GOVERNMENT POLYTECHNIC MIRAJ (0131)

A
Project Report On
“Automated Material Rejection System With Pneumatic
Piston” SUBMITTED BY :-

Sr.
Name Enrollment No. Roll No.
No.
1 Ayyaj Aslam Magdum 2001310228 20419
2 Tofik Sadik Mulla 2001310233 20424
3 Ayan Irfan Shaikh 2001310254 20445

UNDER THE GUIDANCE OF

Prof.A.M.Joshi

(Department of Mechanical Engineering)

 Government Polytechnic Miraj

MECHANICAL ENGINEERING
DEPARTMENT GOVERNMENT
POLYTECHNIC MIRAJ
CERTIFICATE

This is to Certify that the project report entitled “Automated Material

Rejection System With Pneumatic Piston” Was successfully completed by
Student of sixth semester Diploma in Mechanical Engineering

Sr.
Name Enrollment No. Roll No.
No.
1 Ayyaj Aslam Magdum 2001310228 20419
2 Tofik Sadik Mulla 2001310233 20424
3 Ayan Irfan Shaikh 2001310254 20445

in partial fulfillment of the requirements for the award of the Diploma in

Mechanical Engineering and submitted to the Department of Mechanical
Engineering of Government Polytechnic, Miraj work carried out during a
period for the academic year 2022-23 as per curriculum

Prof.A.M.Joshi Prof.A.M.Joshi Capt.Dr.N.P.Sonaje

(Guide) (Head of Dept.) (Principal)
 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my project guide

Prof.A.M.Joshi as well as our principal Capt.Dr.N.P.Sonaje who gave us the
golden opportunity to do this wonderful project on the topic Automated
Material Rejection System With Pneumatic Piston, which also helped me in
doing a lot of research and i came to know about so many new things I am
really thankful to them.
Secondly I would also like to thank my parents and friends who helped
me a lot in finalizing this project within the limited time frame.

Date :

Place :
 INDEX

Sr.
Name of Content Page No.
No.
1 Abstract
2 Introduction
3 Problem identification
4 Problem formulation
5 Working
6 Objectives
7 Present Status
8 Description of System
9 Expenditure
10 Conclusion
11 Reference
 Abstract

The pneumatic reject system is an essential part of modern production

lines. It is used to remove products that do not meet the required specifications
or are unwanted from the production line. The system works by using a
pneumatic piston, which is placed on the side of the conveyor. The size and
weight of the product determine the size of the pneumatic piston used.

When a product is detected that does not meet the required specifications,
the pneumatic reject system is activated, and the pneumatic piston pushes the
product off the conveyor and into a reject bin. The system is quick, reliable, and
accurate, ensuring that only the desired products reach the end of the production
line. One of the main advantages of using a pneumatic reject system is that it
reduces waste and increases efficiency.

It enables companies to produce high-quality products consistently,

reducing the need for manual inspection and removing the possibility of human
error. Additionally, the system is easy to install and maintain, making it a cost-
effective solution for companies looking to improve their production processes..
 Introduction

Conveyor system is one part of material handling equipment that

transports material from one place to another. Further the conveyor system can
also be used for the acceptance and rejection of material or product. Conveyors
are used in almost all industries where materials are to be moved. Automated
conveyor systems are proved to be very useful as cost labor wages and customer
demand is increasing at a great rate. This paper is based on the project which
uses a fully automated material handling system.

Reasons to select automated conveyor systems are:-

1) Saving in manpower.
2) Improvement in quality and efficiency.
3) Increment in consistency and Flexibility.

Manual handling of material could lead to the damage of the product; also
the worker who is to handle the material cannot determine the fault in the
product immediately by observing through naked eyes. This process is very
time consuming. Also there is the requirement of skilled workers.

So taking these problems into consideration, a fully automated material

handling system is developed. The material handling system uses a conveyor
belt for the movement of products. The design parameters such as belt speed,
length of the belt, design of pulley, motor selection is done.

IR Sensor is used to detect the presence of the product, which then allows
starting the conveyor belt.The system uses IR Sensors coupled to the base frame
which detects the size and movement of the product and sends the information
to the Microcontroller unit. A microcontroller is used to receive the signal from
the IR Sensor and to give the signal to the Pneumatic actuator.

