Cftri RD
Cftri RD
Cftri RD
Submitted to
Ministry of Food Processing Industries Government of India, New Delhi By CENTRAL FOOD TECHNOLOGICAL RESEARCH INSTITUTE, MYSORE 570 020
CONTENTS
Page No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. MFPI Final project completion Report format Scientific impact Research work carried out during the project period: Introduction Design considerations Auto grain weigher figures Fabrication and assembly of Auto grain weigher Auto grain weigher assembly figures Calibration & performance evaluation of Auto grain weigher Results Comparison of set weight and measured weight of wheat Conclusion & References Project team & Utilization certificate 3 8 9 10 14 17 18 23 24 25 26 28
Email: [email protected]
4. Total grant sanctioned and expenditure during the entire tenure
Expenditure Head
Amount in Rupees 1st Year 2nd Year Nil Nil Nil Nil Nil 0
*Borne by CFTRI
5. Name
Equipment(s) purchased out of MFPI grant Cost in Rupees Rs.488095=00 + Sales tax @ 12.5%
Low cost servo based PLC operated grain / grain products weigher for Flour Mill Industry
Copy of UC, list of equipments and list of project team members are enclosed as Annexure-III 6. Research fellows associated with scheme: Date of joining 28/01/2008 Date of relieving 30/04/2008
List of research papers published / communicated, based on the research work done under the scheme (Name(s) of author(s), Title, Journal, Volume number, Year and pages): Development & performance evaluation of low cost, servo based PLC operated grain / grain products automatic weigher for Flour mill industry Under preparation
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Details of new products developed/apparatus or equipment designed or Constructed / test developed etc., during the investigation: The project work resulted in development of low cost, servo based automatic grain weigher on a laboratory scale and has the potential to be scaled up to commercial levels.
Sl. Description No. 1 Low cost, servo based PLC Capacity Accuracy Power consumption * Cleaned and dry wheat with bulk density of 750 Kg / m 3
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Technical specifications
The equipment works on the basic principle of batch weighing. Working flow diagram is as shown in the Figure.1. Raw material to be
weighed is automatically fed to the weighing hopper through a quantity regulating servo slide. The movement of the slide is controlled by precision linear motion guide way assembly which is driven by brushless servo motor. Feeding of the material from the collection hopper to the weighing hopper is done in coarse and fine feed. Automatic weighing cycle starts with wide
opening of the servo slide followed by weight register by the load cells. During rapid movement of the servo slide, more quantity of material is passed to the weighing hopper. As the weight of the weighing hopper is nearing to the set weight, servo slide moves slowly to provide fine feeding of the grain. As soon as the weight of the material in the weigher hopper achieves the set value, the servo gate of the storage hopper closes and the weigh hopper gate opens to discharge the set quantity of material on to a downstream process line. Micro controller registers and updates the exact quantity of material
discharged. When the weigh hopper becomes empty, weigh hopper gate closes and the storage hopper servo slide opens for the next weighing cycle. Granular product
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The likely impact of the completed work on the scientific / technological potential in the country Enclosed as ANNEXURE-I
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Whether work for patenting has been initiated? Yes/No; if yes, what action has been taken and if not, its reason thereof: No Technology know how entitled Design & Development of low cost, servo based PLC operated grain / grain products automatic weigher for Flour mill industry has been filed to PDRU, CFTRI
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Detailed account of the work carried out in terms of the objective(s) of the project and how far they have been achieved; Objectives as stated in the project proposal: Design & Development of low cost servo based PLC operated proto type automatic weighing machine Trial run of the machine Performance Evaluation of the machine Feasibility study of the machine for weighing of semolina and Flour before packing Year wise targets for the project and progress made against the same Year Targets Progress made / achieved
(a) Preparation of conceptual design All the targets achieved (b) Preparation of fabrication as per schedule (See drawings Annexure-II) (c) Raw material procurement (d) Servo/stepper control, PLC unit, ball screw, precision slide assembly, procurement
(a) Assembly of fabricated items All the targets achieved (b) Assembly of hopper precision as per schedule (See slide gate, timer belt and pulley, Annexure-II) proximity switches, limit switches (c) Trial run of equipment and modifications if any (d) Evaluation of the system and final report preparation Detailed account of the work carried out during the project period: Enclosed as ANNEXURE-II
