
The capacitive probe senses dielectric other than air, such as glass and plastic parts. The
magnetic pickup by induction responds to the motion of iron and nickel. The eddycurrent sensor, by energy absorption detected nonmagnetic conductors. All are suitable
for counting machine operations.
1.2 Problem Statement
The development of the counter sensor technologies makes the choice of sensor in
market higher. It sometime makes the engineer difficult to make the decision making in
other to choose the best sensor that suitable for the counting part. Sometimes wrong
decision will make the thing even worse. So that, this research is developed to identify
the technology itself, technical requirement, and instrumentation and make the engineer
or other bodies that involves can compare the differential between many types of sensor
and make them can used it in correct condition.
Error-proofing is an industry term that relates to the implementation of mechanisms to
prevent product defects. Also known as Poka Yoke from the Japanese ‘poke’
(inadvertent errors) and ‘yoke’ (to avoid), error-proofing is a common-sense concept
developed and popularized in that country. Based on the philosophy, even the smallest
number of defects is unacceptable. Poka Yoke maintains that the best way to eliminate
defects is to prevent them from happening in the first place. Awareness involves the
acknowledgement of breakdowns in the manufacturing/assembly process and employing
training, audio-visual aids and general assistance for personnel to combat those issues.
Detection introduces manual or automated inspection techniques to filter out defects.
Prevention which includes process improvements or automation to ensure no errors are
(or can be) made.
2
The primary issues are limited range and sensitivity to sensors. There need to increase
the sensing range, reduce cost, and expand capabilities led to the development of
photoelectric sensors optimized for detecting clear objects. Initially, ultrasonic sensors
were more dependable and accurate at identifying targets, but over the last few year
improvements in photoelectric sensors have made them the primary choice for sensing
clear objects (better edge detection, increased resolution, indifference to size, shape, or
temperature of target).
1.3
Objective of Project
Objectives that have to be achieved at the end of this project are design and development
of an automated counting machine.
1.4
Scope of Project
The scope should be identified and planned to achieve the objectives of the project
successfully on the time. Scope of this project is concentrate on how a counting device
works for count an object or particle. Hence, analyses on automated counting machine
such as test and accuracy of counting device to count an object.
Table 1.1: Gantt chart of PSM.
CHAPTER /WEEK
1 2 3 4 5 6 7
CHAPTER 1: INTRODUCTION
CHAPTER 2: LITERITURE REVIEW
CHAPTER 3: METHODOLOGY
CHAPTER 4: DESIGN AND
DEVELOPMENT PLANNING
CHAPTER 5 : DESIGN AND
DEVELOPMENT PROGRESS
CHAPTER 6 : RESULT
CHAPTER 7: DISCUSSION
CHAPTER 8 : CONCLUSION PSM
3
8
9 10
11
12
13
14
CHAPTER 2
LITERATURE REVIEW
2.1
Historical Development of Counting Machine For Industrial
Application
2.1.1 What is counting?
From Wikipedia Encyclopedia, count is a mathematical process for an object where it as
be set aside with desired of number objects to repeatedly action to adding or subtracting.
Hence, counting also can be involved more than one for example; counting by a two (2,
4, 6, 8….). From the archeological, they have found that a counting has been used last
500,000 year.
2.1.2 Historical Counting Device
On 500 B.C to 1300A.C, Babylon culture is the one who made up a first counting device
called Abacus. The Abacus is used to calculate an arithmetic process and it’s also act as
a calculating tool on that time. After hundreds year, a counting board have been develop
by Roman where it’s called the hand of abacus. Year per year, a counting machine
device have been continuous develop until an era of computer been arrived on 1950’s.
4
Figure 2.1: A Roman Abacus (Illustrated from Wikipedia Encyclopedia).
