MULTI SIZE BOTTLE FILLING MACHINE

                                                              ABSTRACT

In small scale industries bottle filling process requires many workers. With the use of automatic machine, each process can have smooth operation and with this the process of bottle filling reduces the manpower requirements as well as operation time.  One of the solutions is proposed in this study for the variant in the bottle sizes. To achieve this system control has been studied along with the various sensors and their functionality in the existing plant. As the diameter of the bottle is the constraint for this operation obviously the height is the parameter which is varying for the different liquid storage in the bottle. Literature survey suggests that the infrared proximity sensor is suitable to sense the height of the bottle. The control system is arranged in such a way that the sensor will sense the height and accordingly the liquid is filled in with the appropriate amount from the solenoid valve.  

 Introduction

 Introduction about bottle filling machine:-

 The   system can faster for the   produce   product in   factory.  In   the industries, the    filling   used   because the   system   to be operated with automatic.   This  project  is  divided  into  4 sections; the loading  section, the  conveyor  section(transfer section),  filling  section and    path divider  section. The whole sections are controlled by the Microcontroller. The  mechanical  part of the project  consist of mechanical measuring  and fabricating process, while electrical  part consist  of  electrical  wiring and  programming. and now it is available in multi size bottle filling system we can fill different amount of or the different capacity bottles. The software of the  microprocessor theory  includes the  electrical  and  mechanical actuators  for  the   hardware  will be  showing  good  result  to fulfill the  objective  of this  project.

                                                           FIG1.1: bottle filling machine

 Problem definition:-

The problems that  existing in the present machines are that it can fill only a particular type of containers of certain height, and the filling amount is as set by the operator. If the machine has to fill different type (size) of container then again the operator has to set the filling amount for each container. Time taken for filling will become more in such conditions. Sometimes in special environments which are dangerous and not conductive for human operation, the operator cannot go and set the filling amount. By this the rate of production was affected due to the use of manual inspection systems .Sometimes in special environments which are dangerous and not conductive for human operation.

 Function and Working:-

The main objective of the project is to Design and Develop a Automatic liquid filling to bottles of controller Integration. Programming the system in microcontroller ladder logic diagram. To develop a filling machine which can fill same sizes of containers on the bases of  height same principle can be used in different industries like medicine, oil, chemical industries for filling liquid to different sized component by one machine.

                                                                   FIG  LAYOUT OF SYSTEM

 WORKING OF FILLING MACHINE

Bottles are kept in position in a carton over a conveyor belt; they are sensed to detect their presence. Infrared proximity sensors are used for sensing the bottles. Depending on the output of the sensor the corresponding valve switch on and filling operation takes place. If the particular bottle is not present then the valve in that position is switched off, thereby avoiding wastage of the liquid. The filling process is done based on timing. Depending on the present value of the timer the valve is switched on for that particular period of time and the filling is done.

          
        FIG  OVER VIEW OF SYSTEM

BLOCK DIAGRAM

              

                                                                                FIG  BLOCK DIAGRAM OF SYSTEM              

COMPONENTS, ADVANTAGE, LIMITATION AND     APPLICATION OF MULTI SIZE BOTTLE FILLING MACHINE

 COMPONENTS USED:-

•        DC MOTOR
•         CONVEYOR BELT
•         BEARING
•         ROLLERS
•         FRAMES
•         SENSOR
•         MICRO CONTROLLER
•         SOLENOID VALVE

· DC GEARED MOTOR

Geared DC motors can be defined as an extension of DC motor which already had its Insight details demystified here. A geared DC Motor has a gear assembly attached to the motor. The speed of motor is counted in terms of rotations of the shaft per minute and is termed as RPM .The gear assembly helps in increasing the torque and reducing the speed. Using the correct combination of gears in a gear motor, its speed can be reduced to any desirable figure. This concept where gears reduce the speed of the vehicle but increase its torque is known as gear reduction.  This Insight will explore all the minor and major details that make the gear head and hence the working of geared DC motor.

External Structure

At the first sight, the external structure of a DC geared motor looks as a straight expansion over the simple DC ones

                   SPECIFICATION:   Speed- 30rpm   

                                                     Voltage: 12 V

FIG    DC MOTOR     

    

Internal Structure

On opening the outer plastic casing of the gear head, gear assemblies on the top as well as on bottom part of the gear head are visible. These gear assemblies are highly lubricated with grease so as to avoid any sort of wear and tear due to frictional forces. Shown below is the top part of the gear head. It is connected to rotating shaft and has one gear that allows the rotation. A strong circular imprint shows the presence of the gear that rotates the gear at the upper portion.