This is done by using infrared sensors coupled with a microcontroller

unit. There is synchronization between the speed of belt and actuator. Further
the micro controller gives the signal to the actuator whether to plunge the
product towards the rejecter bin or to allow it to pass towards the accepter bin.
This automation reduces time and improves the material handling speed as
compared to manual handling and inspection.
 Scope Of The Project

The scope of the Automated Material Rejection System with Pneumatic

Piston is significant, as it aims to improve the quality and efficiency of
industrial production lines by automating the material rejection process. The
system uses advanced sensors and algorithms to detect defective materials in
real-time and automatically reject them using a pneumatic piston.

The primary objective of the project is to reduce production downtime

and minimize the cost of manual inspection and material handling. By
automating the material rejection process, the system can identify and remove
faulty materials quickly, reducing the time and resources required for manual
inspection and material handling.

The system's use of advanced sensors and algorithms ensures that it can
detect and reject faulty materials with a high degree of accuracy, improving the
overall quality of the final product. The use of a pneumatic piston system
enables the system to physically eject defective materials from the production
line, ensuring that only defect-free materials are used in the manufacturing
process.

The system's scope also includes providing real-time data analytics and
insights that can be used to optimize production processes and improve the
system's performance. The data collected by the system can be used to identify
trends and patterns in the material rejection process, enabling manufacturers to
optimize their production processes and reduce the overall cost of production.

The system's flexibility and customizability make it suitable for a wide

range of industries that handle high volumes of materials and require a reliable
and accurate material rejection system. The system can be integrated into
existing production lines with minimal disruption, providing an efficient and
effective solution for manufacturers looking to improve their production
processes' quality and efficiency.

Overall, the scope of the Automated Material Rejection System with

Pneumatic Piston is vast, providing a comprehensive solution to improve the
efficiency, quality, and cost-effectiveness of industrial production lines. The
system's integration into existing production lines will have a significant impact
on the manufacturing industry, providing a reliable and accurate material
rejection system that will enhance the production process's overall quality and
efficiency.
 Methodology

1) Define the problem and goals: Identify the problem that the
automated material rejection system will address and the specific goals
that the system should achieve. For example, the system may need to
detect defective materials and automatically remove them from the
production line to prevent them from being used in the final product.
2) Determine the system requirements: Determine the specific
requirements of the automated material rejection system, including the
detection method, the speed of operation, the accuracy of detection,
and any other relevant factors.
3) Select the appropriate components: Based on the system
requirements, select the appropriate components for the system,
including the pneumatic piston, sensors, valves, and other necessary
parts.
4) Design the system: Using the selected components, design the
automated material rejection system. This will involve creating
schematics and layouts of the system and determining the sequence of
operation.
5) Build the system: Once the system design is finalized, build the
system by assembling the components and installing them in the
appropriate locations.
6) Test the system: Test the system to ensure that it meets the required
specifications and functions as intended. This will involve testing the
detection and rejection capabilities of the system, as well as the speed
and accuracy of operation.
7) Refine and optimize the system: Based on the results of the testing,
refine and optimize the system as necessary to improve its
performance and ensure that it meets all required specifications.
8) Document the system: Document the design and operation of the
automated material rejection system, including any modifications
that were made during the refinement process.
9) Implement the system: Implement the system in the production
environment, ensuring that all necessary training and
maintenance procedures are in place to ensure the system
operates correctly.
10) Monitor and maintain the system: Regularly monitor and maintain
the automated material rejection system to ensure that it continues to
operate effectively and efficiently over time.
 Problem Identification

Sorting good and bad material is a crucial part of the production process
for many industries. However, relying on manual labor to carry out this task can
lead to a range of issues, including delays, errors, and safety hazards. When a
worker is responsible for sorting materials on a fast-moving conveyor belt, they
can easily become overwhelmed, leading to a decrease in the efficiency of the
process.

Moreover, workers may struggle to maintain focus and accuracy when

sorting materials for extended periods, leading to errors in sorting that can affect
product quality. Additionally, sorting materials manually is a labor-intensive
task that can take more time than an automatic system, leading to lower
productivity and increased labor costs.

On the other hand, automating the sorting process can significantly

improve efficiency, accuracy, and speed. By using advanced sensors and
software, an automated system can quickly detect and sort materials with
minimal human intervention, reducing the risk of errors and delays. The system
can also operate at high speeds, sorting thousands of products per hour, thereby
increasing productivity and reducing labor costs.

Furthermore, an automated sorting system can improve workplace safety

by reducing the need for workers to sort materials manually, reducing the risk of
accidents and injuries. This, in turn, can lead to a decrease in workers'
compensation claims and an increase in overall productivity.
 Problem Formulation

The sorting process requires a reliable and efficient system to ensure that
only acceptable materials make it to the next stage of production. To
accomplish this, a material rejection system is utilized at the sorting station.
This system employs sensors and actuators to quickly identify and remove
unacceptable materials from the conveyor, ensuring that only the good materials
are directed towards the acceptor bin.