2.1.3
Historical counting machine
2.1.3.1
Cremer Company
On 1949, Cremer Company has built up a counting machine in packaging and counting
line logistics. This company preferred supplier for counting machine and packaging
solution on pharmacy, confectionery, bakery and frozen foods, packed snack food,
hardware, medical supplies, flower bulbs, etc. A customer of this company in this world
wide used counting and packaging machine are Nestle, Cadbury, Frito Lay, Kraft Foods,
Glaxo, General Mills, Masterfoods, ConAgra, Chupa Chups, De la Rosa, Sabritas,
Philips, Bayer, Wyeth Ayerst, Pfizer and Boehringer, Eli Lillyand and Dr. Oetker.
In 1982, Cremer introduced the first linear tablet and capsule counting machine. Ever
since, the CF model has been renowned worldwide for its 100% accuracy, high capacity,
simple cleaning and operation, high reliability and durability. The Cremer CF counting
machine is a high-speed tablet and capsule counting machine for pharmaceutical and
pharma industries - medicines, vitamins, food supplements, health products etc.
5
Figure 2.2: First counting machine (Illustrated from Cremer Company).
2.1.3.2 Cremer’s Method
A line principle is used on all counting machine in Cremer Vibratory plates to separation
of products before falling through detector channel. Cremer’s method on count products
is products are cascaded down through a Memory flap see Figure 2.3. Hence, the correct
quantity is discharged into a bucket elevator or packaging machine.
Figure 2.3: Cremer’s counting principle (Illustrated from Cremer Company).
6
DESIGN AND DEVELOPMENT OF AUTOMATED COUNTING
MACHINE FOR INDUSTRIAL APPLICATION
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours.
by
MUHAMMAD FARIS B MD YUSUF
FACULTY OF MANUFACTURING ENGINEERING
2009
ABSTRACT
This project describes and reviews various sensor technologies, particularly through
beam sensor and retro reflective sensor, which is applicable to counting an object in
industrial applications. Aspects of review include technical requirement, design and
fabrication, and instrumentation procedures for the sensors. A comparative between two
sensors on the relative merit and selection criteria is carried out through an analysis of
advantage and disadvantage on real applications of sensors in counting method. Hence, a
details drawing for each part components were prepared and will be check to fabricate
and develop. Electrical component to control a machine were determined with its
function. Some of analysis will be taken as consideration to achieve a target objective of
project such as time productivity counting and type of product been used.
i
ABSTRAK
Projek ini dijalankan untuk membincangkan dan mengulas tentang kepelbagaian teknologi
sensor khususnya sensor sinar penembus dan sensor pemantulan sinar, dimana ia boleh
digunakan dalam membilang objek didalam aplikasi industri. Aspek yang dibincangkan
adalah termasuk rekaan dan fabrikasi pembangunan mesin serta prosedur yang diperlukan
semasa pemasangan sensor dan keperluan teknikal sensor tersebut. Perbandingan di antara
dengan kelebihan setiap sensor dan kriteria yang diperlukan semasa membuat pemilihan
sensor dibuat berpandukan kelebihan dan kekurangan dalam aplikasi sebenar penggunaan
sensor dalam kaedah membilang objek. Justeru itu, gambarajah terperinci di lakukan seblum
proses membangunkan di jalankan. Beberapa analisis dijalankan terhadap projek
membangunkan mesin kira ini untuk mencapai objektif projek dari segi masa yang di ambil
terhadap productivity dan jenis-jenis bahan yang sesuai digunakan untuk applikasi dalam
projek ini.
ii
DEDICATION
Special Dedicated to My Beloved Family
Md Yusuf Mahmud
Jawizah Mamat
Yusrizan Md Yusuf
Nor Fathilah Md Yusuf
Khairul Azli Md Yusuf
Al-Yani Md Yusuf
Nur Ashikin Md Yusuf
Ahmad Mokhzani Md Yusuf
Muhammad Asraf Md Yusuf
And
All my Friends
iii
ACKNOWLEDGEMENT
I wish to thank my supervisor, Mr. Lokman Abdullah for his valuable advice,
constructive criticisms, stimulating discussions and valuable suggestions during the
preparation of this project report. I would like to express my thanks to all colleagues
who are always ready to give their helping hands. Last but not least, no words can be
used to express my deepest gratitude to my parent and family for their encouragement
and love, which are forever indebted.
