ADDIS ABABA SCIENCE AND TECHNOLOGY

UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL

ENGINERING

DEPARTMENT OF ELECTRO-MECHANICAL ENGINEERING

DESIGN AND FABRICATION (prototype?) OF AUTOMATED SEALING MACHINE

Advisor: Mr. Yemane. G (M.Sc.)

Ethiopia, Addis Ababa
 February, 2021

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 Abstract

Many small scale food production business owners and small and medium scale
farmers the process of packaging their product manually. Small and Medium scale food
production business owners who particularly produce items like ‘flour, fast food, species,
fruits, seeds ’, etc. has to do the packaging process manually. The sealing process is carried
out with the help of candles and other traditional methods. This process is very time and
effort consuming and thus it limits their production?? as well as their business.

It is observed that the cheapest machine which would automate this process of
packaging costs and it is manufactured by ‘All pack Engineers’. Automated Packaging which
is priced at the rate mentioned is not affordable for small scale and medium scale businesses.

This project aims to develop such a machine which automatically packs the foods and
seeds with the help of microcontroller and sensors. The idea is to manually place the bag, and
then automatic packaging is done. The purpose of doing this project is to reduce human
efforts and time consumption. Decreasing machine cost and foreign currency is the major
advantage of project. The machine design is based on simple mechanisms and it can be
installed easily. The speed of packaging is increased thus resulting in more production and
business. It will eradicate the traditional packing and sealing method. This process will
reduce the number of paid workers. Why?

Key Words: Automatic packaging, sealing machine ….

Page numbering is I, II, III….not Roman

Preliminary page should contain list of tables, figures, acknowledgment etc.

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 Table of Contents (centered)
Abstract......................................................................................................................................1
CHAPTER 1...............................................................................................................................4
INTRODUCTION......................................................................................................................4
1.1 Background and Justification......................................................................................4
1.2 Problem Statement.......................................................................................................4
1.3 Objectives....................................................................................................................5
a. General Objectives......................................................................................................5
b. Specific Objectives..................................................................................................5
1.4 Motivation........................................................................................................................5
1.5 Scope of the project..........................................................................................................5
1.6 Significance of the Project...............................................................................................6
1.7 Limitations.......................................................................................................................6
Chapter 2....................................................................................................................................7
Literature review........................................................................................................................7
2.1: Introduction.....................................................................................................................7
2.2: History of packaging machine........................................................................................8
2.3: Current packaging methods in Ethiopia..........................................................................8
2.3.1 Sealing using candle light.........................................................................................8
2.3.2 Sealing using paraffin stove......................................................................................9
2.3.3 Sealing using flame from burning plastics................................................................9
CHAPTER 3.............................................................................................................................10
3.1 Materials used automated sealing machine....................................................................10
a. Arduino Board...........................................................................................................10
b. Pneumatic Cylinder................................................................................................11
c. Frame.........................................................................................................................11
d. Ball bearing............................................................................................................12
e. Conveyor Belt............................................................................................................12
f. DC Motor...................................................................................................................13
g. IR Sensor................................................................................................................13
h. Relay......................................................................................................................14
i. Solenoid Valve..........................................................................................................14
j. Switches.....................................................................................................................15
3.2 Methodology..................................................................................................................15
CHAPTER 4.............................................................................................................................16
DESIGN OF ATOUMATED HEAT SEALING/PACKING MACHINE PROTOTYPE......16

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 4.1 Mechanical design..........................................................................................................16
a. Design parameters:....................................................................................................17
b. Design of the jaw Sealing......................................................................................17
c. Design Analysis for Conveyor Belt...........................................................................18
d. Diameter of the pulley...........................................................................................18
e. Width of the pulley....................................................................................................18
f. Design Analysis for electric Motor...........................................................................20
g. Selection of DCV for the Cylinder........................................................................20
h. Design for the equipment frame............................................................................21
4.2 Pneumatic system design...........................................................................................23
4.3 Electrical system............................................................................................................25
a. Components Required...............................................................................................25
b. Circuit Diagram.....................................................................................................25
c. Arduino Program.......................................................................................................26
4.4 Engineering Bill of Material..........................................................................................28

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 CHAPTER 1

INTRODUCTION
The main purpose of this project was to provide the s machine for sealing of the
packets of food, species, agricultural products and flour items. Arduino based automation
system was employed for packing process. Small Scale Industries (SSI) with a platform that
they are able to process their food item in safe packets by reducing the cost of packaging
machines. In comparison with the large who have multi brand packing system show case
their nutritional value of their products and additional information regarding show case and
other information, which provide them a great source and huge marketing opportunity in
business and customer satisfaction. We did it through designing the whole machine in virtual
environment where every component was based on standard available mainly electronic part
for automation. The design and simulation was based on the company layout factory area
where we took it on virtual environment and simulated it .The synchronization of machine
was done according to the controller employed in the control of machine for sealing of the
packets of food items. Microcontroller based automation system was employed for
automation.

