Sample ENEM20002 Fluid Power Engineering and Control Report

ENEM20002 Fluid Power Engineering and Control Report Sample

Assignment details

Project 1

Students in group (maximum 4 students) are supposed to select a topic from the list provided and then they will collaboratively work out the project and submit written technical report as scheduled.

Demonstration of your knowledge gained in areas of design of industrial automated machines using specifically hydraulic, pneumatic and pneumatic integrated with PLCs is the major goal.

Essential sections of Project 1 and the report are:

1) Title page (refer to template provided in Unit Moodle site)

2) Introduction and background (describe the problem of your selected project, demonstrate your understanding about the problem following available publications, mention the scope of application of the machine in industry, etc.);

3) Design layout/assembly drawing (2D/3D) in side view/s and top view, visualise it and get clear understanding of your projected machine, you may need to produce part drawings of the selected parts of your machine (selection can be done by your Tutor);

4) Sketch required fluid (hydraulic or pneumatic) power system, calculate and select required fluid (hydraulic or pneumatic) components for your project. You may need to start learning simulation using SimScape or FluidSim at this stage.

5) Industrial applications and value of your projected machine for engineering.

6) Safety factors that to be considered for operation of the projected machine.

7) List of references.

Produce a Report in group and present it together in group sharing sections of presentation in Week 6 using a PowerPoint file in the Workshop class. Presentation time 10 mins and another 5 mins for question and answer.

During the project work and in presentation you need to demonstrate your engineering professional skills such as solving engineering design and control problems, preparation of design documents and reading and understanding design documents, communication skills, team working skills, code of practice including dress code, etc.

Solution

(1) Table of content

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Introduction and Background

In the present days, automation is very crucial for productivity improvement and effectiveness in the fast-moving industrial environment. The packaging industry is one of the areas where automation has had a great impact mainly in bottling processes. This paper concentrates on an automated bottle capper development and implementation particularly those that run using a hydraulic system.

The Problem:

Precision, speed and consistency are necessary during the bottling process in manufacturing industries. Key among these challenges is the capping phase where bottles need to be closed tightly within short durations without compromising quality of products and production targets. Manual sealing may lead to slower production rates, inconsistent seals, or even risk of contamination which can affect both the value of product’s quality as well as firm’s profit margin.

This also increases likelihoods for human errors with manual or semi-automatic procedures leading to faulty products or delays in manufacturing. It especially becomes problematic in sectors such as food and beverage, medications, cosmetics, etc., where integrity of packaged contents must be upheld throughout its shelf life. The solution lies in creating an automatic bottle caper with which bottles will always be capped with specified levels of torque and pressure that will guarantee process repeatability. Understanding the Problem through Available

Publications:

Botting automation is a topic that has been widely researched and written about in literature. For instance, automating the cap machines lowers the labor costs and enhances the production rates as supported by different studies. Moreover, hydraulic systems have a high level of control over force and motion hence are suitable for tasks that need accuracy such as bottle capping. Published articles have shown how automation improves precision and reduces variability for industrial processes thereby promoting product quality for the assignment helpline.

Hydraulic systems have an edge since they give a steady force during capping. The research suggests that hydraulic cappers provide more consistent application of torque thus reducing chances of over-tightening or under-tightening caps. This consistency is important for keeping packaging intact and ensuring no contamination or spoilage gets into the products inside it.

The Scope of Application in Industry:

The automated hydraulic bottle capper has many uses across various industries. In food and beverage industry, it guarantees sealed bottled water, soft drinks, sauces among others; enhancing their shelf life while averting leaks from taking place. A precision automated capper is critical when used in pharmaceuticals sectors because it Moreover, the integration of hydraulic systems into automated cappers allows for greater flexibility in handling different bottle types and sizes, making these machines adaptable to various production needs. This adaptability, combined with the benefits of automation, makes hydraulic bottle cappers an essential component of modern production systems.

3. To design and visualize a layout/assembly drawing for an automated hydraulic bottle capper, I will outline the key components and their arrangement. The drawing will include a side view, top view, and a 3D perspective to give a clear understanding of the projected machine.

The Key Elements of the Automated Hydraulic Bottle Capper:

Base Frame: This forms the structural support for the whole machine, it is usually made of steel or aluminum to make it strong and steady. It houses hydraulics, electrical components, and conveyor mechanisms.

Conveyor Belt System: Bottles are moved to the capping station by the conveyor belt which is motorized and synchronized with the capping mechanism to enable smooth operation.