The system uses three sensors that measure the height of the materials
passing through the conveyor. Based on these measurements, the system can
identify and sort the acceptable and unacceptable materials. When an
unacceptable material is identified, a pneumatic piston cylinder assembly is
activated to push the material off the conveyor and into a reject bin.

The use of pneumatic piston cylinder assembly provides a reliable and

efficient way of pushing the unacceptable materials off the conveyor. This
technology is designed to quickly and effectively remove the materials without
causing any damage to the conveyor or the materials themselves.
 Working

The accuracy of product dimensions is a critical aspect of manufacturing,

as even a small deviation can result in product defects and quality issues. In
order to ensure accurate product dimensions, a system has been developed that
utilizes an IR sensor to measure the vertical height of products on a conveyor
belt.

The system works by using an IR sensor to detect the presence of a

product on the conveyor belt. When a product is detected, the motor connected
to the driving pulley is activated, causing the conveyor belt to move forward. As
the product moves along the conveyor belt, it passes over the IR sensor, which
measures its vertical height. The measured height is then compared to a
specified dimension by a microcontroller.

If the measured dimension matches the specified dimension, the product

is allowed to continue on its path towards the acceptor bin. However, if the
measured dimension does not match the specified dimension, the
microcontroller sends a signal to a pneumatic actuator. The pneumatic actuator
then pushes the non-conforming product off the conveyor belt and into a
rejecter bin.

This system provides a reliable and efficient way to ensure the

dimensional accuracy of products, reducing the risk of defects and improving
overall product quality. By utilizing advanced sensing and actuation technology,
the system can quickly and accurately detect and remove non-conforming
products, leading to increased efficiency and productivity in the manufacturing
process.
 Applications
1) Manufacturing industry: The system could be used in a
manufacturing plant to detect and remove defective materials from the
production line. This could help to improve the overall quality of the
final product and reduce waste.
2) Food industry: The system could be used in the food industry to
detect and remove contaminated or spoiled food products from the
production line, ensuring that only safe and high-quality food is
delivered to consumers.
3) Pharmaceutical industry: The system could be used in the
pharmaceutical industry to detect and remove faulty or contaminated
pills or capsules from the production line, ensuring that only safe and
effective drugs are delivered to patients.
4) Packaging industry: The system could be used in the packaging
industry to detect and remove damaged or misaligned packaging
materials from the production line, ensuring that products are properly
packaged and protected during shipping.
5) Recycling industry: The system could be used in the recycling
industry to sort and separate materials based on their composition,
allowing for more efficient and effective recycling processes.
6) Agriculture industry: The system could be used in the agriculture
industry to sort and separate crops based on their quality, ensuring
that only high-quality crops are sold to consumers.
 Objectives

Our objective of this project is as follows :-

1) To automate the material rejection process in industries to
improve efficiency and reduce human error.
2) To detect and reject faulty materials in real-time using sensors
and advanced algorithms.
3) To use a pneumatic piston system to physically reject the faulty
materials from the production line.
4) To reduce production downtime and minimize the cost of
manual inspection and material handling.
5) To increase the quality of the final product by ensuring that
only defect-free materials are used in the manufacturing
process.
6) To provide a flexible and customizable solution that can be integrated
into existing production lines with minimal disruption.
7) To improve workplace safety by removing the need for
manual intervention in the material rejection process.
8) To provide real-time data analytics and insights that can be used
to improve production processes and optimize the rejection
system's performance.
9) To reduce the overall cost of production by minimizing waste and
ensuring that only high-quality materials are used in the
production process.
10) To provide an efficient and effective solution for industries that
handle a high volume of materials and require a reliable and accurate
material rejection system.
❖ Main Parts of Machine :-
➢ Conveyor belt
➢ Selection bin for the good products
➢ Rejection bin for the defective products
➢ Motor
➢ Sensor unit
➢ Pneumatic actuator
➢ Control system
➢ Air compressor
➢ Power supply for all systems.
➢ Interface components such as buttons, switches, for controlling
the system.
 Description of System Components

1) IR Sensor :-

An infrared sensor is an electronic instrument which is used to senses

certain characteristics of its surroundings by either emitting and/or detecting
infrared radiation. An IR sensor consists of a transmitter and a receiver. The
transmitter transmits the infrared rays while the receiver receives the transmitted
rays.
The IR sensor detects the material if present on the conveyor and then
only sends the signal to start the conveyor system. The second use of an IR
sensor is to measure the vertical dimension of the object. The IR sensor is
placed at a desired height of the material. Below which material can pass
without reflecting the IR rays. If the material size is above the predefined size
then the rays will be reflected back to the receiver and the receiver will send the
signal to the microcontroller for further rejection of material by actuation.