1.1 Background and Justification

Many leading packaging machinery manufacturers which have global sales and
facility networks at their disposal are focusing on producing supplementary automated and
faster machines which are incompatible for the capacities handled by small scale producers in
developing countries. At the same time these machines are sold at high cost, through
purchasing them may not be an issue but after sales service and maintenance is also a limiting
factor. A packaging machine should reduce time and labor inputs, increase the rate of
production and consequently improve profit returns for the benefit of small scale producers
and also for the reduction of cereal losses since packing improves safety and quality.

I.2 Problem Statement

Some of the uprising entrepreneurs are facing limitations on their goal fulfillment of starting
a packaging business due to high cost of packaging machines and packaging itself. Farmers
are experiencing losses in transporting their crops from farms to cities and towns for sale to
large packaging companies.

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 I.3 Objectives

a. General Objectives
Many small and medium scale food production business owners have to do the process of
packaging manually. This process is time consuming and it limits their business and
production. The cheapest machine available in Ethiopian costs around 100,000 birr
which is not affordable to small and medium scale businesses and farmers.

(Short description in action verb….it looks problem statement)

The greatest asset of the packaging machines that are manufactured in the market is that they
are advanced and they provide effective coordination with the other processes of production
in the best possible manner. It is important for the food industry to stick to the market
standards in a position that will make sure their brand value and also attach to the industry
quality standards in the best possible Manner. Since the machine is cheap, it will be
affordable to small and medium scale Businesses. This will result in increase in production
and business. The accuracy and time consumption will be decreased.

b. Specific Objectives
The literature survey carried at during course of work reveals that the packaging process
needs to be simplified. It must not require a special skill-set to operate the machine.

The specific objectives of the project are:

I. To design a machine which provides clean bag packing

II. To design a machine which is space saving???
III. To design a machine which is easy to handle and which runs on simple
mechanical operations.
IV. To create? a machine which would be stable while operations??

1.4 Motivation
We are motivated to prepare our project on this topic for the following reason

 To protect the food from contamination

 To improve production quality of small scale industry

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 1.5 Scope of the project. (New title on a new Page) use next page
This machine can be used in many industries some of them are written below, but scope of
using this machine is not limited to this only.

II. Small scale food production industries

III. Automatic packaging machine manufacturing industries
IV. Farmers can use it directly for packaging their agricultural products

1.6 Significance of the Project

The project is plays a significant role in solving the problems arising due to packing quality
and speed. This project seeks to improve production quality by minimizing human contact.
Generally, the project is designed to add a certain value to the small and medium scale
industry and farmers.

1.7 Limitations
There are some limitations

 For this project is not weighing over 10 kg

 ?
 ?

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 Chapter 2

Literature review

2.1: Introduction
[1]
G. Sujatha et al. gives the information of integrating the sensors with the Programmable
Logic Controller and control of the conveyor system using PLC. To control the conveyor
ladder logics are used.

Sagar P. Jain et al. [2] designed the conveyor system with varying speed and effective
movement of the objects on the conveyor belt using Variable Frequency Drive. Here SCADA
is used to monitor the conveyor system effectively.

Kaushal Pratap Singh et al. [3] proposed the conveyor belt design with IR object counting
sensor for counting the objects, IR sensing circuit and voltage conversion for energy saving.

K. Ganesan et al. [4] explained about low cost machine vision system for fault detection
using Beagle Bone Black micro computer board. Hardware is controlled by arduino micro
controller board.

Dong et al. [5] applied the concept of less motor operation technique for electricity saving
and improvement of the belt conveyor system in coal yard. This technique has the advantages
of low cost, stable performance and obvious effect in energy saving.

Slim Abdelhedi et al. [6] used the Gigabit Ethernet network and GigE vision camera to insure
seamless integration with in the production line, image processing, fault detection and alarm
generation are done on a common work station for real time production monitoring within the
bottling chain.