Hydraulic Cylinder: As a result of this, one can make sure that a bottle is sealed using the correct torque as well as pressure due to downward force applied on its cap.

Cap Feeder and Sorter: A machine that automatically organizes caps for placement on bottles; ensures proper orientation of caps before they are introduced into the capper.

Capping Head: The physical application of the cap to the bottle is done by this part linked with hydraulic cylinder; inclusive of torque control ensuring consistent capping.

Control Panel: It has an interface system that enables human beings operate such machines including settings for hydraulic pressure, speed, and torque among others.

Safety Enclosures: Protective enclosures in place to safeguard operators from moving parts of machines; these include safety.

3D View:

Presents a three-dimensional perspective to illustrate the machine's spatial design and arrangement of components.

Fig (3D Layout)

Fig (2D Layout)

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To design a hydraulic power system for an automated bottle capper, some steps must be followed namely: sketching the system, calculating key parameters (i.e., force required, pressure and flow rate) and selecting appropriate hydraulic components. This step-by-step guide will enable you to get through the process.

Step 1: Sketch the Hydraulic Power System

The hydraulic system of an automated bottle capper generally consists of:

Hydraulic Pump – It provides flow of hydraulic fluid.

Reservoir – It stores hydraulic fluid.

Hydraulic Cylinder – It applies the necessary force on the capping mechanism so as to cap bottles.

Pressure Relief Valve – The maximum pressure is limited by this valve in order to protect the system.

Directional Control Valve – The movement of cylinder is regulated by this valve that directs the flow of hydraulic fluid.

Hydraulic Hoses - These components connect all other parts and move hydraulic oil from one component to another.

Sketch:

Reservoir → 2. Pump → 3. Directional Control Valve → 4. Cylinder → 5. Pressure Relief Valve → 6. Return Line to Reservoir

• The reservoir feeds fluid into pump which pressurizes it then sends it through direction control valve; which in turn directs the fluid either extend or retract the twin rod cylinder; finally pressure relief valve ensures that pressure never goes beyond safe limits and with no danger return line back into reservoir

Step 2: Calculate Hydraulic Requirements

1. Force Calculation:

Step 3: Select Hydraulic Components

Hydraulic Pump:

Select a pump that can provide the necessary flow rate Q at the required pressure P.

Example: A fixed-displacement gear pump rated for your pressure and flow requirements.

Hydraulic Cylinder:

Based on your calculations, select a hydraulic cylinder with the correct bore size and stroke length to provide the required force and movement.

Directional Control Valve:

Choose a 4/3 way valve (4 ports, 3 positions) to control the extension and retraction of the cylinder.

The valve should be rated for the operating pressure of the system.

Pressure Relief Valve:

Select a relief valve that is adjustable and rated for the maximum system pressure.

Hydraulic Hoses and Fittings:

Ensure that the hoses and fittings can handle the system's pressure and flow rate. Choose hose sizes based on the required flow and pressure rating.

Reservoir:

Size the reservoir to hold at least three times the total fluid volume required by the system, ensuring adequate fluid for operation and cooling.

Step 4: Final Checks and System Integration

Ensure all components are compatible with the hydraulic fluid used (e.g., mineral oil).
Verify that the system can handle peak loads and ensure that the pressure relief valve is set to protect against overpressure.

If necessary, include filters to keep the hydraulic fluid clean and free of contaminants.

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Industrial Applications

Bottling Plants:

Primary Application: The most direct application is in bottling plants where liquids such as beverages, chemicals, and pharmaceuticals are filled and capped. The automated bottle capper can handle high speed production lines, ensuring that bottles are capped securely and quickly.

Integration with Conveyor Systems: The capper can be integrated into larger conveyor systems to perform synchronized capping as bottles move through the production line, contributing to overall production efficiency.

Food and Beverage Industry:

High-Volume Production: The machine is essential in the food and beverage industry, where thousands of bottles need to be sealed daily. Hydraulic power provides the force necessary to apply caps at high speeds with precision and uniformity.

Consistency and Quality Control: Automated systems reduce human error, ensuring consistent sealing quality, which is critical for product safety and shelf life.

Pharmaceutical Industry:

Sterile and Secure Packaging: In pharmaceutical production, the machine can ensure that caps are applied securely, maintaining the sterility of the product. Automation reduces contamination risks and improves safety.

