Contoh Fyp Gmi

8/10/2019 Contoh Fyp Gmi

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CHAPTER I

INTRODUCTION

1.1 PROJECT BACKGROUND

We have overcome to make a Post-Mix Instant Noodle Machine for our Final year

project in our last semester at German Malaysian Institute. This project is being set offas one of requirement to finish our diploma program and the most important thing is it

gives us a feel of a real working life by making a machine that we create and apply all

things that we have study during these three years of diploma.

First of all, this idea comes from when one of our members wanted to eat instant

noodle. Later we found out that making an instant noodle ready to eat has some step to

follow. So it was good to make our busy live much easier if we have make a ready to

eat instant noodle machine. As it was like a vending machine that are easy for us to

use.

This machine gives entrepreneur another way to promote their product.

Entrepreneur can put this kind of machine at the market area like inside shopping

complex, nearer house area or office building. This place is where most of people exist.

This kind of vending machine does not been make in our country yet, so it was our

advantages to introduce this machine to industrial by making a variety for vending

machine. It would give people a better choice to eat what they want freely.

We have done some researched about vending machine outside off our country

and study about their way of handling vending machine. It is to make sure that we will

have enough information and knowledge about vending machine.


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1.2 OBJECTIVES

Project Objectives:

The objectives we doing this project are to design and construct Post-Mix

Instant Noodle Machine and acquainting with the process to fully automatic process. As

also to assemble the new machine for SMI (Small Medium Industry) and produce the

cooked instant noodle in 2 minutes.


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CHAPTER II

LITERATURE REVIEW AND FEASIBILITY STUDIES

2.1 FEASIBILITY STUDY

During a brainstorming session between team members, we had been carried

out feasibility study for our project. Each team members will give their own opinion and

solution for every process station in our machine system including designing

mechanical or electrical part. The discussion included:

Discuss between team members

Discuss and refer to supervisor and TTO

Refer to our senior, which is have been done their Final year project to get the

guidance through doing the project.

Get an extra information through book, internet

Give solution through idea, knowledge, skills and experience while studying at

German Malaysian Institute and during Industrial Training.


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2.1.1 Primary Source

Grab a packet of two minute noodles, any brand will do.

Get a kettle and boil around 1L of water(depends onsize of bowl).

Empty packet into bowl.

Add flavoring on top or anything you desire.

Now, wait until the water has boiled.

Once boiled pour water into bowl.

Either put on a cover over them so the moisture staysin the bowl or grab a fork and start eating


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Figure 2.1: Primary Source

2.1.3 Type of Plastic

Material that we are using for placing flavour is plastic. Plastic used in food

packaging should be of greater purity than plastic used for non-food packaging. Food

grade plastic does not contain dyes or recycled plastic deemed harmful to human. It

has to follow HACCP (Hazard Analysis and Critical Control Point) standard

Figure 2.2: Recycle symbol

Type 5: PP (Polypropene)

High tensile strength, making it ideal for use in caps and lids that have to hold

tightly on the threaded openings

Because of it high melting point, polypropene can be hot filled with products

designed to cool in bottles, including ketchup and syrup.It is also used for

products that need to be incubated such as yogurt.

Different PP grades are available dependent on the application and chosen

processing method.

Physical Properties

Tensile Strength 0.95 - 1.30 N/mm

Notched Impact Strength 3.0 - 30.0 Kj/m

Thermal Coefficient of expansion 100 - 150 x 10-6

Max Cont Use Temp 80 C

Density 0.905 g/cm3

(Source : Plastipedia.co.uk)


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Resistance to Chemical

Dilute Acid ****

Dilute Alkalis ****

Oils and Greases ** variable

Aliphatic Hydrocarbons *

Aromatic Hydrocarbons *

Halogenated Hydrocarbons *

Alcohols ****

KEY * poor** mo derate *** good **** very good

(Source : Plastipedia.co.uk)

Figure 2.3: Hazard symbol 1

It is suitable for oven use. Our silicon ware is manufactured from state-of-the-art

material that is light, flexible & withstands temperatures ranging from -25C to 220C,

making it ideal for use in the freezer, refrigerator, microwave & conventional oven.

Figure 2.4: Hazard symbol 2

The fork and glass symbol guarantees the suitability of using Tupperware products for

foodstuffs. It means that the product has been tested and proven to not transfer


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components into food in quantities that can endanger human health, change food

composition in an unacceptable way or deteriorate its taste & odour.

2.1.4 Stainless Steel

Figure 2.5: Stainless Steel Bowl

Stainless steel is used for the water heating tank. We had chosen to use the

stainless steel grade 304 because it is suitable to be used as water heating tank. The

SS304 also have low carbon properties thus making it safe to use to boil water.

2.1.6 Heating element

Figure 2.6: Emersion Heater

A heating element converts electricity into heat through the process of Joule

heating. Electric current through the element encounters resistance, resulting in

heating of the element. Most heating elements use Nichrome 80/20 (80% nickel, 20%

chromium) wire, ribbon, or strip. Nichrome 80/20 is an ideal material, because it has


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relatively high resistance and forms an adherent layer of chromium oxide when it is

heated for the first time. Material beneath the wire will not oxidize, preventing the wire

from breaking or burning out.

2.1.7 Feasibility study report

Experiment 1

Figure 2.7: Suction cup and bowl dispenser

Title : Suction cup and bowl dispenser

Date : 30/4/2011

Objective : To see if suction cup can pull bowl downward from bowl

dispenser

Equipments : 1) Suction cup

2) Bowl

3) Bowl dispenser

Method :1) Put supply on suction cup

2) Place the bowl inside the bowl dispenser

Discussion : When suction cup try to pull the bowl downwards, the bowl did

not follow it. It seems that the suction cup did not give enough

vacuum air to make bowl removes from bowl dispenser or the

bowl dispenser is too tight for the bowl to removes.