Alhade A. Algitta et al. [7] designed and fabricated automatic packaging machine using PLC
successfully, by increasing the production rate and decreasing production time as compared
with traditional manual system.

Maitrey Trivedi et al. [8] explained about the closed loop conveyor system using PLC which
is capable of stopping the bottle on the conveyor belt at the filling station and a fixed amount
of liquid is poured in the bottle using solenoid valve. The input to the plc is given by the
different sensors placed at different positions.

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Packaging refers to the technology and material for enclosing or protecting products for
distribution, storage, sale, and use. It helps to ensure quality and safe conveyance of packed
products. Food packaging is vital; the package is responsible for serving as an unswerving
block between the product and impending contaminants from the outer environment.
Effective packaging strengthens shelf life, protects food from bacteria contamination and
reduces agricultural product loss due to packing process.

2.2: History of packaging machine

In the early 90’s, hand sealing was done with the use of gloves to press a heated foil. This
method was not reliable to a great extent and encounters a lot of difficulty in proper sealing.
Then there was this local fabricated manual type which utilizes a foot pad to operate the
sealing head it incorporated a heating element at the sealing head. In the recent past, the
emergence of production industries with the latest technology have led to the design and
manufacture of equipment to give an improved and excellent finishing and packaging. This
consists of the high efficiency and microprocessor control panel, induction head unit and
efficient air circulation system. According to research, the cost of these sealing machines
importation cost which is very expensive and cost of maintenance through the expatriate are
on a very high side for the small scale industries to manage in Ethiopia.

2.3: Current packaging methods in Ethiopia

These methods has been phased out mainly by developed countries through their production
of highly advanced packaging machinery though they are still in operation in many
developing countries as displayed by a survey carried out at Merkato, Addis Ababa. These
methods include sealing of packets using candle light, plastics as fuel and paraffin stove. The
methods though seems cheap, are very hazardous to both the people and environment. Since
the marketplace is an almost open place, the roof surrounding the place has almost gone with
ages. If in any case heavy winds come, the whole place can blew up with fire.

2.3.1 Sealing using candle light

As cheap as a candle might be, there are many disasters to which the women and also the
marketplace are exposed to. The hands as well as the women’s body are exposed to fire
burns. If it happens that a person has burnt, it’s most likely that there will a life loss due to
large medicational charges in many developing countries of which these people cannot
afford.

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2.3.2 Sealing using paraffin stove
The burning of paraffin produces a lot of carbon dioxide as shown by the equation:

C25H52 + 38O2 25CO2 + 26H2O

Hence for every one mole of paraffin burnt, 25 moles of carbon dioxide are produced and
released to the atmosphere.

2.3.3 Sealing using flame from burning plastics

In this type of sealing, plastics are burnt inside a container in which the flame they produce is
used to seal the packets.

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 CHAPTER 3

MATERIALS AND METHODOLOGY

3.1 Materials used automated sealing machine

a. Arduino Board
The Uno is a microcontroller board based on the ATmega328P. It has 14 digital input/output
pins, 6 analog inputs, a 16 MHz quartz crystal, a USB connection, a power jack, an ICSP
header and a reset button. It contains everything needed to support the microcontroller;
simply connect it to a computer with a USB cable or power it with an AC-to-DC adapter or
battery to get started.

The ATmega328 on the Uno comes preprogrammed with a boot loader that allows you to
upload new code to it without the use of an external hardware programmer. It communicates
using the original STK500 protocol (reference, C header files).

The board can operate on an external supply from 6 to 20 volts. If supplied with less than 7V,
however, the 5V pin may supply less than five volts and the board may become unstable. If
using more than 12V, the voltage regulator may overheat and damage the board. The
recommended range is 7 to 12 volts.

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 b. Pneumatic Cylinder
Pneumatic cylinder is used to reject or accept the object depending on the signal send by the
delay timer. Pneumatic cylinder is mechanical device which is use to power of compressed
gas to produce a force in a reciprocating linear motion.

It is design for small scale industries to increase their market value by providing them low
cost packaging machine.

c. Frame
The conveyor system has a square shaped aluminum and iron frame and the total setup is
made by welding the frame in to a required dimension. The bearing is fit in to the bearing
holder and makes weld on it for required dimensions. The bearing holder is welded parallel to
each other. And the roller is interfaced with bearing, when rollers are fitted, and anther end of
the roller setup is adjustable it is made only for belt tightness and make the objects to travel
on straight without slippages

The aluminum frame consists of square shaped and with the dimensions of
(1500*420*800)cm length, breadth, and height respectively. Fig. shows the square aluminum
tube. It can able to withstand high loads and strain resistances while comparing to other
frames. The cutting machine is used to cut the square tube for required dimensions.