iv
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
ix
List of Figures
x
1. INTRODUCTION
1.1
Background Study
1
1
1.2
Problem Statement
2
1.3
Objective of Project
3
1.4
Scope of Project
3
2. LITERATURE REVIEW
2.1
4
Historical Development of Counting Machine
For Industrial Application
4
2.1.1
What is counting?
4
2.1.2
Historical counting device
4
2.1.3
Historical counting machine
5
2.1.3.1
Cremer Company
5
2.1.3.2
Cremer’s Method
6
2.2
Feeder Mechanism in Counting Machine
7
2.2.1
Type of Feeder Mechanism
7
2.3
Counter Detector in Counting Machine
11
2.3.1
Photoelectric Sensor
11
2.3.2
Principle of Photoelectric Sensor
12
2.3.3
Detection Object by Using Photoelectric Sensor
15
2.4
General Counting Machine
17
2.4.1
Method of Sorting and Counting Cans
17
v
2.4.2
Discrete Tablet Counting Machine
18
2.4.3
Counting Method in a Leaves Counting Machine
19
2.4.4
Apparatus and Method for Counting Fruits and Other Object
22
2.5
Counting by using Programmable Logic Circuit
21
3. METHODOLOGY
22
3.1
Description Project Procedure
24
3.2
Counting Method Process
25
3.2.1
Description of Counting Method Process
26
3.3
Application Automated Counter by OMRON Industrial Automation
27
3.3.1
Step for Counting Procedure
28
3.3.2
Description of the Timing Chart
29
3.4
Design Detail of Photoelectric Sensor
30
3.4.1
Technique Used in Photoelectric Sensor
31
3.4.1.1
Through Beam Sensor
31
3.4.1.2
Sensing Method of through Beam Sensor
31
3.4.2
Retro Reflective Sensor
32
3.4.2.1
Retro Reflective Sensor Method
32
3.4.2.2
Retro-reflective Sensors with Polarization Filter
33
3.4.2.3
Limited-reflective Sensors
33
3.4.3
Advantages and Disadvantage Type Sensor
34
3.4.3.1
Through Beam Sensor
34
3.4.3.2
Retro Reflective Sensor
35
3.4.4
Comparison between Through Beam Sensor and
3.5
Retro Reflective Sensor
35
Reason Choosing Through Beam Sensor for Counting
36
vi
4. DESIGN AND DEVELOPMENT PLANNING COUNTING
DEVICE
39
4.1
Design Procedure
39
4.2
Working Process Counting Device
40
4.3
Simulation of Working Process
41
4.4
Process Sequence of Simulation
42
4.5
An Electrical of Hardwiring Process
43
4.6
Development Counting Device Planning
44
4.6.1
Description Development Procedure.