Handling Various Container Sizes: The system can be adapted to handle different container sizes and types, making it versatile for pharmaceutical packaging needs.

Chemical and Petrochemical Industry:

Sealing Hazardous Materials: Hydraulic-powered cappers can be used in industries dealing with hazardous chemicals, where secure and consistent sealing is crucial to prevent leaks and spills.

Automated Handling of Bulk Products: The machine can handle bulk liquid packaging operations, reducing manual labor and exposure to hazardous materials.

Cosmetics Industry:

Packaging Variety: In the cosmetics industry, the machine can handle various bottle shapes and sizes, providing flexibility in packaging and ensuring consistent presentation of products. Bottling Plants:

The most direct application for bottling plants is filling and capping bottles with liquids like beverages, chemicals and pharmaceuticals. This automated bottle capper can work well in high speed production lines making sure that the bottles are sealed in a secure way.

Integration with Conveyor Systems: Through synchronizing the capping of bottles as they move along the production line, it can be integrated into bigger conveyor systems, thereby improving overall productivity.

Food and Beverage Industry:

High-Volume Production: In food and beverage industry this machine is indispensable because it seals thousands of bottles every day. Hydraulic force allows speedy application of caps uniformly.

Consistency and Quality Control: Consistent sealing quality which guarantees product safety and shelf life is achieved due to reduction of human error by automatic systems.

Pharmaceutical Industry:

Sterile And Secure Packaging: The machine could be used in pharmaceutics to apply tight caps thus maintaining product sterility. Automation minimizes contamination risks thus enhancing security.

Handling various container sizes: Being adaptable to different sizes and types of containers makes it useful for the pharmaceutical industry.

Precise Capping: Hydraulic systems offer precise control over the force applied during capping, which is important for delicate cosmetic products.

Engineering Value

Efficiency and Productivity:

Quick Activity: Hydraulic systems are used to achieve high speeds of motion with a large amount of force, making them ideal for rapid automated processes in industries. This enhances production output reducing bottling time and labor costs

.Continuous Operation: They are capable of running non-stop for long periods without overheating, which make hydraulic systems appropriate for 24/7 production firms.

Precision and Control:

Accurate Force Application: Correct Power Application: By way of hydraulics, the capping strength can be controlled to provide uniform sealing pressure on all bottles thereby minimizing defects and ensuring that caps are put on appropriately without damaging the bottles.

Tailored Settings: Different force, speed, timing elements for engineering designs mean the machine can be changed to fit different bottle types and capping needs.

Versatility:

Multiple Cap Types and Sizes: Different Cap Types and Sizes: These may include screw caps, snap-on caps or tamper-evident ones among others that such system can be engineered to handle. This is useful in industries that produce a wide range of products.

Flexible Design: Modularity in design allows hydraulic machines to be easily customized or reconfigured depending on various product lines or production processes.

Safety and Reliability:

Continuous Operation: Hydraulic systems are known for their reliability and can operate continuously under heavy loads. This reduces costs and maintenance, which is important in large enterprises

Safety Features: Engineering designs can include safety mechanisms, such as pressure relief valves, to prevent overloading and ensure safe operation.

Automation and Smart Integration:

Programmable Control Systems: The machine can be combined with programmable logic controllers (PLC) and sensors to automate the entire capping process. This reduces the need for manual intervention and allows immediate maintenance and adjustment. reduce and reduce energy demand..

Industry 4.0 Integration: With smart sensors and data connectivity, the system can be part of an Industry 4.0 ecosystem, where data analytics are used to optimize performance, predict maintenance needs, and reduce energy consumption.

Energy Efficiency:

Energy-Saving Technologies: Modern hydraulic systems can reduce energy consumption by using different pumps and motor controls. This increases safety and reduces operating costs.

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Safety is a critical aspect of designing and operating any industrial machine, particularly one involving hydraulic systems for automated tasks such as bottle capping. Below are key safety factors to consider for the operation of the projected hydraulic bottle capper machine:

1. Hydraulic Pressure Control

Overpressure Protection: The hydraulic system must include pressure relief valves to prevent overpressure, which could cause equipment failure or safety hazards such as bursting hoses or seals.

Pressure Monitoring: Sensors should be installed to continuously monitor the hydraulic pressure, and the system should be designed to shut down or alert operators if the pressure exceeds safe limits.

Proper Sealing: Ensuring all hydraulic connections are securely sealed reduces the risk of leaks, which can lead to dangerous situations, such as oil spills or reduced operational control.