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 d. Ball bearing
Most rolling bearings contain rings with raceway (inner ring and outer ring), rolling parts
(either balls or rollers) and cage. Fig shows the bearing. The cage separates the rolling parts
at regular intervals, holds them in situ at intervals the inner and outer raceways, and permits
them to rotate freely.

e. Conveyor Belt
A conveyer belt consists of two pulleys or shaft is directly coupled with motor, with a
nonstop loop of fabric - the transporter - that rotates regarding them. One or each of the
pulleys area unit powered, moving the belt and therefore the material on the belt forward. The
powered pulley-block is named the drive pulley-block whereas the unpowered pulley-block is
named the do-nothing. There area unit two main industrial categories of belt conveyors;
Those normally material handling like those moving boxes on within a manufacturing plant
and bulk material handling like those accustomed transport industrial and agricultural
materials, like grain, coal, ores, fines and lumps material. Conveyors area unit sturdy and
reliable components employed in automatic distribution and storage. Together with
computer-controlled pallet handling instrumentation this enables for a lot of economical
retail, wholesale, and producing distribution. It’s considered a labor-saving system that
permits massive volumes to maneuver speedily through a method, permitting corporations to
ship or receive higher volumes with smaller space for storing and with less labor expense.

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 f. DC Motor
A DC motor is any motor inside a category of electrical machines whereby electricity electric
power is reborn into mechanical power. Most often, this kind of motor depends on forces that
magnetic fields turn out. Despite the kind, Fig shows the double-geared DC motors that have
some quite internal mechanism, which is electronic or mechanical device. In each case, the
direction of current flow partly of the motor is modified sporadically. The speed of a DC
motor is controlled employing a variable providing voltage or by dynamic the strength of the
present inside its field windings. Whereas smaller DC motors are ordinarily utilized in the
creating of appliances, tools, toys, and automobile mechanisms, like car seats; larger DC
motors are utilized in hoists, elevators, and electrical vehicles. A 12v DC motor is tiny and
cheap, nevertheless powerful enough to be used for several applications. During this project
we tend to use the 100rpm brushed gear motor to supply the high force that makes the
conveyor to hold the specified weight.

g. IR Sensor
An IR sensor is an electronic gadget which is utilized to detect certain qualities of its
surroundings by either transmitting or recognizing infrared radiation with no contact. IR
Sensors work by utilizing a particular light sensor to distinguish a select light wavelength in
the Infra-Red (IR) range. By utilizing a Drove which creates light at an indistinguishable
wavelength from what the sensor is searching for, you can take a gander at the power of the
got light. At the point when a protest is near the sensor, the light from the Drove ricochets off
the question and into the light sensor. This outcomes in a huge hop in the power, which we
definitely know can be identified utilizing a limit. Since the sensor works by searching for
reflected light, it is conceivable to have a sensor that can restore the estimation of the
reflected light. This kind of sensor would then be able to be utilized to gauge how "brilliant"
the protest is. This is valuable for errands like line following.

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 h. Relay
A hand-off is an electrically worked switch. Transfers are utilized where it is important to
control a circuit by a different low power flag, or a few circuits must be controlled by one
flag. Numerous transfers utilize an electromagnet to mechanically work a switch. It is utilized
to turn on or off electrical circuit working at high voltage utilizing a low DC controlled
voltage. Transfers are utilized to give high voltage to engines. The exchanging of transfer
sister performed utilizing engine controller. The core of a transfer is an electromagnet (a curl
of wire that turns into a brief magnet, when power move through it). Switch it on with a small
present and it switches on another machine utilizing a considerably greater current. As the
name proposes, numerous sensors are unimaginably delicate bits of electronic gear and create
just little electric current. Be that as it may, regularly we require them to drive greater bits of
contraption that utilization greater streams. Transfers overcome any issues, making it feasible
for little streams to enact huge ones that imply transfers can work either as a switch or as a
speaker.

i. Solenoid Valve
A solenoid valve is an electromechanically worked valve. The valve is controlled by an
electric current through a solenoid. Their undertakings are to stop, discharge, and
measurements, disperse or blend liquids. Solenoids offer quick and safe exchanging, high
unwavering quality, long administration life, low control power and minimal plan. There are
numerous valve plan varieties.

