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1 SAI THATIPAMULA 20BME0293

Manufacturing
Automation

Digital Assignment - 1

Faculty: Nithin Sai Thatipamula

Prof. Boopathi M 20BME0293
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1. Yes, I am able to understand how the production flow is being occurred and
how the process has been designed for maximum output with minimum
errors and faulty products. The process is explained as follows:

Container Segregation:
The bottles or containers in which the pulp
extract is being stored are first introduced into the
Bottle Unscrambler Machine, usually the stack of
containers is introduced at once and periodically
as the number of containers decrease a new stack
is brought and introduced into the machine.
Containers Being Segregated in
Scrambler Machine
The containers are then aligned in a straight line over
the conveyer belt, and are made to flow in one
direction and only in one path, the pathway is
designed as such. The pathway can only fit one
container at a time thus containers will be flowing one
after in a straight line.
Alignment of Containers by a
Container Orientation: Modified Pathway
This step is done in two simultaneous procedures,
during the first procedure the containers now
flowing in the straight line are made uni-directional
such that bottom of the container flows first, this is
done with the help of hanging hook, such that if the
hook gets into the open neck of the container it picks
up the container and changes its orientation.
Making the Flow of Containers
Uni Directional by Hook
In second procedure, the containers are made Mechanism
vertical with the help of a wedge type
arrangement, such that when the containers
which are flowing in horizontal orientation will
now interact with the wedge and finally become
vertical. After these the containers will be in
vertical position, with the open neck on the top
and the bottom resting on the belt, and will be
Making Containers Vertical by
flowing to next unit.
Wedge Arrangement
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Container Cleaning by Ionized Air Jet:

The Containers are mostly imparted with purities
during the production or transport from the
storage facility, thus the cleaning of the containers
take place in a particular specified unit, where 4
containers at a particular given instant are cleaned
with the help of ionized air through a setup
designed. These containers are held by custom
made grip in helical shape holding the containers Cleaning of Containers by
such that proper alignment of lid occurs and cleaning Ionized Air
takes place.

Pulp Extract Filling by Filling Machine:

The Containers now cleaned are made to flow to
the next unit where the filling of pulp material
takes place into the containers. The containers
arrive at unsteady rates and the filling machine is
designed to fill 6 containers at an instant, so with
the help of sensors placed near the conveyer belt
around the unit, these sensors help in filling the
material into the containers, also the amount of
material to be filled into the containers are Filling of Containers with Pulp
predesigned and given as a command. Once the Extract by the Use of Filling
filling into containers is done, a closing type
mechanism is arranged, such that pulp from
filling machine won’t go waste much.

Infeed Capping Machine:

The Filled Containers are now carried into the
unit consisting of Capping Machine, where
each container is slowed for a certain amount of
time and then accelerated to get required speed
to pick up the cap. This capping machine
collects the cap (for packing the container), Containers fed Into the Capping
simultaneously through other procedure, as Machine
given below:

Container Cap Segregation:

The caps would be first be in the form of a
pool where hundreds of caps are available,
the vertical cap elevator collects the cap in
different slots, 1-4 per slot and are carried
vertically to a height, after which the opening
is given in the design where the caps roll and
fall into the groove. Container Cap Segregation
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Container Cap Orientation:

The Caps orientation will be done during the
pickup of caps, because owing to curved surface
on the cap, the caps fall out of the slot before
they start to travel up, thus minimizing the error
of orientation. While being carried by the
Vertical Conveyer a bar is arranged in a slanting
position such that, the caps won’t go further
high and roll out of the slot as interacting with A Cap falling into the groove as it
interacts with the slanting bar.
the bar, finally falling into the groove. The
orientation of caps is however checked with the
help of sensor arranged in the groove.