2. Mechanical Safety

Guarding and Enclosures: Moving parts such as the hydraulic cylinder and the capping mechanism should be enclosed in protective guards to prevent accidental contact by operators or other personnel.

Pinch Point Protection: Any part of the machine where moving parts come together (e.g., between the hydraulic cylinder and the bottle) should be equipped with sensors or guards to prevent injury from pinch points.

Emergency Stops: Emergency stop buttons should be easily accessible at multiple points around the machine, allowing operators to quickly halt operation in case of an emergency.

3. Fluid Containment and Management

Leak Detection and Containment: The system should include mechanisms to detect hydraulic fluid leaks early. Drip trays or containment areas under the machine can help contain spills, preventing slips, falls, or environmental hazards.

Fire Hazard Prevention: Hydraulic fluids are typically flammable. Using fire-resistant hydraulic fluids and ensuring that fluid containment systems are in place can minimize fire hazards.

Proper Fluid Disposal: Ensure that hydraulic fluids are properly disposed of or recycled according to local environmental regulations to prevent contamination.

4. Electrical Safety

Electrical Isolation: All electrical components, such as pumps, motors, and control systems, should be properly insulated and grounded to prevent electrical shock hazards.

Lockout/Tagout Procedures: Implement lockout/tagout (LOTO) procedures to ensure that the machine is properly shut down and cannot be restarted during maintenance or repair work.

Circuit Protection: Use circuit breakers and fuses to protect electrical systems from overloads and short circuits, which could cause fires or damage equipment.

5. Operator Safety and Training

Operator Training: Ensure that all operators are thoroughly trained on the safe operation of the machine, including how to recognize potential hazards and respond appropriately to alarms or emergency situations.

Safety Instructions and Signage: Provide clear and visible safety instructions and warnings on and around the machine. This includes labeling all high-pressure lines, moving parts, and electrical components.

Personal Protective Equipment (PPE): Operators should be required to wear appropriate PPE, such as gloves, safety glasses, and protective clothing, to reduce the risk of injury from moving parts, fluids, or electrical hazards.

6. Automation and Control System Safety

Interlocks: Use interlocks to ensure that the machine cannot operate unless all safety guards are in place and all conditions are met for safe operation.

Sensor Redundancy: Include redundant sensors and control systems to ensure that a failure in one part of the system does not lead to unsafe operation. For example, dual pressure sensors can prevent an unsafe rise in pressure if one sensor fails.

Programmable Safety Controllers: Modern safety controllers can be programmed to monitor various aspects of machine safety and automatically shut down the machine if unsafe conditions are detected.

7. Ergonomics and Human Factors

Ergonomic Design: The machine should be designed to minimize the need for manual intervention, reducing the risk of repetitive strain injuries or accidents caused by operator fatigue.

Accessible Controls: Ensure that controls are within easy reach of operators and are clearly labeled to reduce the chance of operator error.

8. Maintenance and Inspection

Regular Maintenance: Establish a regular maintenance schedule for all hydraulic and mechanical components to ensure that the machine operates safely and reliably. This includes checking for wear and tear, leaks, and proper operation of all safety devices.

Inspection Procedures: Periodic inspections should be conducted to identify potential issues before they become safety hazards. For example, hydraulic hoses should be checked for cracks, kinks, or signs of wear.

9. Risk Assessments and Compliance

Risk Assessments: Conduct a thorough risk assessment during the design phase to identify and mitigate potential hazards. This should include failure mode and effects analysis (FMEA) to predict how failures might occur and their potential impacts.

Regulatory Compliance: Ensure that the machine complies with relevant safety standards and regulations, such as those set by the Occupational Safety and Health Administration (OSHA) in the U.S., the European Machinery Directive, or other local governing bodies. Compliance with ISO standards, such as ISO 12100 for machine safety, should also be considered.

10. Emergency Response Planning

Emergency Shutoff and Alarm Systems: The machine should be equipped with alarms and shutoff mechanisms that trigger in the event of a malfunction, such as loss of hydraulic pressure or an electrical fault.

Fire Suppression Systems: Depending on the operational environment, consider integrating fire suppression systems to address any potential fire risks related to hydraulic fluid leaks or electrical failures.

Evacuation Plans: In the event of a major malfunction or hazard, there should be clear evacuation plans and procedures in place for the operators and other personnel in the area.

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Books: