Report

Automatic packaging machine
Diploma in Mechatronics Page | 1
INTRODUCTION
The level of automation in the industry continues to improve,
and the application scope is also expanding.
Packing is the process of covering an object/pack within another object for
many reasons like keeping it safe, avoid it from natural element etc.
The machine used for this packaging machines. Nowadays we are using
many types of APM*.
The automation in packaging machine industry is changing the packaging
process actions and containers and packaging materials processing
methods.
To realize the automatic control of the packaging system can greatly
improve the production efficiency and product quality, and reduce
packaging.
It makes revolutionary changing of automated packaging machine industry
production method and its product transmission mode.
In recent ten years, packaging industry attaches great importance to
improve the packaging machinery and the whole packaging system.
Especially for the food, beverage, pharmaceutical, electronics and other
industries.
Now we have done a small part of APM technology.
*APM – AUTOMATIC PACKAGING MACHINE

AIM
AIM OF OUR PACKAGING is an idea of a young entrepreneur; it was
formed to provide qualitative and competitive packaging solutions to the
world. The vision of ours is to provide a wholesome packaging solution
and provide all round technical assistance to the clients regarding there
packaging need’s.
OBJECTIVE SCOPE
GENERAL OBJECTIVES
To reduce the man power in packaging field and to increase the
productivity
ACADEMIC OBJECTIVES
While progressing our project, we will gain the knowledge in
the fields of Mechanical System, PLC, Embedded System and its
programming and Fluids System.
Skills to manage creative teams and project processes effectively and
efficiently.

TARGET
Target of our project is to be installed in small scale industries
and home provision in order to increase the production in low cost
automation.
ACTIVITY
The workflow of our project is described by process by process using
activity flow diagram.
Step1-Analyzing the current packaging machine system.
Step2-Referring some information resources.
Step3-Collecting the data (dimensions and specification)
Step4-Following the below activity flow diagram.
Task1
Building of
hopper
Task2
Building of
physical
structure
Task3
Welding of
physical
structure
Task4
Adding
motor and
switches
Task5
Writing
embedded
program
Task6
Checking
program
Task7
Burning the
program
Task8
Giving
connections

DATA COLLECTION
For the reference we have collected data from internet and from the
external resources.
We have referred the books related to electronics, electrical, pneumatics,
embedded and programming
 For embedded system
http://www.devlearn2008.com
 For electrical
Basics of electrical volume 1 – B.L. Theraja
 For electronics
Principles of electronics – Bakshi
Electronics for you (magazines and websites)
 For pneumatics
BOOKS:-
Fundamental of pneumatic control engineering- Festo
Fluid mechanics and pneumatic- Dr. Jagdish lal
Hydraulic and pneumatic power for production- Stewart

ANALYSIS
It is done on the analysis of PQCDSM
PRODUCTION
The production in increased when compared to manual operation.
In manual process time taken for packaging is more when compared to do
the same with the automation.
It takes more manpower for packing a material by manual by processing
this by automation the manpower reduced
QUALITY
Quality of packaging is increased by processing it by automation.
By increasing the quality of packaging benefits through increased sales
As a result the customer satisfaction is improved
DELIVERY
In the view of small scale industries our project has high delivery due to
these factors.
 Cost
 Productivity

SAFETY
There will be no chance for shock due to short circuit. As we are not
using any heavy material. In our project, there will be no injury for human.
Even we are not using a sharp material so, that it don't hurt human. The
safety precaution to be taken is that of taking aware of heat and pneumatic
pressure.

PROJECT RELEVANCE
The main objective of our project is to design a automatic packaging
machine which is a low cost automation.by which it meets the customer
needs and satisfaction.
For reference we browsed in web and referred some books
https://www.youtube.com/watch?v=3GA4GRZW29E
https://www.youtube.com/watch?v=Q__0hpr66Cc
https://www.youtube.com/watch?v=I7MMwuOQ3co
https://www.youtube.com/watch?v=c3iHJpi2Etc
https://www.youtube.com/watch?v=8hoBozPzppQ
https://www.youtube.com/watch?v=DJb-YceV-ms
BOOKS REFERRED
Principles of electronics – Bakshi
Electronics for you (magazines and websites)
Fundamental of pneumatic control engineering- Festo
Fluid mechanics and pneumatic- Dr. Jagdish lal
Hydraulic and pneumatic power for production- Stewart

RELEVANT LITERATURE SURVEY
In the small scale industries, because of cost factor they do not
buy the automated packaging machine and so they pack the smaller
quantities by manually. So we have designed the automatic packaging
machine and implemented in some provision shops and small scale
industries and received feedback.
Here is the feedback form.
S.R. CHAITANYA; G. DHARANIDARAN; K. SURYA