Container Cap Feed in Capping

Machine:
The caps are now collected one by one in the
groove and are descended in a strip type
arrangement, into the capping machine. The
strip is designed in such a way that each cap is
aligned one after the other with no overlap and
only one cap is available at a particular given
instant. Caps collected, sorted and are ready to be
used in the Inline Cap Pickup for
Packaging
Packing of Containers by Inline Cap
pickup:
During this process, the containers now filled
with the material are made to go through pickup
line where an arrangement is made such that
when the containers flowing with some speed
picks up the cap with the heading edge, and the
cap aligns itself over the containers as a lid and
won’t fall off as the container travel on the
conveyor belt. As one container picks up one
cap, another cap would be available A Container Picking up as it flows
simultaneously.
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Container Capping by Rotating

Wheels:
The cap on the container after passing from inline
pickup is very loose and tightening of the
packing is required for storage and transport,
thus with the help of rotating wheels the cap is
made tight onto the container. This is done in
such a way that the two rotating wheels have a
material which is rotating with the wheels,
(mostly made of material which grips the cap like
rubber or leather), the spinning of the wheels will
Usage of Rotating Wheels to Generate
be in the same direction, either clockwise or
Torque
anticlockwise such that they develop a torque on
the cap and make it revolve over the container thereby fitting tightly onto the container.

Quality Check of Packed Product:

The product now almost made is checked
through simple procedure, where in a sensor
along with an actuator is installed just after the
rotating wheels (with sensor being first in line
then actuator), the sensor checks the capping
of the container. If the sensor detects some
uncapped, cross capped or error in the
capping the actuator, pushes away the
container which has error into the slot. The
A Sensor and An Actuator is used
Final Product is then collected on rotating table, During Quality Check of The Packed
and further steps such as packing, storage,
transportation etc are carried out after this.
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A Simple Block Diagram as Shown below Explains the Flow of Components

during the process:

2. There are many instruments and sensors used during the process for
maintaining the flow, some of them are shown below along with their
function and the process they are used in:

Instrument: Scrambler Machine

Used in the Step: Container Segregation
Operation: Providing the Containers into the One
Directional Feed

Sensor: Orientation Laser (Photo Sensor)

Used in the Step: Container Orientation
Operation: To Check whether the Container are
positioned and flowing Vertically

Instrument: Ionized Air Cleaner

Used in The Step: Container Cleaning by Ionized Air Jet
Operation: Cleaning of Containers by Blowing the
Ionized Air into the Container in closed apparatus.
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Sensor: Photon Counter

Used in the Step: Before Pulp Extract Filling
Operation: To Count the number of containers flowing
during the process

Instrument: Filling Machine

Used in the Step: Pulp Extract Filling
Operation: To fill the containers with the material (pulp
extract), with required amount of capacity.

Instrument: Photo Sensor Laser

Used during the step: Pulp Extract Filling
Operation: Gives command to the Filling Machine to fill the
material, once containers are in position.

Instrument: Cap Elevator

Used in the step: Container Cap Segregation and Orientation
Operation: To pickup the Container Caps and Properly
Orient them.

Instrument: Banner Engineering Photoelectric

(Photo-Eye) Sensor
Used in the Step: Quality Check of Packed Product
Operation: To Check whether the Cap is perfectly aligned
and packed to the container

Actuator: Pneumatic
Used in the Step: Quality Check of Packed Product
Operation: To eliminate the incorrectly packed containers
from the production line.
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3. Considering the Pulp extract is already done and available to be filled, we

hereby estimate the cost for the individual components, and final total
plant cost.

S. Cost per
Component Required Total Cost
No Item
1 Bottle Unscrambler 1,50,000 1 1,50,000
2 Conveyer Belt 5,00,000 3 15,00,000
3 Motor for Belt 4,500 6 27,000
4 Positioning Sensor 40,000 2 80,000
5 Ionized air Cleaner 40,000 1 40,000
6 Customized Holders 7,500 2 15,000
Temperature and
7 50,000 1 50,000
Vibration Sensor
8 Discrete Node Sensor 25,000 2 50,000
9 Bottle Filling Machine 7,00,000 1 7,00,000
10 Cap Elevator 1,00,000 1 1,00,000
11 Orientation Sensor 20,000 2 40,000
12 Bottle Containers 40 10,000 4,00,000
13 Roller Belt 1,500 6 9,000
14 Motor for Roller Belt 1,000 6 6,000
Mixing and Storage
15 1,20,000 1 1,20,000
Tank
Support Table for Flow
16 30,000 3 90,000
of Items
Additional
17 1,50,000 - 1,50,000
Modifications
Total - - 35,27,000

To be noted that, Ionized air cleaner and bottle filling machine needs to be
customized as in ionized air cleaner we observe 4 bottles are cleaned at a particular
time and during the filling of bottles with the pulp extract 6 bottles are filled at a
particular time, so modifications need to be done, which are included in the final
cost.