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 j. Switches
Switches are electrical or electronic contact devices used to turn (ON) or (OFF) the flow of
electricity through a circuit. Switches are essential components in almost all the electronic
devices used today. Switches require another device or action (Force) to change their state
from open to close or close to open. Switches might operate manually or mechanically.

3.2 Methodology
The electrical systems were designed and functionally investigated on the heat sealing
packaging prototype. These systems can be used as same for larger packaging plants with
same costs of construction. The low-cost concept is depending on using open sources
(software is free and available on webs and the hardware is had a reasonable price) instead of
other expensive sources as PLC and multifunction systems. The arduino system is a computer
system doing a definite function inside a greater mechanical or electrical system. Each one of
these systems (pneumatic actuator and conveyor motor control system) was designed on
virtual software package of Proteus Design Suite 8, Figure below which provides a powerful
working environment to develop the Printed Circuit Board (PCB) and other advantage of this
virtual program of Proteus its ability to simulate the written instructions program of the
microcontroller Arduino-Uno

Sealing Machines are most commonly used in agricultural products, flour and food
processing industries. These machines use a conveyor belt which is an economical, fast and
easy way to pack bags. Mostly PLCs are used for Automatic packing machines, but we can
make very basic and versatile bag sealing using an Arduino. we can program the Arduino to
automatically detect the bag using IR sensor and allow the bag to seal by stopping the
conveyer belt for some time. Then again move the belt and stop when the next bag is
detected.

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 DETAIL STUDY

DESIGN THE SYSTEM

DESIGN OF CIRCUIT DIAGRAM

FABRICATE THE SYSTEM

TESTING THE SYSTEM WITH PROGRAMED MICROCONTROLLER

CONDUCT THE EXPERIMENTS

VALIDATION

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 CHAPTER 4

DESIGN OF ATOUMATED HEAT SEALING/PACKING MACHINE PROTOTYPE

A microcontroller basis automatic packaging prototype manufacturing is depending on three

engineering approaches as Mechanical, Pneumatic and Electrical.

4.1 Mechanical design

Detailed design process using the knowledge from the existing literature in prior sections, the
authors generated three different possible concepts to packaging for small scale food
processing industries and farmers. Drawings for the possible solutions were done using
SOLIDWORK 2016. Based on functionality, cost and ease of manufacture as important
factors heat sealer and conveyor concept design was chosen as it satisfies most requirements
for product packaging by the small scale industrials.

Material selection was done and the necessary parameters for the materials were noted where
they were necessary for calculations.

In designing for the production of the automated packing machine, the following factors were
taken into consideration;

 Selection of materials
 Form and size of the parts
 Convenient and economical features
 Safety operations
 Workshop facilities available
 Cost of construction etc.

However, the best design of a machine is one which is more economical in the overall cost of
production and operation.

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 a. Design parameters:
5760 paper and plastic bag per day

8 hours of operating the machine are recommended

5 seconds of packaging each bag of product

b. Design of the jaw Sealing

Temperature 130 – 140 degrees Celsius

Pressure 276 kPa

Dwell time 1.5 seconds

Both jaws will be heating for uniform sealing. The time, temperature and pressure to produce
a good seal are as highlighted above. A heating element and a temperature sensor will be
included in the jaw.

Area for pressing = 0.25*0.005 = 0.00125

Pressure required = 276000 Pa

Force required = pA= 276000*0.00125 =345N

c. Design Analysis for Conveyor Belt

Formulae,

Length of belt=(2L) +(2 x π x R) (5)

where,

L= Center distance between the rollers

R= Radius of the rollers Center distance between the rollers= 500mm

Diameter of the rollers= 50mm

Therefore, Length = (2 x 1500) + (2 x π x 25) = 3157mm (6)

The width of the belt was chosen according to the table size and the carton sample. Width of
the belt = 400mm.

Thus the length and width of the belt was calculated and order and purchased.

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 d. Diameter of the pulley
By using the space considerations of the machine, the standard diameter of the pulley can be
taken as 200 mm. This will then be verified using the stress considerations by using the
following formula:

Speed of the pulley, N = 100 rpm

Density of the rim material, ρ = 7200 kg/m3 for cast iron

Diameter of pulley, D = 200 mm

Velocity of the rim,

ν = πDN / 60= π*0.2*100/60= 1.047 m/s

e. Width of the pulley

The width of the belt for this drive mechanism is chosen in the Belt Selection section. Width
of the pulley or face of the pulley (B) is taken 10% greater than the width of belt

Width of belt = 400 mm

Pulley width, B = 420 mm

Thickness of the pulley

Thickness, t = 300/200 + 2 = 3.5 mm

Select standard = 4 mm

Dimensions of arms

The pulley is of 200 mm diameter and is therefore made with solid disc instead of arms. The
thickness of the solid web is taken equal to the thickness of rim measured at the centre of the
pulley face.