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Abstract of research achievements In flour mill industry weighers & weighing mechanisms are to be very accurate. Without this accuracy, extraction figures are meaningless. Weigher is the necessity of a flour mill either to weigh the clean wheat before the 1st break rolls or to weigh the final products to calculate extraction rate. Low cost automatic weighing machine using latest technology of servo control and Programmable Logic Control (PLC) was designed and developed considering the advantages of electronic weighing and linear motion guide ways moving accuracies. The results of studies carried out for automatic weigher indicated that the equipment could be used as weigher in Flour mills. Statistical analysis indicated that there was no significant difference in mean value of measurements from set weights (1500, 3500, 5000 grams) and measured weights at the 95% probability level. Minimum average percentage error (< 0.2%) was observed for 3500, 4000, 4500 and 5000 grams weight measurements. Weight measurements on the dispensed material under
repeatability conditions produced results within 0.22% of displayed set weight for 3000, 3500,4000, 4500 and 5000 grams revealed that weighing of product by auto grain weigher was very precise. Automatic weighing
equipment can be successfully used for weighing and dosing of any granular products into bags, containers in automated production processes. 13. Mention here whether or not the unspent grant has been refunded to MFPI: Unspent grant refunded to MFPI (DD No. 870456 dated 30.10.2009) on 03.11.2009 14. UC as per Annexure-D submitted? Yes/No: Yes
Date: 11.11.2009
ANNEXURE I
Impact of the completed work on the scientific / technological potential in the country
The current frontier in the flour milling industry is to either weigh the clean wheat before the 1st break rolls or to weigh the final products to calculate extraction rate. Rate of extraction can have a considerable effect on the production cost of the flour. From an overall manufacturing cost stand point, the output per hour or 24 hours can affect the profitability of the whole of operation of the mill. Mechanically
operated auto grain weighers are obsolete and maintenance oriented. New level of resolution in automation technology leads to the need for design and development of state of art technology i.e. low cost automatic weighing machine using latest technology of servo control and Programmable Logic Control (PLC) concepts. Electronic weighers are sophisticated and calibrate themselves by using built in calibration procedures and save the data themselves. Linear motion guide ways accompanied with precision ballscrew greatly enhance moving accuracy. Equipment developed in conjunction with latest servo drive, PLC, linear motion guide ways, load cells and micro controllers have unique potential to make precision weighing. In this endeavor there is huge potential for incorporating servo technology for various machineries in the field of grain milling. Automatic weigher followed by bagging machine can be used as packer in the packaging line to pack granular product of any range between minimum to maximum of designed weighing capacity.
automatic grain weigher (Shimauchi, 2000) consisted of mechanical gate to provide feed opening/closing for easy handling on the completion of the weighing operation. Solenoid valve and lever mechanism operates gate mechanism which leads to wear and tear of links, arm knife edges etc., two positions either open or close affects the weighing accuracy. Automatic grain weighing machine (Okada & Shimauchi, 2001)
consisted of hopper, weigher with hooks arrangements for empty bag & drop hole mechanism. Full open to half open or full close of the gate operated through drop
hole mechanism was used to fill the specified quantity of matter into the bag which affects the accuracy of weighing. Continuous monitoring of set weight and matter feeding was absent. Conventional filtering methods employed in dynamic weighing systems have limitation in improving accuracy and throughput rate (Halimic, Balachandran & Enab, 1996). Fluctuations in the bulk density of the raw materials in volumetric or rotary charger dosing results in alterations in weight (Efremenkov, Subbotin & Khaimovich, 2001). Weighing machines equipped with platform scales or beam balances with dials do not ensure the required accuracy of weighing batch materials (Efremenkov et al, 2003). Mechanical scales are not reliably precise and their applications in automatic lines are complicated (Bubulis, Jurenas & Kranclukas, 2005). Mechanically operated autograin weighers are obsolete and maintenance oriented. Electronic weighers are sophisticated and calibrate themselves by using
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built in calibration procedures and saves the data themselves (Gustavo Gonzalez & Angeles Herrador, 2006). Load cells are widely used in a variety of industrial weighing applications such as wending machines and weighing systems (Jafaripanah, Al-Hashimi & White, 2004). Load cells interfaced with integrated