FIG DC MOTOR( INSIDE STRUCTURE)     

FRAMES

Some frames are of steel galvanized, heat-treated aluminum, and powder coat painted steel. The structure that supports the machinery components of a conveyor.

FIG  FRAME STRUCTURE   

CONVEYORBELT

A belt conveyor consists of an endless belt of a resilient material connected between  two  pulleys  and  moved  by  rotating  one  of  the  pulleys  through  a  drive  unit gearbox, which is connected to an electric motor.

                              

                                             FIG    CONVEYOR BELT

PVC Roller conveyor is break down due to impact load so shutdown of plant works. Roller are use for the transfer of the raw material, raw  material filled from the Hooper and proper mix the material , this material suddenly enter to the roller conveyor, due to impact load Roller conveyor is break down.

           FIG    PVC ROLLER CONVEYOR  

                  Sometimes bearing attach with the PVC roller, if this bearing is jammed than PVC will harmed, so here two types of bearing can be used. One is attached to inside the PVC and also at the main conveyer pulley. So if one pulley is damaged than other can convey. So here the alternative bearings are use to avoid the damage.

The development of belt conveyors, capable of transporting virtually any bulk material at thousands of tons per hour in a continuous and uniform stream, has been one of the most important innovations for modern industry.

  

           

                           Fig   General arrengment of a belt conveyor. 

Belt conveyors have attained a dominant position in transporting bulk materials due to such inherent advantages as their economy and safety of operation, reliability, versatility, and practically unlimited range of capacities. In addition, they are suitable for performing numerous processing functions in connection with their normal purpose of providing a continuous flow of material between operations. Recently, their conformity to environmental requirements has provided a further incentive for selection of belt conveyors over other means of transportation.

A conveyor generally consists of a drive station, tail station, intermediate standard frames, drive units, the rollers and the belting. In a typical all above components contributes individually for overall performance, yet the “ROLLER” are conspicuous by their vast number and also by their critical function. Hence, it is of paramount importance that these rollers are designed, manufacturing and maintained with maximum life, as the main criteria.

 SOLENOID VALVE

q  A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current through a solenoid: in the case of a two-port valve the flow is switched on or off. The valve is controlled by an electric current through a solenoid: in the case of a two-port valve the flow is switched on or off. It works by 12volt dc current and controlled by pcb.

FIG Solenoid valve

Ø   BEARING

         As we all know, Bearings are used to give support the shaft of the roller or idle pulley at both ends. They give also rotational motion of shaft by giving it support with very less  friction.  Though  some friction  is  taken  place due  to  the  metal  to  metal  contact inside the bearing between metal balls and metal casings, it is very negligible as compare with the direct contact of rotating shaft and main frame of the conveyor.

Types of Bearings:

         There are many types of bearings, each used for different purposes. These include ball bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered roller thrust bearings.

Ball Bearings

          Ball bearings, as shown below, are probably the most common type of bearing. They are found  in  everything  from  inline  skates  to  hard  drives.  These  bearings  can  handle  both radial and thrust loads, and are usually found in applications where the load is relatively small.

Roller Bearing:-

A roller bearings use cylinders of slightly greater length than diameter in the gap between outer and inner races.

 Roller bearings have higher radial load capacity than ball bearings, but a low axial capacity and higher friction under axial loads. If the inner and outer races are misaligned, the bearing capacity drops quickly compared to either a ball bearing or a spherical roller bearing.

                       

FIG  BALL BEARING     

Ø    INFRARED PROXIMITY SENSOR

An infrared proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. A infrared proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal. The object being sensed is often referred to as the infrared proximity sensor's target. Different infrared proximity sensor targets demand different sensors. For example, a capacitive photoelectric might be suitable for a plastic target; an inductive infrared proximity sensor always requires a metal target. The maximum distance that this sensor can detect is defined "nominal range". Some sensors have adjustments of the nominal range or means to report a graduated detection distance.

          FIG INFRARED SENSOR   

Infrared proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object. Infrared proximity sensors are also used in machine vibration monitoring to measure the variation in distance between a shaft and its support bearing. This is common in large steam turbines, compressors, and motors that use sleeve-type bearings.

FIG   SENSOR LAYOUT

Ø MICROCONTROLLER

Microprocessors and microcontrollers are widely used in embedded systems products. Microcontroller is a programmable device. A microcontroller has a CPU in addition to a fixed amount of RAM, ROM, I/O ports and a timer embedded all on a single chip. The fixed amount of on-chip ROM, RAM and number of I/O ports in microcontrollers makes them ideal for many applications in which cost and space are critical.