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Conclusion : Failed, the bowl cannot be removed from bowl dispenser

Recommendation : Use a bigger suction cup so it has enough air to pull the bowl.

Experiment 2

Figure 2.8: Motor pump

Title : Motor pump water flow

Date : 30/4/2011

Objective : To see the flow of water inside the pump

Equipments : 1) Pump motor

2) Hose

3) Tank

Method :1) Connect pump motor with tank using hose

2) Put supply on pump motor

Discussion : When the motor start running, the water flows too fast inside

the tank. It seems that we had to control the water flow as our

tank is small and only need 300ml water in one time.

Conclusion : Failed, need to slow the flow of water to the tank.


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Recommendation : Put on water level sensor so that motor pump will stop when

sensor detect.

Experiment 3

Figure 2.9: Before Figure 2.10: After

Title : Temperature controller cut-off

Date : 29/4/2011

Objective : To see whether the temperature controller will cut-off heater

when it reaches certain boiling point.

Equipments : 1) Temperature controller

2) Heater

3) Tank

4) Thermocouple

Method : 1) Put water inside the tank with heater at side of tank and

connect the thermocouple with temperature controller

2) On supply for heater and temperature controller and start

process

3) Wait until temperature controller cut off which mean it reach

curtain degree of heat.


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Discussion : From our observation, the temperature controller gives a right

value for the temperature as the thermocouple detects the

temperature heat. When it reaches at desired temperature,

temperature controller cut off the heater supply.

Conclusion : Success, temperature controller cut off the heater when it

reaches certain temperature

Recommendation : Put a buzzer as another notification about the water

temperature


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Experiment 4

Figure 2.11: Suction cup and bowl dispenser

Title : Suction cup and bowl dispenser

Date : 30/4/2011

Objective : To see if suction cup can suck bowl downward from bowl

dispenser

Equipments : 1) Suction cup

2) Bowl

3) Bowl dispenser

Method :1) Put supply on suction cup

2) Place the bowl inside the bowl dispenser

Discussion : When suction cup try to suck the bowl downward, the bowl did

follow it. It shows that the suction cup have enough vacuum air

to make bowl removes from bowl dispenser.

Conclusion : Success, suction cup can pull the bowl downward and remove

it from the bowl dispenser.


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Recommendation : As other option, if does not have a bigger suction cup, use two

small suction cup as it is also can give enough air to pull the

bowl.

Experiment 5

Figure 2.12: Boiler temperature

Title : Feasibility of heater temperature

Date : 24/5/2011

Objective : To know the heater functionality

Equipments : 1) Heater

: 2) Relay

: 3) Power Supply

: 4) Test pen

: 5) Water

Method : 1) Connect heater with relay

: 2) Relay connected with power supply and on supply

: 3) Put heater inside water

: 4) Check using test pen if the heater is on or not


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: 5) See if water is boiling or not

Discussion : After 3 minute on testing, the water does not heating up.

Conclusion : Failed, the heater does not function correctly

Recommendation : Use another heater whether recycles or buy a new one.

2.2 PROJECT COSTING

2.2.1 Purchase Planning

At first, we have to determine what the components we need to buy or usedrecycle. Once we determine that, we have to list down the entire component and find a

product requirement for it.

When we are really sure to buy the components, find a suitable price for our

budget costing. The price for all purchased item should not be over the limit to avoid

over budget.

2.3 AUDITING METHOD OF COSTING

Auditing methods also has to be considered to avoid over budget. The method

includes:

List the required components of the machine.

List the components that already have from recycled component.

Conduct survey which companies can supply those components.

Get the quotation from the suppliers.

Compare the price, specification and delivery period.

Make the decision. Consider the cheaper price, good quality and fast delivery.

Estimate the total cost of recycled components.

Estimate the total cost of purchased components.

Get the total cost for the machine.


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For the recycled components, it has to be checked thoroughly to make sure the

component are usable and in good condition. If there some damage components or

parts cannot be used anymore, change it if it is still available. Otherwise get the new

one from the supplier.

2.3.1 Petty cash

This second method is meant for items, which is low in terms of amount or

value that cannot be purchased in credit item. Due to that, we have to buy it in cash.

This petty cash will only be provided at the end of the month during the implementation

stage through the number of claims, which varies among the different group.

2.3.2 Purchase order

This method is used for the parts that use a large amount of money or standard

part that have a certain specification and to buy at the place itself.

Firstly, we need to give the part specifications to the right company or supplier

and wait for them to give a review about their current product according to the

specification that has been given. Once we are satisfied with the product given, we will

ask for the quotation on product price. Later, after receiving the quotation, we will do a

purchased request for a product to send to GMI finance for their reference and account

statement. One member in a group represent for RM1000 for a project budget. Once

finance receive purchase request, they will process the purchased order for us to send

to the supplier.


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2.4 RECYCLED PARTS

Recycled part is the part that is being used for the past semester student or part

that are commonly use for all mechatronics course.

Mechanical component

No. Component Quantity Price per unit / RM Price / RM

1 Screw, bolt & nut 100 0.50 50.00

2 Aluminium profile (40 X 40) 2 330.00 660.00TOTAL 710.00

Table 2.1: List of Mechanical Parts (Recycle Part)

Pneumatic component

No

.