Solid web thickness = 4 mm

Dimensions of hub

(i) The diameter of the hub d1 in terms of shaft diameter d is fixed by the following
relation:
d1 = 1.5d + 25 mm
d1 = 1.5*70 + 25 = 130 mm

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The diameter of the hub is appropriate since it’s less than 2d.

(ii) The length of the hub, L = 2d = 2*70 = 140 mm

This is appropriate according to the standards.

Conveyor drum summary

Pulley/Core Diameter = 200 mm

Finish Diameter = 210 mm

Face Width = 400 mm

Wall/Rim Thickness = 4 mm

Crown/Profile = flat

Shaft/Axle = 70 mm

Hub = 10 mm

Bore Diameter = 70 mm

f. Design Analysis for electric Motor

The motor is the power source or provides the drive for the machine. The power of the motor
can be determined as follow.

The motor, which is used to run the conveyor belt, only has to have a RPM of 60-100. If the
rpm is more, the job will vibrate.

Weight of the roller to be rotated =W= 10 kg Let N be assumed as 75rpm Rotation force,

F of the roller =Mg =10 x 9.81 = 98.1N

Torque required =F x d(where, d is the distance in meters)

= 98.1 x 0.5

= 49.05Nm Power required,

P = (2 x π x T x N)/60

= (2 x 3.142 x 49.05 x75)/60

=385W

1hp = 746 w

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 Power required, P = 0.51hp

Since there is power loss in the belt drive a motor of higher power is used.

g. Selection of DCV for the Cylinder

Calculations for the pneumatic components are listed below

The DCV selection depends on the flow rate of the air that should be given to the cylinder.

The stroke length of the cylinder must be 200 mm.

The time for the stroke = 2 sec

From equation of motion,

We know that S=u x t + ₁⁄₂ x a x t²

Where,

S-stroke length

a-acceleration of the cylinder

u-initial velocity=0m/s

Substituting the values of the s and t, we get the value of a as: 0.20 = 0 + 0.5 x a x 2 x 2
Therefore, a = 0.1m/s2

By equation of motion, we know that V=u + (a x t)

where,

v- the final velocity of the cylinder

u- the initial velocity of the cylinder

a - acceleration of the cylinder

t – time taken

Substituting the value of u, a and t, we get v= 0 + 0.1 x 2

Therefore,

v= 0.1m⁄s

Discharge is given by the formula Q = A x V where, Q-discharge A – area over which flow
occurs V – final velocity

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Substituting values for A and v, we get Q = (π/4) x (D2) x 0.1 = (3.142/4) x (0.05) x 0.1
=1.15m3/sec

h. Design for the equipment frame

This frame was design in order to reduce cost and weight of the equipment. Thus, we selected
mild steel angular iron. In the design for frame dimensions, Ergonomics were considered,
such that we envisaged an average height person to work on this equipment. Also considered
in the dimensioning are other relevant measurements taken on the rollers (A and B), gear
motor, Air tank, pneumatic cylinder, compressor, electrical panel and frame to accommodate
them all. Therefore, the necessary dimensions were taken, angle iron cut to size and shapes.
They are thus joined together by welding process after necessary machining operations on the
various machine tools (such as lathe, grinding and milling machines).

Check for the safety of the designated frame: In order achieve appropriate result to confirm to
safety requirements; the following design factors were made Frame dimensions:

 Length of the frame (L)=1500mm

 Breath of the frame (B)=420mm

 Height of the frame (H)=800mm

 Weight of the rollers=10kg

 Weight of the cylinders=7.5kg

 Weight of other accessories=35kg

 Total weight on the bed=52.5kg

 The total weight can be assumed to be an Uniformly Directed Load DL loaded on a fixed
beam

 Weight per unit length=52.5/1.5=26.25kg/m

Figure 2: Determination of reactions at A and B

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Calculations for the reactions at A and B

ΣM = −R L + wL L B AY → R wL / 2 A ∴ = (+ upwards)

Reaction at A=52.5/2=26.25N

+ ↑ΣF = 0 = R + R − wL = 0 y Ay BY → R wL / 2 B ∴ = (+ upwards) Reaction at

B=52.5/2=26.25N

Calculation of bending moment diagram for the fixed beam

Figure 3: Bending moment diagram for Uniformly Distributed Load

M.max (-) =MA=-WL/12=52.5 x 1.5/12=6.56Nm

M.min=WL/24 at x=L/2=52.5*1.5/24=3.28Nm
The obtained bending moment at the Centre and at the ends was within the permissible limits.
Hence the design was safe.

IV.2 Pneumatic system design

The pneumatic conveyor system is used in one location and used to shove the Ohmic heating
coil on the plate for welding the plastic and paper bag. The pneumatic heat sealing with
conveyor system consists of the following components as:

i. Step down transformer of 220V to 12V which is sufficient in providing the

required power of 12V and 3A to the air brush compressor.
ii. Air brush compressor with outlet flow rate of 50 liters per minute and air
pressure of 5 to 10 bar is connected to an air tank with a capacity of 15liters and
pressure class of 10bar.

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 iii. Check and safety valves for air delivered non-return by the air brush compressor
and air tank high air pressure eluding, respectively.
iv. Supplied air pressure regulator SQUARE D keeps the air pressure in the tank
constant by turning the air brush compressor 'ON' or 'OFF' to be at the range
between 4.5 and 5.5 bar which is more suitable for system operations.
v. Delivered air pressure regulator which controls the air discharging pressure from
the air tank to the pneumatic three ways solenoid valve.
vi. Pneumatic three ways solenoid valve two solenoid valves of five ways were used
for the two pneumatic cylinders for forward and backward pushing operations
controlled by the Arduino board.
vii. Pneumatic air exhaust silencers Two exhaust silencers were used for each
pneumatic air solenoid valve to regulate the pushing force of the two pneumatic
cylinders
viii. Pneumatic air cylinder Two stainless steel adjustable stroke type pneumatic air
cylinders were used, Table1; the first one is exploited to transfer the packaging
plate from the weighing unit to be centered under the Ohmic heating coil (first
location) which thrust by the other vertical pneumatic air cylinder (second
location).

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 4.3 Electrical system

To design a prototype for Automated Packing/Sealing Machine using Arduino Uno,

conveyor belt, solenoid valve, IR sensor, and DC motor. Belt conveyor is driven by a DC
motor at a constant preset speed. The DC motor will keep driving the belt until an IR sensor
detects the presence of a bags on the belt. We used the IR sensor as an external trigger. So
whenever the IR sensor goes high it sends a trigger to Arduino to stop the motor and turn on
the solenoid valve. A preset required delay is already entered in the code for bag sealing. The
Arduino will keep the solenoid valve on and DC motor off until that specified time. After that
time, the solenoid valve turns OFF and the actuator return automatically, and the conveyor
starts moving so that the next bag can be sealed.

a. Components Required

 Arduino Uno
 DC Motor
 Relay
 Solenoid Valve

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  IR Sensor
 A4988 Motor Driver
 Battery

b. Circuit Diagram

The circuit diagram for the Automatic Sealing machine using Arduino is given below.

we have used protous to draw the circuit diagram. In this circuit, Solenoid Valve is connected
to Arduino through the Relay module and the A4988 driver module is used to control the
stepper motor.

The input pin of the Relay module is connected to pin 7 of Arduino. Direction and Step pins
of the A4988 module are connected to 2 and 4 pins of Arduino. In this project, an IR sensor is
used as an external interrupt to Arduino. In Arduino Uno, digital pin 2 & 3 are the interrupt
pins, so connect the Out pin of IR sensor to the 3rd pin of Arduino. Solenoid Valve is powered
by a 24V power source, and DC motor is powered by a 12V power source.

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 c. Arduino Program
Code

#include <DCmotor.h>

#define STEPS 200

#define motorInterfaceType 1

Stepper stepper(STEPS, 2, 4);

int relay=7;    

int step_num =700;

void setup() {                        

  Serial.begin(9600);

  pinMode(relay,OUTPUT);  

  stepper.setSpeed(500);

  pinMode(4,OUTPUT);

  pinMode(2,OUTPUT);

 attachInterrupt(digitalPinToInterrupt(3),IR_detected,RISING);

boolean solenoid_on = false;

void loop() {

  if (solenoid_on)

 {

    delay(6000); //wait for 6 sec

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    solenoid_on = false; 

 }

  digitalWrite(relay,LOW);    // now relay is off condition (and motor is on  condition)

  stepper.step(step_num);

 }

void IR_detected()           //ISR function excutes when IR sensor goes high.

{                    

  Serial.println ("Interrupt Detected");

  stepper.step(150); //To run the stepper motor few steps before it stops

  digitalWrite(relay,HIGH); //to turn on solenoid

  stepper.step(0); //to stop the stepper motor

  solenoid_on = true;

 }

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 4.4 Engineering Bill of Material
The dimension and cost of materials selected for the fabrication of the automated packing
machine are as follows;
Table 1 Purchased Spare Parts

S/N Name Specification Quantity Unit Total

Cost Cost
1 Air Compressor Operation pressure: 3 bar 1 1500 1500
Unit Min: 3 bar
Max: 8 bar
Temp.:0-40oC
2 Pneumatic Drive generates a linear movement 2 1000 2000
Cylinder • Mode of operation: single-acting.
• Medium: compressed air
• Shape of piston: Round
• Shape of piston rod: Round
• Piston diameter: 45 mm
• Piston rod: 15mm
• Stroke length: 50-100mm
• Optimal pressure: Min. = 2bar; Max =
12bar
• Ambient temperature: 0– 80°c
3 Electric Motor • Maximum Output: 500W 1 550 550
• Speed: 100 rpm
• Voltage: 24VDC
• Current: 25A
4 3/2 Way •Medium: compressed air 1 150 150
Directional
• No of ports: 3
Control Solenoid
Valve • No of positions: 2

• Direction of flow: Non-reversible

• Operating principle: Disc seat

• Operating pressure: min= 3 bar; max= 8

bar

• Temperature: 0-40°c

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 •operating voltage:5VDC

5 Resistive Heat • Sealing temp.:250oC 2 100 200

Sealing • Temp accuracy: ±0.2oC
• Dwell time:0.1-999.9S
• Sealing pressure: 0.05MPa-0.7MPa
•sealing Area: 0.005m*0.4m
6 Flow Control 1 80 80
Valve
7 Conveyor Belt Maker: Lakodhia Material: Leather 1 75 75
Size: 1230 x 250 mm
8 Air Receiver 1 600 600
10 Photoelectric • Detecting range:24 cm 2 250 500
Sensors • Voltage – Supply: 2.5 V ~ 5.5 V
• Current – Supply: 0.7mA
• Mounting Type: PCB, Through Hole
• Operating Temperature:0-40oC
11 Relay Material: Circuit board 1 110 110
•Voltage – Supply: 5 V
•Trigger Current: 5mA
•Max. Current: 190mA

12 switch single pole 1 25 25

13 CIRCUIT single phase 10A 1 95 95
Breaker
14 ARDUINO Uno •Operating Voltage 5 V Input Voltage 1 550 550
(recommended) 7 – 12 V
•Input Voltage (limits) 6 – 20 V
•Digital Input / Output Pins 14 (of which
6 provide PWM output)
•Analog Input Pins 6
•DC Current per I/O Pin 40 mA
•DC Current for 3.3V Pin 50 mA
15 PCB Board •Material: SRBP 1 50 50
•Pitch:0.1"
•Holes:1.0mmØ
•80 x 100mm:31 x 38 Holes
16 Bolt and Nut M10/4th and 6th grade 16 10 160
17 Cables and Other       200
Sub Total  

Table2 Construction Materials

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 S/N Materials Specification Quantity Unit Cost Total Cost
1 Stainless Steel Sheet        
2 Iron Sheet        
3 Iron Pipe        
4 Iron Rode        
5 Angle Iron        
6 Aluminium sheet        
7 Electrode        
8 Saw Blade        
9 Screw        
Sub Total  

Table 3 Machining Job

S/n Name Type of Job Material Used Labour Cost

1 Shaft Cutting and Turning Cutting and lathe machine
2 Roller Turning and Boring Lathe machine and drilling
machine
3 Stainless Welding and Cutting Welding and cutting
Steel machine
4 Frame Cutting, Drilling and Hacksaw, drilling machine
Support Welding Machine and welding machine
 Hacksaw and welding
5 Iron Pipe Cutting and Welding Machine
Sub Total  

Table 4 Non-Machining Job

S/ Jobs Labour Cost Total Cost

N
1 Transportation    
2 Cutting    
3 Filling    
4 Machine Assembly    
Sub Total  

Total Cost= Spare Part Cost + Construction Materials + Machining Job + Non Machining Job

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