45
5. DESIGN AND DEVELOPMENT OF AUTOMATED
COUNTING MACHINE
5.1
Design of Automated Counting Machine Component by Using
46
Solid Work
46
5.1.1
Design a Component of Automated Counting Machine
46
5.1.2
Step of Designing of Automated Counting Machine
47
5.2
Automated Counting Machine Circuit
52
5.2.1
Component Electrical of Automated Counting System
52
5.3
Development Process of Automated Counting Machine System
55
5.3.1
Developing conveyor
56
5.3.1.1
Part of conveyor
56
5.3.2
Control panel
57
5.3.2.1
Step developing control panel
58
5.3.3
Laser beam
59
5.3.4
Sensor Receiver
59
6. RESULT
60
6.1
Result of Development Automated Counting Machine System
60
6.2
Automated Counting Machine Testing
61
6.2.1
Manually Counting Testing
61
6.2.2
Automatically Counting Testing
64
6.2.2.1 Description of Automatic Counting Testing
vii
66
7. DISCUSSION
69
7.1
Discussion of Automated Counting Machine
69
7.2
Analysis of Counting Machine
72
7.3
Limitation of Counting Machine
78
8. CONCLUSION
79
8.1
Summary of Project
79
8.2
Conclusion
80
8.3
Recommendations
80
REFERENCES
81
APPENDICIES
A-Design Counting Machine
viii
LIST OF TABLES
1.1
Gantt Chart of PSM
3
3.1
Advantages and Disadvantages of Through Beam Sensors
34
3.2
Advantages and Disadvantages Retro Reflective of Sensors
34
3.3
Comparison between Sensors
35
7.1
Comparison between Manually and Automatically Counting Operation
69
7.2
Counting Time for One Object for Variable
Width Size of Object
74
7.3
Sample with Different Width Size Object
75
7.4
Time Taken to Count with Different Width
75
7.5
Time Cycle for Five Objects
75
7.6
Object Sensed by Sensor Detector
76
ix
LIST OF FIGURES
2.1
A Roman Abacus
5
2.2
First Counting Machine
6
2.3
Cremer’s Counting Principle
6
2.4
Tumbling Barrel Hopper
7
2.5
Bladed Wheel Hopper and Tumbling Barrel Hopper for Feeding of
Durable Cylindrical Parts
7
2.6
Rotating Drum for Orientating Plastic Bottles
8
2.7
Rotary Centerboard Hopper
9
2.8
Feeding of bottle caps in correct orientation.
9
2.9
Creating a single file of washer in a vibratory.
2.10
Orientating Headed Screws or Rivets at the Top Discharge
10
Potion of Vibratory Bowl
10
2.11
Through-beam Sensor
11
2.12
Retro-reflective Sensors
11
2.13
Diffuse-reflective Sensors
12
2.14
Mode Reflectivity Table
13
2.15
Diffused Mode with Mechanical Background Suppression.
13
2.16
Diffused Mode with Electronic Background Suppression.
14
2.17
Variation the Bottle Moves Through The Light Beam.
17
3.1
Summary of Project Procedure
23
3.2
Count Method on Counting Machine
26
3.3
Counter Automated in Production Line
27
3.4
The Input, Control and Output Signal Sequence in a Boxing Process
27
3.5
Input Signal
28
3.6
Control Count
28
3.7
Output Control Count
29
3.8
Preset Counter
30
x
3.9
Photoelectric Counter
31
3.10
Sensing Method Through Beam Sensor
32
3.11
Retro Reflective Sensor
32
3.12
Retro-reflective Sensors with Polarization Filter
33
3.13
Sensing Method Reflective Sensors
34
3.14
Structure of a Typical Counter
37
3.15
The Effective Beam of Opposed-Mode Sensors
37
4.1
Step in Design Procedure
39
4.2
Flow Chart Working Process
40
4.3
Electrical Circuit by Using Automation Studio
41
4.4
Hardwiring Process
43
4.5
Development Procedure
44
5.1
Process designing automated counting machine
47
5.2
Shaft’s Conveyor
47
5.3
Conveyor Body
48
5.4
Stand Conveyor
48
5.5
Belt Conveyor
48
5.6
Assembly Component of Conveyor
49
5.7
Box
49
5.8
Digital Counter
49
5.9
Push Button
50
5.10
Indicator light
50
5.11
Control Panel.