Component Quantity Price per unit / RM Price / RM

1 4/2 way valve 6 250.00 1500.00

2 5/3 way valve 2 250.00 500.00

3 Standard cylinder 6 250.00 1500.00

4 Vacuum module 2 450.00 900.00

5 Solenoid valve 1 250.00 250.00

TOTAL 4650.00


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Table 2.2: List of Pneumatic Parts (Recycle Part)

Electrical component

No. Component Quantity Price per unit / RM Price

1 MCCB 1 8.00 RM 8.00

2 ELCB 1 50.00 RM 50.00

3 Programmable logic

controller

1 2000.00 2,000.00

4 Expansion module 1 1250.00 1,250.00

5 Tower lamp 1 120.00 120.00

6 Terminal block 1 70.00 70.00

7 Buzzer 1 32.00 32.00

8 Emergency button 1 20.00 20.009 Pushbutton 3 2.00 6.00

10 Dc geared motor 3 500.00 2,000.00

11 Dc geared motor 1 1000.00 1000.00

12 Ac pump motor 1 159.00 159.00

13 Reed switch 15 75.00 1,125.00

14 Thermocouple 1 50.80 50.80

15 Temperature Controller 1 805.00 805.00

16 Proximity Capacitive sensor 5 180.00 900.00

TOTAL 9595.80

Table 2.3: List of Electrical Parts (Recycle Part)

Total recycled component


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No. Component Price / RM

1 Pneumatic component 4650.00

2 Electrical component 9595.80

3 Mechanical component 710.00TOTAL 14,955.80

Table 2.4: Total Cost Recycle Parts

2.5 PURCHASED PART

Mechanical component


1 Aluminium profile (40 X 40) 2 330.00 660.00

2 Aluminium profile (20 X 20) 4 75.00 300.00

TOTAL 960.00

Table 2.5: List of Mechanical Parts (Purchase Part)

Electrical component


1 Heater 1 40.00 40.00

TOTAL 40.00

Table 2.6: List of Electrical Parts (Purchase part)

Fabrication component

No. Component Quantity Price per unit / RM Price

1 Boiler Tank 1 1000 1000

TOTAL 1000


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Table 2.7: List of Fabrication Parts

Miscellaneous component

No. Component Quantity Price per unit /

RM

Price / RM

1 Instant noodle 1 packet x 8

pieces

13.80 13.80

2 Curry flavour 1 packet x 500g 6.50 6.50

3 Chicken flavour 1 packet x 500g 7.00 7.00

4 Soto flavor 1 packet x 500g 6.00 6.00

5 Container 1 x 30 container RM 12.00 12.00

TOTAL 45.30

Table 2.8: List of Miscellaneous Parts

Total Purchased component

No. Component Total Price / RM

1 Mechanical component 960.00

2 Electrical component 40.00

3 Fabrication component 1000

4 Miscellaneous component 45.30

TOTAL 2045.30

Table 2.9: Total Cost Purchase Parts

Total Costing


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No. Component Total Price / RM

1 Recycled component 14,955.80

2 Purchased component 2045.30

TOTAL 17,001.10

Table 2.10: Total Overall Costing

2.6 SAFETY SIGN

Figure 2.13: Safety Sign

Safety sign are use to give a user extra safety while running this machine, other

than put a safety feature, sign should be put together so that people are aware of

danger and it was one of the way of safety by vision.

We are using 4 types of safety sign. One is Beware of Moving Parts. This sign

is use to make people aware of moving part in our machine. In our machine, there is

conveyor and actuated cylinder that moving without warning as it were following the

sequence.

Second is Hot Surface sign. This sign is use to avoid people from touching our

boiler. The boiler is use a stainless steel as it was hot on the surface and it may cause

a burn on our skin if we touch it.


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Third is Keep Hands Away sign. This sign is use to make people aware of pick

and place area where our hands may be stuck in between while the process are

running.

Lastly, we are using Electrical Hazard signs. This sign is use to make people

beware of 240v voltage flow in project. And it is dangerous for people to touch it without

a safety as it may hurt our body if we touch it while the current are still flow.

CHAPTER III

PROJECT METHODOLOGY

3.1 PROJECT SPECIFICATION

Machine Description

The design of this product is new in the market. The Automatic instant noodle

machine is constructed based on DIN standard as below:

Machine name Post-Mix Instant Noodle Machine

Product Instant noodle

Number of station 4 stations

Power supply 220~240 Vdc, 50Hz

Power supply unit 24 VdcPneumatic source 6 bar

Controller Programmable logic controller (PLC) Siemens s7-200

Sensor Capacitive sensor and Photo sensor

Indicator Tower lamp

Transfer system Conveyor and cylinder

Drive system Dc motor

Cycle time 2 minute for 1 instant noodle

Dimension 1m x 1m x 1.8m


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Operation mode Automatic Mode and Manual Mode

Table 3.1: Machine Description

Material specification

Material Quantity

Noodle 77 gram

Water 300 gram

Flavour 8 gram

Container 1 gram

Cover container 1 gram

Estimation of end product (outflow): approximately = 387gram

Table 3.2: Material Specification

Part description

No. Part Picture Description

1. Pneumatic

Cylinder

Used to pull the bowl into

desired place

2. Dc geared motor Used to move the propeller

to blow out flavour from

canister to bowl

3. Dc geared motor Used to move the conveyor


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4. Ac pump motor Used to pump water into the

silo at station 3

5. Proximity

Capacitive Sensor

Used to detect presence of

noodle bowl into the area

and to give a signal into

other devices

6. Heating Element Used to heating up water

Table 3.3: Part description

3.2 PROJECT FEATURES

This Post-Mix Instant Noodle Machine consists of 4 station which is feeding, flavour

filling, water filling and capping station. Operation in station are being controlled by

PLC Siemens S7-200 and actuated by Pneumatic Valve Cylinder.