CUSTOMER REQUIRMENT
Our project has satisfied some of the customer needs.
After implementing and receiving the feedback we came to know that they
required some changes in our project for varying the weight of the
packaging and dimension of the project. So they can use in home
provisions.
Provision shops:-
 Dimensions of the physical structure.
 Varying packaging weight
Small scale industries:-
 Varying packaging weights
 Emergency stop and alarm.
 Conveyor and counters

DESIGN ALTERNATIVES
After the analysing the feedback we came to know that we can do some
alteration in these field to satisfy the customer requirement.
Alteration to be done:-
 External timers
 Analog timers
 Digital timers
 Varying packaging size
 Counters
 Push buttons and keypad control
 Alarm system
Estimated cost for implementing this design alternatives:-
Rs 25000/-

DESIGN STEPS
BLOCK DIAGRAM
Loading
cover
Two Motors
DAC OutputHorizontal Sealing
Hopper Filling
Same Time Action

TWO MOTORS
This two machine are used to load the cover to the Hopper pipe.
One motor rotate clockwise and other motor rotate counter clock wise.
Both motors are inversely proportional.
LOADING COVER
 This block the cover has loaded into top side in the hopper pipe.
 To make a more gripness load a cover more.
HOPPER
 A hopper is a large, pyramidal shaped container used in industrial
processes to hold particulate matter that has been collected from
expelled air.
 Hoppers are usually installed in groups to allow for a greater
collection quantity.

 They are employed in industrial processes that use air pollution
control devices such as dust collectors, electrostatic precipitators,
and bag houses/fabric filters.
 Most hoppers are made of steel.
HORIZONTAL SEALING

DAC
 Pneumatic cylinders use them where it is needed to produce a force
in both directions.
 A double-acting hydraulic cylinder has a port at each end, supplied
with hydraulic fluid for both the retraction and extension of the
piston.
 A double-acting cylinder is used where an external force is not
available to retract the piston or where high force is required in
both directions of travel.
OUTPUT

CIRCUIT DIAGRAM

MODULE #1
POWER SUPPLY
BILL OF MATERIALS:
Transformer 1 230V to 5V
S.NO COMPONENTS SYMBOLS QUANTITY
1 230V AC Supply __ 1
2 1N4001 Diode D1 to D4 4
3 0.1 micro farad Capacitors C1 to C2 2
4 470 micro farad capacitor C3 1
5 IC LM7805 - 1
Transformer 2 230v to 12v
1 230VAC Supply - 1
2 1N4001 Diodes D1 to D4 4
3 1000 Micro farad Capacitor C1 1
4 1Micro farad
capacitors
C2 1
5 IC LM7812 - 1
DESCRIPTION
The power supply module converts the 230v AC to 12v DC. After
converting to DC it filters the supply and gives the constant supply.
As per requirement it is again converted to 5V DC supply.

MODULE #2
SWITCH INPUTS
BILL OF MATERIALS:
1 LIMIT SWITCHES LIMIT 1
LIMIT 2
2
2 PUSH BUTTONS MASTER- -
START
COVER- -LOAD
2
DESCRIPTION
In this circuit we will use 2 limit switches & 2 push buttons which are used
to control micro controller. The 2 limit switches are used to control the
hopper motor and the cover load push button is used to load the cove,
the master start push button is used to start the entire process.
Limit switch 1
Limit switch 2
Master start
Cover loading

MODULE #3
PIC UNIT
BILL OF MATERIALS:
S.NO COMPONENTS SYMBOL QUANTITY
1 PIC 16F877A -- 1
DESCRIPTION
In this circuit we had used an microcontroller, pic 16F877A. It receives
the input from switch input unit and gives output to the relay units as per
the programme written.

MODULE #4
RELAY UNIT 1
BILL OF MATERIALS:
1 12v relay RE1 to RE4 4
2 1kilo ohms Resistors R1 to R4 4
3 1Micro farad Capacitors C1 to C2 2
4 Driver IC ULN2803 U1 1
5 Connectors S1 to S4 4
DESCRIPTION
In this circuit we have used 2 relay kits one is of 4relay kit and other is 2
relay kit. Here is the 4 relay kit, it is used to control the 3 motors present
in the circuit.

MODULE #5
MOTORS
BILL OF MATERIALS:
1 12V DC MOTOR M1; M2; M3 3
DESCRIPTION
In this circuit we had used 3 12V DC motors which are used to load cover
and open & close the hopper.
M1, M2 are used to load the cover in the machine. M3 is used to open and
close the hopper and control the flow of the material.

MODULE #6
RELAY UNIT 2
BILL OF MATERIALS:
1 12v relay RE1 to RE2 2
2 1kilo ohms Resistors R1 to R2 2
3 1Micro farad Capacitors C1 to C2 2
4 Driver IC ULN2803 U1 1
5 Connectors S1 to S2 2
DESCRIPTION
In this circuit we have used 2 relay kits one is of 4relay kit and other is 2
relay kit. Here is the 2 relay kit, it is used to control the sealing machine
and solenoid valve present in the circuit.

MODULE #7
OUTPUT UNIT
Sealing machine Solenoid valve DAC pneumatic
piston
BILL OF MATERIALS:
1 230v sealing machine - 1
2 220v 5/2way solenoid
valve
-
1
3 DAC pneumatic piston
(100spm;
30dia ;)
-
1
4 28.9mm hose - APR
DESCRIPTION
In this project this is the main unit. It consists of
 Sealing machine to pack the particles in cover.
 Solenoid valve to control the DAC
 DAC (10 bar) pneumatic piston to share the work of sealing.

INTER-CONNECTION DIAGRAM

MATERIAL SELECTION
First, we decide on the requirements of the project. Second, we decide on
the possible materials we can use in the project. Third, we decide what
changes in the material properties are needed. Lastly, we decide which
material out of the possible materials best fulfils the requirements of the
project given possible changes in the material properties.
For our project the physical structure is made up of steel and iron
material. As the material is lower cost and easily available. Hopper is built
by stainless steel. As it is alloy prevent from rusting.An Alloy is type of metal
that is composed of two or more elements
DESIGN CALCULATION
Power supply design

12V DC POWER SUPPLY DESIGN
TRANSFORMER DESIGN
Required output voltage =12V / 1A D.C
The regulator output is less than 3V of the regulator input.
So the regulator input = 12V+3V=15V
So Vdc=15V
Vrms=Vdc/0.9
So Vrms = 15/0.9
Vrms = 16.6V
10% margin voltage = 16.6+10% 0F 16.6
= 16.6+1.66=18.2V
Transformer: - 230V / 18V, 1A
VOLTAGE REGULATOR CIRCUIT DESIGN
From Data sheet:-
Vref = 1.25volts
Iadj = 100μA
Assume:-R1 = 220Ω
Vout= Vref (1+R2/R1) + (Iadj) R2
Output Volt (required) = 15V
Vout = Vref (1+R2/R1) + (Iadj) R2
12V = 1.25 * (1+R2/220) + (100*10 -6)
R2
12 – 1.25 = 1.25R2/220 +0.1*10 -3

10.75 = 5.69* 10 -3
R2+0.1 * 10-3
R2
10.75 = 5. 79 * 10-3
R2
R2 = 10.75/5.79*10-3
R2 = 1.8kΩ
CURRENT LIMITING
Output current= 1A
Transistor volt for 2N2222 = 600mV
So, R3 = 0.6V/1A (ohms law R = V/I)
R3=0.6Ω
R4 = 3R3
R4 =2*0.6Ω
R4= 1.2Ω

DAC DESIGN
Clamping mass = 1Kg
Force = 1Kg
If p is pneumatic pressure
p= 6Kg/cm2
(available)
F=p*a
1=6*a
a=1/6 cm2
r2
= 1/6 cm2
r=  (1/6 )
= 0.23 cm
Diameter= 0.46cm
Considering an efficiency () of 80%, diameter works out to
= 0.46/0.8 = 0.58 cm say 0.6 cm
Taking factor of safety = 2.5

We get diameter = 1.5cm
Although 1.5cm diameter is sufficient, we used a DAC diameter of 1.8cm
as it is readily available in the market.
Stroke length depends upon the size of the machine and the work piece.
We have selected a stroke length of 30mm, as it is readily available in the
market.
COMPARED TO the conventional work and the APM work the PPM is
calculated as the following,

MANUFACTURING PROCESS

COST ESTIMATION
S.NO MATERIALS SPECIFICATION QUANTITY PRICE
1 DC MOTOR 12V, 45RPM 2 Rs.400
12 HOPPER 300 DIAMETER 1 Rs.1000
3 SOLENOID VALVE
+ DAC
220V AC, 10BAR 1 Rs.3000
4 LIMIT SWITCH 5V 2 Rs.100
5 COMPRESSOR 12 BAR 1 Rs.5000
6 CONTROLLER
(PIC)
PIC16F877A 1 Rs.300
7 POWER SOURCE 12V, 05V- DC SOURCE
230V AC-12V DC- 5V DC
1 Rs.500
8 RELAY 12V 4 Rs.100
9 SEALING
MACHINE
230v 1 Rs.1000
10 DC MOTOR 12V,5RPM 1 Rs.150
11 ROLLERS 100MM 2 Rs.200
12 PLASTIC TUBES 4X0.75 REQUIRED Rs.2X50
13 RELAY DRIVER IC ULN2003A 1 Rs.250
14 PLASTIC FILM - REQUIRED Rs.300
15 EXTENSION BOX 230V 1 Rs.200
16 IRON ROD STAINLESS,IRON REQUIRED Rs.2000
17 RACK AND
PINION
1:3 1 Rs.80
18 BUSHES PLASTIC 12 Rs.180
Total amount: Rs.15,400