electronics convert the weight force to an electric signal and deliver the output signal to an automation system (Udo, 2002). Linear motion guide ways accompanied with precision ballscrew can greatly enhance moving accuracy. Hence, considering the advantages of electronic weighing accuracy and Linear motion guide ways moving accuracy, the present project was undertaken to design and develop state of art technology i.e. low cost automatic weighing machine using latest technology of servo control and Programmable Logic Control (PLC) concepts. 2.0 2.1 Materials and Methods Materials Raw materials used were stainless steel sheet metal (SS 304), Indian standard medium channel, mild steel square tube, load cells, Hopper weighing controller ( IPA, Bangalore, India), Linear motion guide ways(Hiwin, Taiwan), AC Servomotor & drive, PLC, Control panel with PLC & Junior MMI (L & T Chennai, India) were purchased from Balaji Autotech Pvt. Ltd. Mysore, India. 2.2 Design consideration
2.2.1 Storage and weigher hoppers Storage and weigher hoppers were designed for 25kg & 5 kg holding capacity respectively by considering density of wheat as 750kg/ m 3 and shape of the hopper as trapezoidal. Volume (Vol) of hopper was calculated using equation (1) Mass Vol = Density Height (H) of the hopper was calculated by using equation (2) Vol of trapezoidal hopper = H (A1 + A2 + A1A2) 3 Where A1= Area of bigger end of hopper (Inlet length x width) A2= Area of smaller end of hopper (outlet length x width) H= Height of hopper
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(1)
(2)
Weight of hopper was calculated by equation (3) Weight of hopper = Vol of trapezoidal sheet metal * Density of sheet metal Total Vol of sheet metal was calculated using equation (4) Total Vol = (Vol of trapezoidal sheet metal)(No. of sides) Vol of trapezoidal sheet metal = (Area of trapezoidal sheet) (thickness) Area of trapezoidal sheet = 1 (X + Y)C 2 Where X & Y are lengths of parallel sides C = Height of trapezium Weight of hopper was calculated by using equation (5) Weight of hopper = (Vol of sheet metal) (density of metal) (5) (4) (3)
2.2.2 Load cells Load cell capacity was calculated by considering the weight of weigher hopper, discharge material weight, weigher hopper location pins and weigher hopper pneumatic gate. Load cell capacity = (weight of weigher hopper+ discharge material weight + weight of location pin+ weigher hopper pneumatic gate) Load cells were selected for safe overload of 150% and ultimate overload of 200% of the rated load
2.2.3 Pneumatic cylinder Double acting piston pneumatic cylinder was selected for the operation of weigher hopper. In-stroke force of pneumatic cylinder was calculated by equation (6) P (d12 - d22) F1 = --------------------------4 Where F1 =In-stroke force P=Pneumatic cylinder air pressure d1=Bore diameter of cylinder d2=Piston rod diameter
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(6)
Out-stroke force of pneumatic cylinder was calculated by equation (7) P d12 F2 = --------------4 Where F2 =Out-stroke force P=Pneumatic cylinder air pressure d1=Bore diameter of cylinder (7)
2.2.4 Linear motion guide ways Linear motion guide ways series suitable for lathe applications were selected from Hiwin catalogue. Model size was determined based on ball screw diameter used. Four numbers of Linear guide ways blocks were considered. Loads acting on guide ways were calculated by equation (8) Wh P= 2d 2d F l (8)
Where P= Loads acting on guide ways W= Weight on blocks h= weight height from guide ways F= Acting force l= Acting force distance d= Distance between blocks Critical load acting on block was calculated by equation (9) Pc = Pmax + Pz Where Pc= Calculated load Pmax = P (Maximum load) Pz = Pre load (9)
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Nominal life of the guide ways was calculated by equation (10) Fh Ft C L= Fw Pc x 50 km (10)
Where L=Nominal life Fh =Hardness factor Ft =Temperature factor C =Basic dynamic load rating Fw =Load factor Pc =Calculated load Km =kilometer
2.2.5 Equipment The Automatic system designed and developed for weighing grain / grain products is shown in Fig.2. Inside view and isometric views of Auto grain weigher are shown in Fig.3 & 4. Automatic grain weighing equipment consisted of storage hopper (Approx. 0.04m3 capacity, sheet metal thickness 3.5 mm, 100 mm Square bottom opening), quantity regulating servo slide, linear motion guide ways with precision ball screw (20 mm width, 17.75 KN dynamic load rating, 37.84 KN static load rating, 16 mm diameter ballscrew), AC Servomotor (1.27 Nm torque, 3000 rpm, 400 watts) with drive (220 volts, single phase), weighing hopper (5 kg capacity, sheet metal thickness 2.5 mm, 75 mm square bottom opening), load cells (10 kg capacity), weighing control (Micro controller, 16-character, 2-line LCD display), programmable logic controller (Micro PLC, 16/12 digital Input / Output) and pneumatic cylinder (6 Bar operating pressure) with gate, supporting structure-1 for storage hopper (1.4meter height, 0.53meter square length & width), and Supporting structure-2 for weigh hopper (0.05 meter square pipe, 0.7 meter height, 0.38meter square length & width).