Station 1: Feeding station


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Figure 3.1: Station 1

Firstly, user will choose the instant noodle flavour that they want. We areincluding three most wanted flavour which is curry, chicken and asam laksa. After

choosing and press the button, cylinder 1will pull out bowl and put on the rail. Then,

cylinder 2will feed instant noodle into the bowl. Later, cylinder 3which is in extended

position will start to retract until bowl reach on the conveyor.

Station 2: Flavour filling station


After cylinder 3 extend, motor 1will start running and conveyor start moving.

Bowl that on the conveyor will follow conveyor moving until sensor detect. Conveyor

will stop when sensor are detect for filling a flavour. Conveyor will stop according to the

flavour we are choosing. For sensor 1is curry flavour, sensor 2is chicken flavour and

sensor 3 is asam laksa flavour. If we are choosing curry flavour, conveyor will stop

when sensor 1detects and it will pass for sensor 2and sensor 3. When sensor 1

has detect and motor 1stop, motor 2will start running and fill out the flavour into the

bowl. Motor 2 are run for using a timer and stop when timer stops counting. Then

conveyor will continue move until next station. It happen the same for sensor 2 with

motor 3and sensor 3with motor 4.


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Station 3: Water filling station


Conveyor will continue to move until sensor 4detect. Once sensor 4detect

solenoid valvewill start drain water into the bowl. Solenoid valvewill stop drain out

when timer off. Then conveyor will continue moving until sensor 5 detects the bowl.

When sensor 5 detect presence of bowl motor 1 will stop the conveyor. Then,

cylinder 4will extend and push bowl into the rail. Cylinder 4will only extend half for a

first move, because station 4 is in the middle of the rail.

Station 4: Capping station


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After cylinder 4is extend and stop at the middle, cylinder 5extend and pick upbowl cover and retract back. Then, cylinder 6will extend and move the cylinder 5on

the top of the bowl and cylinder 5will extend to cap the cover into the bowl. Later, both

cylinders will go back to their initial position. After finish capping station, cylinder 4

continues extend until it reach at the end of the rail and lastly serve to custo


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3.3 SYSTEM LAYOUT

3.3.1 Machine Layout Diagram

Figure 3.5: Actual Machine View


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Figure 3.6: Isometric Drawing


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Figure 3.7: Front View


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Figure 3.8: Top View


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3.3.2 Electrical Wiring Diagram

POWER

SUPPLY

24VDC

PLC S7-200

CPU 226 @ 224

EXPANSION

MODULE 1

TOUCH

SCREEN

POWER

SUPPLY 12VDC , 3A

MOTOR 2

MAIN SWITCH ELCB

MCB

6A

MCB

3A

K1

MOTOR 3

K2

MOTOR 4

K3

MOTOR

1

K4

L

N

PE

K6

HEATER

MCB

13AMCB

6A

POWER

SUPPLY 24VDC , 3A

MCB

3A

MOTOR 5

K5

MCB

10A

TEMPERATURE

CONTROLLER

DC

MOTOR

DC

MOTOR

DC

MOTOR

DC

MOTORAC PUMP

MOTOR

3 PIN PLUG

Figure 3.9: Electrical Wiring Diagram

From figure above, it shows the connection for the electrical wiring diagram according to actual. The red line indicate life wire, the blue line

indicate neutral wire and the green wire indicate ground or also called earth wire.


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3.3.3 Pneumatic Wiring Diagram

Figure 3.10: Pneumatic Wiring Diagram

From figure above, it shows the f low and pressure of air inside pneumatic cylinder for this machine

50%

70%

100%

100%

30%

70%

R 1 R 2 R 3 R 4 R 5 R 6 R 7 R 8 R 9 R 10 R 11 R 12 R 14 R 15 R 16

100%

R 17 R 18

Y 1Y 2

Y 3 Y 4

Y 5 Y 6

Y 7 Y 8

Y 9 Y1 0

Y1 1 Y1 2

Y1 3 Y1 4

45%

R 19R 13

Y1 5 Y1 6

4 2

1 34 2

1 3

4 2

1 34 2

1 3

4 2

1 34 2

1 3

4 2

1 34 2

1 3

30%

100%

30%

100%

70%

70%

100%

45%

Y 2

4 2

1 3


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I2.0 I2.1 I2.2 I2.3 I2.4 I2.5 I2.6 I2.7 I3.0 I3.1 I3.2 I3.3 I3.4 I3.5 I3.6 I3.7

CPU 226@224

EXPANSION MODULE 1

Q2 .0 Q 2. 1 Q 2. 2 Q 2. 3 Q 2. 4 Q 2. 5 Q2 .6 Q2 .7 Q 3. 0 Q 3. 1 Q 3. 2 Q 3. 3 Q 3. 4 Q3 .5 Q3 .6 Q 3. 7

RS7 RS8 RS9 RS10 RS11 RS12 RS13 RS14 RS15

0V

24V

K1 K2 K3 K4 K6 L1 L2 L3K5

RS6

SL1 BZ

RS18SN7 RS17 thermo

Figure 3.12: PLC Wiring Diagram 2

Figure above are the expansion of PLC Module as we are used more input and output component for this project.


