Automated Packaging Machine

PROJECT DUTIES

Design: Most of the conceptual designs occurred during sleepless nights laying up in bed, but the real design process came down to 3D modeling using AutoCAD where ideas could be rendered and movable parts tested virtually for range of motion. Once satisfied with the design,schematics of machinable parts were produced. 

Fabrication: The fabrication process consisted of machining each part using equipment such as a MIG (SMAC) welder, lathe, mill, drill press, and band saw. 

Assembly: In the assembly process, the machined parts were integrated with any corresponding commercial components such as motors and pneumatic cylinders. All parts built were designed to fit on T-slotted aluminum framing system. 

Circuitry: Circuits were developed using perforated PCB where transistors, relays, and micro-controllers used control each commercial component could be placed and soldered. 

Programming: Programming was the last step since it was practical to test micro-controller code on the components to be automated. The micro-controllers were programmed using the Arduino integrated development environment (IDE). 

OVERVIEW

The automated packaging machine is a prototype that was built and designed for the paper conversion industry. In the competitive and ever-growing manufacturing industry of mass production, speed and efficiency are key to a company's survival. The purpose of this machine is to automate the process of counting and removing paper bags from the bag forming machine, bundle the bags into the correct configuration, and finally, package the bundle into a carton that will be ready for shipment. 

In the early stages of development, the prototype consisted of Baldor motors and drivers that were controlled by IDEC programmable logic controllers (PLC).  As the design evolved, these previous components were replaced by pneumatic cylinders, small geared motors, and servos. These compact and inexpensive components are more readily available and can be controlled by Arduino programmable micro-controllers which are also significantly smaller and cheaper devices. In addition to the reduced size and price, the Arduino C based programming language offers a more sophisticated and efficient platform than PLC ladder logic.

Further videos on concepts and designs of potential integrated axillary units:

• Carton/box labeler

BREAK DOWN OF TIME SPENT ON EACH PROCESS

The design aspect is where ideas are put into motion. Many ideas that seem practical in thought turn out to be impossible once converted into a 3D model. Often a design went through many changes. Hence, the design process is the longest. 

The methods of machining can be tedious and time consuming. Sometimes, setting up the machine in the correct configuration to mount the part to be fabricated can take longer than the machining process itself.

Fabrication of circuity (soldering components to PCB) was a relatively quick task. Internet searches and flipping through literature for the correct placement of resistors and diodes (in a relay circuit, for example) is what took the most time. However, this was also the most rewarding process where I learned much about electronics.