ASSEMBLY DRAWING
We have use creo 2.0 parametric software as the design tool
Back view

Top view

Front view

BILL OF MATERIAL
S.NO MATERIALS SPECIFICATION QUANTITY
1 DC MOTOR 12V, 45RPM 2
2 HOPPER 300 DIAMETER 1
3 SOLENOID VALVE + DAC 220V AC, 10BAR 1
4 LIMIT SWITCH 5V 2
5 COMPRESSOR 12 BAR 1
6 CONTROLLER (PIC) PIC16F877A 1
7 POWER SOURCE 12V, 05V- DC SOURCE
230V AC-12V DC- 5V DC
1
8 RELAY 12V 4
9 SEALING MACHINE 230v 1
10 DC MOTOR 12V,5RPM 1
11 ROLLERS 100MM 2
12 PLASTIC TUBES 4X0.75 REQUIRED
13 RELAY DRIVER IC ULN2003A 1
14 PLASTIC FILM - REQUIRED
15 EXTENSION BOX 230V 1
16 IRON ROD STAINLESS,IRON REQUIRED
17 RACK AND PINION 1:3 1
18 BUSHES PLASTIC 12

PART LIST
Rack & pinion
A rack and pinion is a type of linear actuator that comprises a pair
of gears which convert rotational motion into linear motion.
In our project we have used 1:3 ratio rack and pinion.
Sealing machine
A heat sealer is a machine used to seal products, packaging, and
other thermoplastic materials using heat. This can be with uniform
thermoplastic monolayers or with materials having several layers, at least
one being thermoplastic. Heat sealing can join two similar materials
together or can join dissimilar materials, one of which has a thermoplastic
layer.

DAC
Pneumatic double acting cylinder (sometimes known as air cylinders)
are mechanical devices which use the power of compressed gas to
produce a force in a reciprocating linear motion.
Stoke length of cylinder piston 100mm.
Diameter=32mm
Nozzle=8mm
Pressure-5 to 10 bar
DC Motors
A DC motor is any of a class of rotary electrical machines that converts
direct current electrical power into mechanical power. The most common
types rely on the forces produced by magnetic fields.
We have used 3 motors in our project.
2 motors are used to load cover=45RPM
Motor used for hopper control=5 RPM

WORKING
 In this project we shall pack the powder material automatically.
 We are doing this using PIC16F877A.
 We are using 4 actuators (A1,A2,A3,A4,), 4 relays (R1,R2,R3,R4) 1
sealing machine (S1), 1 DAC
 The material falls from the hopper to a cup like structure, from there
it falls to the cover
 There Is a motor connected with rack and pinion controlled by 2 limit
switches and PIC IC.
 The materials from the hopper falls to the cover through the pipe, the
actuators A2, A3, A4 actuates at the same time through relays R1,
R2, R3, R4. So, the sealing machines connected to the A3 seals the
packet and cuts the packet with the sealing machine heat itself.
 This process repeats again.

PROGRAM
LIST P=16F877A
#INCLUDE<P16F877A.INC>
__CONFIG 3F7A
START
BSF STATUS, RP0
MOVLW 07
MOVWF PORTB
BCF STATUS, RP0
CC: BSF PORTB, 4
BCF PORTB, 5
BCF PORTB, 6
BCF PORTB, 7
CALL DELAY
AA: BTFSS PORTB, 1
GOTO AA
BCF PORTB, 4
BSF PORTB, 5

BSF PORTB,6
BSF PORTB, 7
CALL DELAY
GOTO CC
DELAY:
MOVLW 0FF
MOVWF 30
MOVWF 40
DD: DECFSZ 30
DECFSZ 40
GOTO DD
RETURN
END

PHOTOGRAPH
Please refer the link for video
https://www.youtube.com/watch?v=sKl6EMIoN70

CONCLUSION
The automatic packaging machine can be used in any industry
provided they should have the pneumatic and electric source. This
automatic machine is mainly designed to reduce the human fatigue. Once
the material is loaded on the hopper and after switching on the Machine,
the machine works automatically and load the cover and sealing this
process happen continuously.

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