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Input Table

Symbol Address Description

Start I0.0 Start all program

stoper I0.1 Stop

S1 I0.2 curry

S2 I0.3 chicken

S3 I0.4 soto

SN1 I0.5 sensor 1 or limit switch






RS1 I1.3 cy1

RS2 I1.4 cy1

RS3 I1.5 cy1

RS4 I1.6 cy2

RS5 I1.7 cy2

RS6 I2.0 cy3

RS7 I2.1 cy3

RS8 I2.2 cy4

RS9 I2.3 cy4

RS10 I2.4 cy4RS11 I2.5 cy5

RS12 I2.6 cy5

RS13 I2.7 cy5

RS14 I3.0 cy6

RS15 I3.1 cy6

floating_sensor I3.2 floating sensor

RS17 I3.3 stoper

RS18 I3.4 suction cup (station 1)

reset I3.5 reset to initial condition

TERMO I3.7 Termocouple

Table 3.4: Input table PLC


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Output Table

Symbol Address Description

Y1 Q0.0 cy1

Y2 Q0.1 cy1

Y3 Q0.2 cy2Y4 Q0.3 cy2

Y5 Q0.4 cy3

Y6 Q0.5 cy3

Y7 Q0.6 cy4

Y8 Q0.7 cy4

Y9 Q1.0 cy5

Y10 Q1.1 cy5

Y11 Q1.2 cy6

Y12 Q1.3 cy6

Y13 Q1.4 cy7

Y14 Q1.5 cy7Y15 Q1.6 suction cup 1

Y16 Q1.7 suction cup 2

K1 Q2.0 conveyor motor

K2 Q2.1 dc motor 1

K3 Q2.2 dc motor 2

K4 Q2.3 dc motor 3

K5 Q2.4 pump motor

K6 Q2.5 heater

L1 Q2.6 lamp (red)

L2 Q2.7 lamp (orange)

L3 Q3.0 lamp (green)SL1 Q3.1 solenoid valve (boiler)

BZ Q3.2 buzzer

Table 3.5: Output table PLC


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3.4 STEP SEQUENCE

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

M10.0

M10.4

M10.3

M10.2

M10.1

M10.5

321

E

N

D

S

T

O

P

Q4.0

Y2, CYLINDER 1 (RET)

Y3, CYLINDER 2 (EXT)

Q4.1

Q4.2

Y1, CYLINDER 1 (EXT)S

S

S

RS1

RS3

RS2

RS4

Y2, CYLINDER 1 (RET)Q4.1NS

Y2, CYLINDER 1 (RET)Q4.1S

Y1, CYLINDER 1 (EXT)Q4.0NS


RS5



RS7

INITIALCONDITION

START

Figure 3.13: Step Sequence 1


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1 2

21

E

ND

S

TO

P

STEP 7 Y5, CYLINDER 3 (EXT)Q4.4S

M10.6

SN1

RS6


K1,MOTOR 1 (RUN)Q6.0S

STEP 8 K1, MOTOR 1 (STOP)Q6.0NS

SN2

STEP 9

SL1, SOLENOID 1 (RUN)Q5.4SM10.7

M20.0

SL1, SOLENOID 1 (STOP)Q5.4NS

RS7

K1, MOTOR 1 (RUN)Q6.0S

STEP 10

SN3

M20.1

STEP 10

SN4

M20.1

STEP 10

SN5

M20.1M1, MOTOR 1

(STOP)Q6.0NS

M1, MOTOR 1

(STOP)Q6.0NS

M1, MOTOR 1

(STOP)Q6.0NS

S Q6.1 S Q6.2 S Q6.3M2, MOTOR 2

(RUN)

M3, MOTOR 3

(RUN)

M4, MOTOR 4

(RUN)

Y5,

CYLINDER 3

(EXT)

Q4.4NS

3Figure 3.14: Step Sequence 2


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STEP 11

STEP 12

STEP 13

Y9, CYLINDER 5 (EXT)

Y9, CYLINDER 5 (EXT)Q5.0

Q5.0

S

NS

RS12

RS13


M20.2

M20.3

M20.4

STEP 14

Y11, CYLINDER 6 (EXT)Q5.2S

RS13

M20.5

21




STEP 15

STEP 16 Y8, CYLINDER 4 (RET)Q4.7S

RS11

RS9


M20.6

M20.7

RS10

RS12

RS14

RS15

3

E

N

D

S

T

O

P

M1, MOTOR 1 (RUN)Q6.0NS




1 2 3



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STEP 11 M1, MOTOR 1 (RUN)Q6.0S

M20.2

STEP 12 M1, MOTOR 1 (RUN)Q6.0NS

SN6

RS8

Y7, CYLINDER 4 (EXT)Q4.6SM20.3

NS Q6.1 M2, MOTOR 2 (RUN)



STEP 13

STEP 14 Y9, CYLINDER 5 (EXT)

Y9, CYLINDER 5 (EXT)Q5.0

Q5.0

S

NS

RS12

Y7, CYLINDER 4 (EXT)Q4.6NSM20.4

M20.5 Y11, CYLINDER 6 (EXT)Q5.2S

RS9

RS11

RS13

3

M1, MOTOR 1 (RUN)Q6.0NS

21

E

ND

S

TOP

STEP 15

RS11

M20.6

STEP 16

RS12

M20.7




STEP 17

STEP 18 Y8, CYLINDER 4 (RET)Q4.7S

RS10

RS8


M30.0

M30.1

RS14






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3.5 INSTRUMENT AND EQUIPMENT SPECIFICATION

