Designing a Pneumatic System for Bottle Packaging Industry

Learning Outcomes

Control systems are paramount to efficient working practice and provide the manufacturing world a system to provide accurate and consistent results.

There are many instances of control systems , not only in operational systems such as power plant and energy production, but also in the manufacturing and production line environment where automated systems are in place to shape and build components into assemblies leading to the finished product. This assignment introduces you to that environment

On successful completion of this assessment, students will be able to:

1. Demonstrate and evaluate the ability to link measured control results to both theoretical analysis and software simulations

2. Evaluate the use and implementation of appropriate industrial control methods.

The Brief

Red : The Part that needs to be completed

A circuit simulation and physical model (CAD based) has to be built for the below scenario using the Festo™ electro-pneumatic and CAD software respectively. The circuit drawings of the simulation need to present as per appropriate standard (EN 81346-2). You also need to identify the individual components and explain reason for selecting these components to control the process. How these components are coordinating with each other i.e. step by step flow of the commands. Furthermore, you need to relate your explanation to the simulation using references. A comprehensive technical report regarding all above activities has to be written as a part of your assignment. (2000 words)

Scenario:

A solution is to be designed for the simulation of the bottle packaging industry. The bottle with the cap/lid will be deflected on one side while others (without cap/lid) will be dropped in the tray below conveyor.

This system must incorporate the following features:

· Emergency Stop

o This should freeze the whole system

o This should also apply the brakes on the conveyer belt.

· The system should have a manual start with push button. The valve should remain in its operating position.

· Checking of the bottle cap/lid.

This should not be able to move if the Actuator/cylinder 2 is already advanced.

· Deflecting the good bottle on other side of the conveyor

This should not be able to retrieve until [Actuator/cylinder 1.] reached to its initial position i.e. dead position

The above system should only be controlled using the pneumatic system.

Actuator/cylinder 3. Will be controlled using electro-pneumatic system.

· After every five parts there is an assumption that a bottle without cap/lid will be passing through the conveyor. This has to be modelled within the whole system using electro-pneumatic system. The counter must be able to reset itself after every five counts.

This assessment will meet the following KSB for Aerospace and Manufacturing Degree apprenticeship students

For Aerospace Degree Apprenticeship students:
Knowledge and Skills

1. Understand engineering process and practices covering: mechanical/electrical/electronic systems design, design and stress analysis e.g. computer aided engineering techniques, systems design, integration and test, in-service and through product life support, advanced manufacturing, aerospace quality and governance

3. Understand and apply analytical methods (engineering mathematics – algebra, differentiation, function, geometry, trigonometry and statistics)

4. Understand Aeronautical Sciences – stress, strain, static and dynamic systems, motion, force, electrical power and resistance, mass and weight

Behaviours

B. Design and development of processes, systems, services and products

For Manufacturing Engineering Degree Apprenticeship students:

Knowledge

K2    Materials and manufacture

S5    Implement engineering processes

S6    Monitor and evaluate engineering processes    

Behaviour

B4    Problem solving orientation: Identifies issues quickly, enjoys solving complex problems and applies appropriate solutions. Has a strong desire to push to ensure the true root cause of any problem is found and a solution identified which prevents further recurrence.    

B5    Quality focus: Follows rules, procedures and principles in ensuring work completed is fit for purpose and pays attention to detail / error checks throughout activities.

Submission Requirements

The submitted assignment will include:

Ø Electronic submission (TurnitinUK)  (2000±10% words report).

Ø 5 minutes recorded presentation is required. You will be asked to save presentation file in the Turnitin/share drive.

Marking Scheme
Portfolio Section
Max mark available
Overall Structure and Format/ Use of Images (Annotations etc.)/ Referencing (Harvard System)
Your assignment will be marked according to the scheme below.
Your presentation will be marked according to the scheme below.
Presentation Section
Max mark available
Subject Content
   
Pace and Quality of presentation
Questions and Answers
Anonymous Marking

All submitted assignments for this module will appear in an anonymous format to the Marking Tutor. As such you are requested not to identify yourself anywhere within your submitted assignment (e.g. by putting your name on the front cover sheet). This will maintain your anonymity to your Marking Tutor. The principle behind the usage of anonymous marking of assignments is to ensure that all assignments are marked in an equitable and unbiased manner, thereby ensuring the maintenance of high academic quality standards within the marking of the assessments.
Reading Materials

· Dunn, William (William Charles), 1932, Bartelt, Terry L. M (2010) Industrial automated systems: instrumentation and motion control

· William C. Dunn. (2005), Fundamentals of industrial instrumentation and process control

· Asfahl, (1988) Robotics and manufacturing Automation.

· Bootheroyd,G, (1982)  Automatic Assembly, Marcel Dekker, Inc,

· Crictchlow A J, (1985) Introduction to robotics, Macmillan.

· Gibbs D (1984) An Introduction to CNC Machining. Cassell

· Thyer, G.E. (1988) Computer Numerical Control of machine tools, Heinemann Publishing

Late Submission

There are no automatic rights to late submission, with a capped mark of 40%. However, the University acknowledges that there may be circumstances which prevent students from meeting deadlines.

There are now three distinct processes in place to deal with differing student circumstances:

1. Assessed Extended Deadline (AED)

Students with disabilities or long term health issues are entitled to a Support Plan. The Support Plan will outline any adjustments to assessments which are required to accommodate an individual student’s needs. For further details refer to the link below:

2. Exceptional Extenuating Circumstances (EEC)

The EEC policy applies to situations where serious, unforeseen circumstances prevent the student from completing the assignment on time or to the normal standard. Students who submit a successful EEC claim will usually be required to complete a different assessment to that which was originally set. All EEC claims will be considered by College panels, which will convene on a monthly basis.

For further details refer to the link below:

3. Late Submission up to One Week

Covering unexpected and severe disruption to study, where circumstances do not require the additional time allowed for by an EEC, the Late Submission process enables students to complete their existing assessment up to one week late, without a cap on the grade. Requests for late submission will be made to the relevant Deputy Head of Department who can authorise an extension of up to a maximum of one week. The Deputy Head of Department will expect to see compelling evidence that such an extension is appropriate.