2) Microcontroller :-

The function of a microcontroller is to receive the signals given from the

IR sensor and further gives the signal to the actuator. There is the
synchronization between the object speed and the actuator and this
synchronization is made using belt speed. Microcontrollers have a very
important role in the actuation of pneumatic actuator.The microcontroller used
in this paper is Arduino Uno.
3)DC Motor :-

For transmission to belt we use Lucas

TVS Starter Motor
The motor specification is as follows:
Brand Name:Lucas TVS
Phase: Single Phase
Material : Cast Iron
Power :5hp

4) Conveyor Belt :-

The conveyor belt used here consists of two pulleys with a continuous
chain of product. One of the wheels is powered by a 5hp motor, moving the belt
and the material on the belt goes forward.
Specifications of belt are:
Type of belt = Flat Belt
Material used = Nylon
5)Pneumatic Actuator :-

Pneumatic actuator used here is Double acting, With stainless piston rod.
 Expenditure

Sr. Name of component Price

No.
1 Conveyor Table and Belt Rs.3000
2 Motor Rs.4000
3 Micro controller Rs.750
4 2 metal boxes Rs.500
5 All electronic components Rs.1100
6 Pneumatic Piston and solenoid valve Rs.3800
7 Air compressor Rs.7500
8 Welding and drilling machine (rent) Rs.800
9 Colour Rs.500
Total : Rs.21950
 Conclusion

The developed model of automatic material sorting is an excellent

innovation in material handling applications due to its working principle and
wide implementation. This system is highly efficient and effective in sorting the
required product according to its demand, providing a reliable and cost-effective
solution to the manual-based tasks and operations. As the system does not
involve any manual labor for sorting of products, it reduces the manpower cost
and time, thereby increasing productivity.
The automated material sorting system is capable of sorting large
quantities of materials quickly, reducing the handling and inspection time to
minimal. With its fast and accurate sorting capabilities, the system can also
identify defects in materials, which helps to maintain the quality of the final
product.
While there are some limitations to the system, its flexibility allows for
certain modifications to be made to eliminate these limitations. The construction
of the system is flexible in nature, which means that various sensors can be used
to detect different faults in the material, making it highly adaptable to various
material handling applications.
The developed model of automatic material sorting system can be
implemented in various industries such as the packaging industry, industrial
quality checks, and production lines to check the dimensions of the product. It
can also be used in other applications where sorting and quality checking of
materials are required..
 Future Scope

The future scope of the Automated Material Rejection System with

Pneumatic Piston is bright and promising, as it has the potential to revolutionize
the manufacturing industry. As technology continues to advance, the system can
be further enhanced to provide even greater accuracy and efficiency in detecting
and rejecting faulty materials.
One of the key areas of future development is the use of artificial
intelligence and machine learning algorithms to improve the system's
performance. By analyzing the data collected by the system, AI and ML
algorithms can identify patterns and trends that can help optimize the material
rejection process, making it even more efficient and effective.
Another area of future development is the integration of the system with
other production line systems, such as quality control systems and inventory
management systems. This will enable manufacturers to create a fully
automated production line, eliminating the need for manual intervention and
increasing the overall efficiency of the production process.
The use of advanced sensors and cameras will also play a critical role in
the system's future development. As these technologies continue to advance,
they will enable the system to detect and reject even more complex defects,
further improving the quality of the final product.
The system's future scope also includes the potential to reduce the overall
cost of production. By automating the material rejection process, manufacturers
can reduce the need for manual labor and minimize the cost of material
handling and inspection. This will help to increase profitability and
competitiveness in the global manufacturing market.
Overall, the future scope of the Automated Material Rejection System
with Pneumatic Piston is vast, providing numerous opportunities for further
development and innovation. As technology continues to evolve, the system's
capabilities will continue to improve, providing manufacturers with a powerful
tool to improve the quality and efficiency of their production processes.
 References
References we used are some websites shown in table below:

Sr.
Name of website URL of website
No.

1 iosrjen https://iosrjen.org

2 LearnMech https://learnmech.com

3 Inst Tools https://instrumentationtools.com