3.5.1 CALCULATION FOR CYLINDER SIZING

Cylinder 1 & 2 sizing

Mass = 0.1 kg Gravity = 9.81 m/s P = 6bar

F = mg

= (0.1kg) (9.81m/s)

= 0.981 N

Safety factor


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Cylinder 3

Mass = 0.71 kg Gravity = 9.81 m/s = 0.25 P = 6bar

F = mg

= 0.25(0.71kg) (9.81m/s)

= 17.413 N

Safety factor


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Cylinder 4

Mass = 7.2 kg Gravity = 9.81 m/s = 0.25 P = 6bar

F = mg

= 0.25(7.2kg) (9.81m/s)

= 17.658 N

Safety factor


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Cylinder 5 & 6

Mass = 0.3kg Gravity = 9.81 m/s = 0.25 P = 6bar

F = mg

= 0.25(0.3kg) (9.81m/s)

= 0.735

Safety factor

Conclusion

We are used a recycled cylinder that have the nearer bore size as the calculation.


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3.5.2 CALCULATION FOR MOTOR SIZING

Motor 1

+ fy = 0

N-w = 0

N = w

= 16.65(9.81)

= 163.35 N

If = N

= 0.8(163.35)

= 130.68

+ fx = 0

F-f = 0

F = 130.68

TL = F D/2

= 130.68 (0.03)

= 3.92

4Nm


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Motor 2

+ fy = 0

N-w = 0

N = w

= 10.00(9.81)

= 98.1 N

If = N

= 0.8(98.1)

= 78.48

+ fx = 0

F-f = 0

F = 78.48

TL = F D/2

= 78.48 (0.03)

= 2.36

3Nm

Conclusion

We are use a recycled motor that are using the same purpose which is motor 1 are

used on conveyor and motor 2 are used on the canister.


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3.6SAFETY FEATURES

Safety features are important in order to minimize and to eliminate hazardousthat can cause injury or damages to the object. In order to ensure the safety of the

personnel operating the machine, there are few safety features that are needed to be

considering for the machine. Below are some of the additional safety requirements that

have been included with this machine:

Emergency Stop Button

Figure 3.17: Emergency Stop Button

Emergency stop button is needed to ensure the safety of the whole system in-

case of any unwanted accident. When any fault occurs, the emergency stop button is

the best way to cut-off all the power supply to the machine to avoid further problems.

Circuit Breaker

Figure 3.18: MCB

Circuit breakers are used to protect the whole system (main power supply)

when there are any short circuit or currents leakages. It will act as a safety switch to cut

off the power supply to the circuit.


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Relays and Contactor

Figure 3.19: Contactor

Relays or contactor are normally used for frequent making and breaking of the

circuit. The purpose is to isolate the main power supply from the control unit and to

provide a better assurance towards the system.

Indicator

Figure 3.20: Indicator

Indicators are used to indicate the current status or the machine status of the

operating machine. In addition, the operator will always be aware on the current

operation status of the machine.

Alarm / Buzzer

Figure 3.21: Buzzer

The buzzer is used to give warning signal when anything goes wrong during the

machine operating. It will attract peoples attention to make sure people will be aware if

there is danger.


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CHAPTER IV

PROJECT IMPLEMENTATION

4.1 PROCESS PLAN

4.1.1 Block Diagram

Figure 4.1: Block Diagram

Station 1:

Feeding station

Station 2:

Flavour filling

station

Station 3:

Water filling

station

Station 4:

Capping station


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4.1.2 Flowchart

4.1.2.1 Main Flowchart

Start

Supply

Initial Position

Press flavor button

Feeding Process

Filling FlavorProcess

Filling Water

Process

Capping Process

End

No

No

Yes

Yes

Figure 4.2: Overall Flowchart


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4.1.2.2 Flowchart Station by Station

Station 1

Cylinder 1 Extend

Start

Vacuum On

Vacuum pull bowl

downward from

magazine

Vacuum Off

Initial Position

RS3 detect

RS2 detect

Cylinder 1 Retract

Cylinder 2 Extend

RS5 detect

Push noodle from

magazine to bowl

Cylinder 2 Retract

RS4 detect

Cylinder 3 Retract

End

No

Yes

No

Yes

No

Yes

No

Yes

Figure 4.3: Flowchart station


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Station 2

Start

Cylinder 3 Extend

RS7 detect

Motor 1 Run

Sn1 detect

Motor 1 Stop Sn2 detect

Sn3 detectMotor 1 Stop

Motor 1 Stop

Motor 2 Run

Motor 3 Run

Motor 4 Run

Curry flavor fall intobowl

Chicken flavor fall

into bowl

Soto flavor fall into

bowl

Motor 2 Stop

Motor 3 Stop

Motor 4 Stop

Motor 1 Run

End

No

Yes

No

No

Yes

Yes

No

Yes

Figure 4.4: Flowchart station 2


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Station 3

End

Start

Motor 1 Run

Sn4 detect

Motor 1 Stop

Solenoid valve on

Hot water flow into

bowl

Solenoid valve off

Motor 1 Run

No

Yes



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Station 4

Start

Cylinder 4 Extend

RS 9 detect

Cylinder 4 Retract

Cylinder 6 Extend

RS 10 detect

Cylinder 5 Retract

Cylinder 5 Extend

RS 12 detect

RS 15 detect

Cylinder 5 Extend

RS 12 detect

Cylinder 6 Retract

RS 11 detect

Cylinder 5 Retract

End

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes



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4.2 QUALITY PLAN

4.2.1 Electrical Component

No Component Quality Checking

1 Power Supply Connect the power supply to the socket and test

using a multimeter. If the multimeter shows output, it

means power supply is in good condition.