50
5.12
Laser Beam
51
5.13
Sensor Receiver
51
5.14
Base
51
5.15
Automated Counting Machine
52
5.16
Schematic Motor Conveyor
54
5.17
Laser Beam Schematic Diagram
54
xi
5.18
Sensor Receiver Circuit
55
5.19
Shaft
57
5.20
Electrical motor
57
5.21
Bearing
57
5.22
Front View Conveyor
57
5.23
Side View Conveyor
57
5.24
Internal View of Control Panel Box
58
5.25
Connector on Control Panel Box
58
5.26
Internal Laser Beam
59
5.27
Laser Beam Position on Conveyor
59
5.28
Sensor Receiver
59
5.29
Sensor Receiver Position
59
6.1
Automated Counting Machine
60
6.2
Flow process manual counting testing
62
6.3
Press push button on orange indicator
63
6.4
Digital counter display
63
6.5
Push button on red indicator
63
6.6
Flow Process of Automatic Counting Testing
65
6.7
Switch Power
67
6.8
The “Dark ON” Operation
67
6.9
Sensor Cannot Receive a Light Beam
68
6.10
Orange Indicator Blinking
68
6.11
Count Up
68
6.12
Count on Preset Value
68
6.13
Red Light
68
7.1
Object Position before Count
70
7.2
Light Beam Blocked
71
7.3
Object through a Light Beam
71
7.4
Position Sensor Detector on Conveyor
72
xii
7.5
Angle of Light Beam to Sensor Receiver
73
7.6
Width Size of Object.
73
7.7
Graph Time Taken for One Object
74
7.8
Graph Time Versus with Width Object
75
7.9
Time Cycle for Five Objects
76
xiii
CHAPTER 1
INTRODUCTION
1.1 Background Study
Development of counting machine in industrial application has been chosen to fulfill PO
and PEO in course Manufacturing Robotic and Automation. Nowadays, there’s much
manufacturing of machine in engineering field. The method and results of measuring the
accuracy of a particle sizing and counting machine are described and compared with the
results obtained when sizing with a microscope. Machine counting appears to be quicker
and more consistent and accurate than counting by eye (Courshee, R. J. 1954).
A counting machine consists of feeding system in electrical and electronic component.
For an example is vibratory bowl where it’s the oldest method and still most common
approach to the automated feeding (orienting) of industrial parts. Part feeders, which
singulate and orient parts prior to packing and insertion are critical components of an
automated assembly line. The oldest and still most common approach to automated
feeding is the vibratory bowl feeder which consists of a bowl filled with parts
surrounded by a helical metal track. An application of vibratory bowls are suitable for
feeding components for subsequent operations on special machines in cosmetic,
electrical, mechanical, pharmaceutical, optical, bearing and many other industries. The
components can be plastic caps, spouts, capsules and electrical connectors, bearings as
well as heavy parts such as anchor bolts, bearing races and metal sockets.
1
Sensing methods based on electrical capacitance, magnetic and eddy-current effects are
extremely sensitive and fasting acting and are suitable in close proximity to the sensor.
The capacitive probe senses dielectric other than air, such as glass and plastic parts. The
magnetic pickup by induction responds to the motion of iron and nickel. The eddycurrent sensor, by energy absorption detected nonmagnetic conductors. All are suitable
for counting machine operations.
1.2 Problem Statement
The development of the counter sensor technologies makes the choice of sensor in
market higher. It sometime makes the engineer difficult to make the decision making in
other to choose the best sensor that suitable for the counting part. Sometimes wrong
decision will make the thing even worse. So that, this research is developed to identify
the technology itself, technical requirement, and instrumentation and make the engineer
or other bodies that involves can compare the differential between many types of sensor
and make them can used it in correct condition.
Error-proofing is an industry term that relates to the implementation of mechanisms to
prevent product defects. Also known as Poka Yoke from the Japanese ‘poke’
(inadvertent errors) and ‘yoke’ (to avoid), error-proofing is a common-sense concept
developed and popularized in that country. Based on the philosophy, even the smallest
number of defects is unacceptable. Poka Yoke maintains that the best way to eliminate
defects is to prevent them from happening in the first place. Awareness involves the
acknowledgement of breakdowns in the manufacturing/assembly process and employing
training, audio-visual aids and general assistance for personnel to combat those issues.
Detection introduces manual or automated inspection techniques to filter out defects.