The Intel 8051 is Harvard architecture, single chip microcontroller (µC) which was developed by Intel in 1980, for use in implant systems. It was popular in the 1980s and early 1990s, but today it has largely been superseded by a vast range of enhanced devices with 8051-compatible processor cores that are manufactured by more than 20 independent manufacturers including Atmel, Infineon Technologies and Maxim Integrated Products.

            8051 is an 8-bit processor, meaning that the CPU can work on only 8 bits of data at a time. Data larger than 8 bits has to be broken into 8-bit pieces to be processed by the CPU. 8051 is available in different memory types such as UV-EPROM, Flash and NV-RAM.

The microcontroller used in this project is AT89C51. Atmel Corporation introduced this 89C51 microcontroller. This microcontroller belongs to 8051 family. This microcontroller had 128 bytes of RAM, 4K bytes of on-chip ROM, two timers, one serial port and four ports (each 8-bits wide) all on a single chip. AT89C51 is Flash type 8051.

Figure   Microcontroller

 APPLICATION

Ø               Dairy  industries

Ø             Soft drinks industries

Ø             Liquid production  companies

Ø  Pharma companies

 ADVANTAGES & LIMITATIONS:-

v Advantages

Ø  Hygiene  and  food  safety  enhanced

Ø  New  way  of  expanding  the  refrigerated  milk and  milk beverages market.

Ø  Its  not  consume  a  more   time

Ø  The  system  is  extremely  less issue  to  human error

Ø  Long- life  and  shelf-stable  of  product  is  possible

v Disadvantages

Ø  Initial cost is high.

Ø  Components which used are expensive.

Ø  Its  installation  cost   is  high

   Design of Shaft & Bearing

   DESIGN OF Shaft:-

Ø  By considering the Roller as a simply Supported beam.

Ø  The roller is supported at the two ends A and C respectively. the load on the roller is 55            kg, which is the point load on the roller. The reactions at the two ends are R_a and R_c.

                                            F= 80 kg

                                              =80

                                  =784.8 N  

à For centre load simply supported beam.

             R_A   = ½×f                                                                          R_B   = ½×f

                  = ½ ×784.8                                                                         =  ½ × 784.8

              R_A = 392.4 N                                                         R_B   = 392.4N

à Vertical shear.

             A   to B                 V = +½×f

                                              = ½× 784.8

                                             = 392.4N

            B to C                  V = -½×f

                                            = -½× 784.8

                                            = -392.4N

           Bending moment.

              A   to  B                 M =  ½×Fx

                                                 = ½×784.8×550

                                                  =215820Nm

              B  to  C                   M =  ½×F×(l-x)

                                                  = ½×784.8×(1100 -550)

                                                 =215820Nm

                Diameter of Shaft = 20 mm.

                Length of Shaft = 1200 mm.

          Moment   of Inertia.

                                    J  = ( π/64) ×  d⁴

                                    =  (π/64) ×2⁴

                                   = 0.785

 Deflection  of  shaft

α = (P(CL – 2C² ) / (4 ×E×J))×((360 × 60) / 2π))

where,  C=  distance  between  shaft  and  bearing  centre.

α = (55(4.25×110 – 2(4.25)²) / ((4 × 2.1×10⁶ × 0.785)) × ((360 × 60) / 2 π))

α = 12.37min.

Ø  The permissible angular tilt in the case of deep groove ball bearing is 16 min. As the deflection of the selected shaft is well within this limit, the shaft could be considered safe. 

 

FIG DESIGN OF SHAFT   

 

FIG  BELT FRAME DESIGN   

  COST ESTIMATION

q Cost Estimation Table:-

Cost Estimation of Multi size bottle filling system
No.	Name of component	No of component          Used	Cost/pie (RS)	Total cost
1	DC motor	1	200	200
2	Conveyor belt	1	50	50
3	Plywood	1	260	260
4	Bearing	8	35	280
5	Rollers	5	10	50
6	Frame structure	1	600	600
7	Sensor	2	100	200
8	Micro controller	1	1500	1500
9	Transformer	2	500	1000
		Total cost		4140

     

               

  CONCLUTION

                      

          In   this  model we  are  providing  the  facility  of automatic  bottle  filling.  With  using   this   model  we  are   reducing  the  human  errors  and  time . its make  the  bottle  filling  work faster  and  provide  safety  to  the  drinks. Productivity is increase. So,  it’s a  effective  and  useful  for  commercial  small scale industries system .

   REFERENCES

·                  www.Gmpindia.com

·                  www.sensorsmag.com

·                  www.wikipedia.com

               

For Further inquary
Email  dibakarkarmokar2@gmail.com