2 Capacitive Sensor Gives a supply to sensor and put the sensor near

object. If the sensor gives an output, it means the

sensor is in good condition.

3 Relay Test using a multimeter, if multimeter show some

output, it means relay are in good condition.

4 PLC Siemens S7-200 Gives a supply to PLC and see if PLC is on or not.

To check the input and output port, construct a

simple program in computer and download to PLC.

Connect a switch in input port and lamp in outputport. If the lamp is giving a response when press a

switch, it means the port are in good condition.

5 Dc Geared Motor (Canister) Connect the motor to the power supply. If motor run,

it means motor is in good condition.

6 Dc Geared Motor (Conveyor) Connect the motor to the power supply. If motor run,


7 Ac pump Motor Connect the motor to the power supply. If motor run,


8 MCB Connect one side of multimeter to MCB and another

side to the ground. If multimeter show a response, it

means the MCB are in good condition.

9 Contactor Connect the contactor to the power supply and put it

in normally open condition. If the contactor gives a

response, it means the contactor is in good

condition.

10 Heater Connect the heater to the supply, put heater inside


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bowl of water. If water does boil, it means heater is in

good condition.

Table 4.1: Electrical Component Quality Plan

4.2.2 Mechanical Component

No. Component Quality Checking

1 Pneumatic cylinder Gives an air supply to the cylinder and see if the

cylinder can move smoothly or not.

2 Canister Clean the canister and removes all dirty inside

canister as it was use to insert the flavour.

3 Roller Check if the roller can move without any disturb.

4 Conveyor Assemble the conveyor and tighten the belting for a

smoothing movement.

5 Aluminium profile Measure the Aluminium profile according to the

desired length and cut using a grinding machine.

Remove the burr using a file.6 PVC plate Measure the PVC plate according to the desired

length and cut using a jig saw. Remove the burr

using a file.

7 Acrylic Measure the acrylic according to the desired length

and cut using a plastic cutter. Remove the burr using

a file.

Table 4.2: Mechanical Component Quality Plan


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4.3 PROJECT SCHEDULE

Every project has its own dateline. To complete this project, we have 4 mainstages that must be follower

4.3.1 Project Proposal

This is the first phase where we begin to make a project. We are meeting with

our supervisor to ask what kind of process of our project we should use as a reference

for us to make an idea for the project proposal. Form project proposal, we will have abrainstorming between team members to give a different kind of idea for our final year

project machine. After we finish discussing what project we want to come out, we will

ask our supervisor if it was suitable to make that machine as our final year project.

Once finish on bring out the idea, we begin to do a feasibility study about the

project and designing the project layout. During feasibility study, we will do a research if

there is other machine that are already made and see how they done the process did.

The research for other machine is only for our reference in making design.

When we start to designing our machine, this is where we are applying what we

had learnt through 2 and half year at German-Malaysian Institute. We will start to

design the mechanical part of the machine by using SolidWork and construct the circuit

wiring by referring to the electrical wiring that we had learn from last semester.


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4.3.2 Project Implementation

After our proposal has been approving, we will start to do a project in a realtime. At this stage, where we will have to really determine the right component that are

going to be use and the mechanical design should be done in a right way as to ensure

the project are in applicable way.

4.3.3 Project Documentation

At this stage is where will prove that we are the one that made this machine. All

the progress while do the project are being recorded in data to show it as a copyright

are made by us. It is to ensure that no other people will make a copy of our machine

process through all the features also. All the works that have been done since proposal

until final presentation are represent in this documentation.

4.3.4 Project Presentation

At this stage is where we will prove that this machine are finish and can do a

process according to the sequence without having any problem. It is to give a person

know that the machine process and what type of process are being use in visual look.


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4.3.5 Task Content

Task content for the project will be divided as project design, which is designing

on project process through mechanical and electrical. After finalize the design, and

then we will order and purchased a product or part according to our design. Start to

constructing mechanical and electrical wiring according to what we have design from

the beginning. Later, doing a programming controller for the machine and do

documentation by according to the first process that we have done for the project until

project function. Lastly, we present it to people to show proves of our project

completion with success.

4.3.6 Delegation of Task

Task has been delegate into 6 main tasks, which is:

1. Project Design

Designing task is the first stage to start a project. This is where the

project are being design according to standard and propose it to lecturer to see

whether the design that we made are correct or need an improvement or totally

doing in a wrong way. Any mistake that we make at this stage will not make a

project function properly or not function at all.

2. Product Enquiry

First, we make a list of the equipment and then find the vendor or

supplier to get the quotation, before submitting the purchase requisition form.

The specification and delivery date must be confirm from the vendor or supplier.

All of this process is important because some careless mistake will affect the

implementation of project.


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3. Mechanical construction

This task can be done only after receiving mechanical part, either

fabricated or recycled part. While waiting for purchased fabricated part, we can

start build other station that are using a recycled part and do a self fabricate

part also. It can help to finish a project in a required time.

4. Electrical wiring

This task is being done by person in-charge to finish the wiring part. It is

containing to connect the power supply with plc controller and together with

input and output device. Input device such a s switch, relay and sensor and foroutput device like pneumatic cylinder, motor or cylinder. All this input and output

device are connected with plc controller as their link.

5. Programming and controller

Person in-charge should do a sequence of the program to control all

component and device. The movement of the process from input area until

output is should be done correctly to avoid crash between components or it may

destroy the component or process.