Prevention which includes process improvements or automation to ensure no errors are
(or can be) made.
2
The primary issues are limited range and sensitivity to sensors. There need to increase
the sensing range, reduce cost, and expand capabilities led to the development of
photoelectric sensors optimized for detecting clear objects. Initially, ultrasonic sensors
were more dependable and accurate at identifying targets, but over the last few year
improvements in photoelectric sensors have made them the primary choice for sensing
clear objects (better edge detection, increased resolution, indifference to size, shape, or
temperature of target).
1.3
Objective of Project
Objectives that have to be achieved at the end of this project are design and development
of an automated counting machine.
1.4
Scope of Project
The scope should be identified and planned to achieve the objectives of the project
successfully on the time. Scope of this project is concentrate on how a counting device
works for count an object or particle. Hence, analyses on automated counting machine
such as test and accuracy of counting device to count an object.
Table 1.1: Gantt chart of PSM.
CHAPTER /WEEK
1 2 3 4 5 6 7
CHAPTER 1: INTRODUCTION
CHAPTER 2: LITERITURE REVIEW
CHAPTER 3: METHODOLOGY
CHAPTER 4: DESIGN AND
DEVELOPMENT PLANNING
CHAPTER 5 : DESIGN AND
DEVELOPMENT PROGRESS
CHAPTER 6 : RESULT
CHAPTER 7: DISCUSSION
CHAPTER 8 : CONCLUSION PSM
3
8
9 10
11
12
13
14
CHAPTER 2
LITERATURE REVIEW
2.1
Historical Development of Counting Machine For Industrial
Application
2.1.1 What is counting?
From Wikipedia Encyclopedia, count is a mathematical process for an object where it as
be set aside with desired of number objects to repeatedly action to adding or subtracting.
Hence, counting also can be involved more than one for example; counting by a two (2,
4, 6, 8….). From the archeological, they have found that a counting has been used last
500,000 year.
2.1.2 Historical Counting Device
On 500 B.C to 1300A.C, Babylon culture is the one who made up a first counting device
called Abacus. The Abacus is used to calculate an arithmetic process and it’s also act as
a calculating tool on that time. After hundreds year, a counting board have been develop
by Roman where it’s called the hand of abacus. Year per year, a counting machine
device have been continuous develop until an era of computer been arrived on 1950’s.
4
Figure 2.1: A Roman Abacus (Illustrated from Wikipedia Encyclopedia).
2.1.3
Historical counting machine
2.1.3.1
Cremer Company
On 1949, Cremer Company has built up a counting machine in packaging and counting
line logistics. This company preferred supplier for counting machine and packaging
solution on pharmacy, confectionery, bakery and frozen foods, packed snack food,
hardware, medical supplies, flower bulbs, etc. A customer of this company in this world
wide used counting and packaging machine are Nestle, Cadbury, Frito Lay, Kraft Foods,
Glaxo, General Mills, Masterfoods, ConAgra, Chupa Chups, De la Rosa, Sabritas,
Philips, Bayer, Wyeth Ayerst, Pfizer and Boehringer, Eli Lillyand and Dr. Oetker.
In 1982, Cremer introduced the first linear tablet and capsule counting machine. Ever
since, the CF model has been renowned worldwide for its 100% accuracy, high capacity,
simple cleaning and operation, high reliability and durability. The Cremer CF counting
machine is a high-speed tablet and capsule counting machine for pharmaceutical and
pharma industries - medicines, vitamins, food supplements, health products etc.
5
Figure 2.2: First counting machine (Illustrated from Cremer Company).
2.1.3.2 Cremer’s Method
A line principle is used on all counting machine in Cremer Vibratory plates to separation
of products before falling through detector channel. Cremer’s method on count products
is products are cascaded down through a Memory flap see Figure 2.3. Hence, the correct
quantity is discharged into a bucket elevator or packaging machine.
Figure 2.3: Cremer’s counting principle (Illustrated from Cremer Company).
6