6. Documentation and presentation

Person in-charge will collect all data from the first day starting to do the

project until project finish. The data should contain all information about project

including design, project progress.


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4.3.6.1 Group Member Task Distribution

We have many jobs that we must do. Because of this, we divide each task to each of

our group member.

ELYAS

He has been given responsible as a group leader for this group. Do for designing and

approving on mechanical drawing and layout also for machine wiring including

pneumatic, electrical and PLC. Lastly, he is also responsible to design and

troubleshoot PLC programming.

RAMZUL

Do for designing mechanical drawing and assembly machine layout also purchasing

and costing for fabrication part and recycled part.

HAJAR

Do for designing mechanical drawing and layout and troubleshooting for PLC

programming. Besides, she is also responsible for organizing the schedule, costing of

part, documentation report and presentation.

EMERSON

Do for designing mechanical drawing and assembly machine layout also for

documentation report and presentation.


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4.3.6.2 Gantt Chart

To do this project we must have a proper planning toward the success of FinalYear Project. Therefore, a clear Gantt chart which list down the necessary tasks and

the duration to complete each tasks is drafted. This Gantt chart will list the task to be

performed by our group, the time scale allowed for each individual tasks and task bar

for better visualization of the individual project phases.

During the project stages, it is possible to keep track on the development of the

project according to the chart. It is also possible to measure the projects phase time

allocation and perform any corrective actions needed in order to complete the project

on time.

In order to complete the machine, we must follow the Gantt chart. Scheduling is

also important in the ways that:

To make sure the jobs / tasks follow the sequence and procedures.

To arrange the times according to the schedule given.

To avoid any clashes with classes or colleges activities.

To prevent from any consequences that might be interrupt the progress such as

delay time of the part delivery or short of money.


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4.4 CONTINGENCY PLAN

Since any project to implement any project or unpredictable problem, acontingency plan should be provide as a back up for the countermeasure in order to

avoid any unsettled problem during implementation stage. This contingency plan

comes in handy when possible problems occur to our plan, therefore we have figured

out some possibilities that might occur due to unexpected factors.

Filling station

If using a sensor does not helping in telling how many gram of flavour and water

are filling inside the bowl, we will choose to use a timer.

Transfer system

If transfer by pushing cylinder at station 4 cannot make it stop at the right angle

at pick and place station, we decided to make a stopper at the middle of the conveyor

to make the bowl are state at the right place to put a cover on top of it.


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CHAPTER VI

FINDINGS AND ANALYSIS

5.1 PROBLEMS ENCOUNTERED & COUNTERMEASURE

No. Problems Encountered Countermeasure

1 For a food and beverage product like

our machine, using stainless steel

surely a must as it was the most

suitable material to be using for food

product.

For the mechanical parts that do not

touch the food we replace it by using

a PVC plate only

2 Temperature controller does not

function

Change to the new temperature

controller.

3 Bowl does not stop accurately at

station 4

Use stopper in between

4 Cylinder 2 extend earlier Reprogram the PLC program

5 Cylinder 2 stuck when retract Align back the cylinder position

Table 5.1: Problem Encountered and Countermeasure


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5.2 RESULTS & DISCUSSIONS

No Process Result

1 Machine Sequence All sequence of machine is running according to

required plan

2 Product Output Product output are as desired

3 Automatic and Manual

Process

All automatic and manual process are running as we

desired

Table 5.2: Result and Discussion


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CHAPTER 6

CONCLUSION

6.1 CONCLUSION

This machine is can run in manual mode and semi-auto mode as it may not fully

function in auto mode yet. After all the process can be done in 2 minutes and the

water are boil correctly according to standard water heating.

Sequence of process is running according to what we had planned. The

process in each station also according to what we have desired.

Finally, we are able to make the machine function manually and semi-auto and

make an instant noodle are cooked well.


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6.2 RECOMMENDATIONS

First recommendation that we would like to suggest is regarding our transfersystem. Instead of using a rollers and cylinders, it is better if we only use a conveyor for

the whole transfer system as it will be much more efficient and systematic. Instead

making the bowl move from one station to another, it will be better to move the station

to the bowl, so that the process may run more smoothly.

Secondly, in order to make it like a real vending machine, we suggest that a coin

slot should be installed and therefore this machine can really be used as a service

machine.

Third recommendation is making a bigger space for noodle dispenser so it can

store more noodles and also making the noodle dispenser to be airtight so that the

noodles stored inside can be kept much longer.

Fourth recommendation is to put a sensor on all dispenser and boiler also to detect

the weight of the flavour and water being put onto the bowl.

Last but not least, we would like to use the real HACCP requirement for a food

safety through biological, chemical, product and economical as follows:

Use a galvanize steel pipe for a water transfer

Use a High Density Polyethylene (HDPE) for food storage.


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REFERENCE

Cals Arizona. (n.d). HACCP Food Safety. Retrieved from

http://cals.arizona.edu/pubs/health/foodsafety/az1082.html

Tupperware Brands (n.d.). Quality Assurance & Warranty, Decoding the codes.

Retrieved from http://tupperware.com.my/safety_assurance_decoding.php

Plastipedia (n.d.). Polymer thermoplastic, Polypropylene PP. Retrieved from

http://www.bpf.co.uk/Plastipedia/Polymers/PP.aspx

EarthOdysse, LLC (n.d.). Recycling symbols(us) Retrieved from

http://www.earthodyssey.com/symbols.html

Youtube (n.d.). Japan Vending Machine. Retrieved from

http://www.youtube.com/watch?v=qdnU2DUS-g8

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