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2.3
Methods
2.3.1 Fabrication and assembly of Auto grain weigher Sheet metal work and welding was carried out to manufacture storage hopper, and weigher hopper using stainless steel (SS 304) sheet metal. Hopper gates assembly were manufactured by using mild steel plates with chromium plating. Bearings were used for frictionless sliding movement. Supporting structure channels (ISMC-75) were cut to a length of 1.4meter and storage hopper supporting frame (0.53 square meters) was fabricated. Storage hopper and LM guide ways were assembled on supporting structure as shown in Fig.5. Mild steel square pipe (0.05
square meters) were cut to a length of 0.7meter and weigher hopper supporting frame (0.38 square meters) was fabricated. Load cells were assembled on weigher hopper supporting frame. Weigher hopper location pins were manufactured and fastened to the weigher hopper (Fig.6). Weigher hopper location pins were aligned with load cells and mechanical stoppers were adjusted. Double acting piston
pneumatic cylinder was connected to the weigher hopper gate and pneumatic connection was provided (Fig.7). AC servomotor was coupled to the ball screw of LM guide way. Position limit switches and reader micro switch were assembled on aluminum track which was mounted on LM guide way (Fig.8). LM guide was
connected to storage hopper gate by suitable bracket. Control panel with micro controller and necessary electrics was interfaced with load cells (Fig.9 & 10). PLC, MMI, AC servo drive and electrics were assembled in a panel and inter faced with servo motor and micro controller (Fig.11 & 12). Auto grain weigher was assembled as shown in General arrangement Fig.13.
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Figure 6. Storage hopper slide gate, weigher hopper & of Auto grain weigher
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Figure 8. Linear motion guide ways with precision ball screw, Limit switches, reader limit switch & servo motor assembly of Auto grain weigher
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Figure 11. PLC & Servo drive assembly of Auto grain weigher
Figure 12. Man machine interface (MMI) touch panel of Auto grain weigher
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2.3.2 Calibration of the weighing system Calibration of the system involved two methods as tare and auto calibration. Empty weigher hopper was ensured before tare operation. After tare, known amount (rated capacity of 5 Kg) was placed in the weigher hopper and value of the load in the hopper was entered in the micro controller using numeric keys. Value displayed on microcontroller was calibrated value.
2.3.3 Operation of equipment Material to be weighed was fed to storage hopper. PLC parameters like Gate open constant weight, gate open speed, feed weight, gate feed speed, gate close rapid speed and weight time for door close were entered using man machine interface touch panel. Zero limit, set high, zero delay, over load, auto/manual, set delay and span load parameters were programmed on micro controller. Pneumatic pressure in the pneumatic line was confirmed to the required value. Weighing cycle operation was carried out by pressing F1 (cycle start) key on MMI touch pad.
2.3.4 Equipment performance evaluations Performance evaluation of the equipment was carried out by operating the equipment to weigh 500, 1000, 1500, 2000, 2500, 3000, 3500, 4000, 4500 and 5000 grams. Discharged material from the weigher hopper was weighed on Essae
Teraoka Ltd., model: PG 10000 electronic balance. Repeatability limit was calculated by using equation (11) Repeatability = 1.96 (2 Sr2) Where Sr = Repeatability standard deviation 2.3.5 Statistical analysis One way analysis of variance (ANOVA) was carried out to test for any significant differences in the mean values of all the groups by using Microsoft Excel. (11)
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3.0
Results Conceptual design was carried out and fabrication drawings were prepared.
Assembly of fabricated items and bought out items was carried out and trial run of the equipment was conducted. Evaluation of the system was done by taking wheat for weighing experiments which had the following characteristics on dry basis: 9% moisture, 76 kg per hectoliter weight, 32 grams per 1000 kernel weight and hardness value of 10kg per grain. Above parameters indicated that wheat used was medium hard type. Table1. shows comparison of set weights and measured weights of
wheat samples from 1000 grams to 5000 grams with an incremental value of 500 grams. P-values for 1500, 3500, 5000 grams were 0.889, 0.068 and 0.48 respectively. Fstatistical values for 1500, 3500, 5000 grams were 0.019, 3.766 and 0.507 respectively. Fcritical values for 1500, 3500, 5000 grams were 4.414, 4.414 and 4.098 respectively. Fstatistical < Fcritical and P-values > 0.05, there is no statistical difference in mean value of measurements from set weights and measured weights. For 1000, 2000, 2500, 3000, 4000 and 4500 grams, P-values > 0.05 and Fstatistical > Fcritical indicated that there is a significant effect due to weight measurements at the 95% probability level. Differences could be minimized by proper tuning of storage hopper gate open speed, feed speed and close rapid speed parameters. Average percentage error was observed from 0.1% to 0.6%. Minimum average percentage error (< 0.2%) was observed for 3500, 4000, 4500 and 5000grams weight measurement. Maximum average percentage error (>0.2% and <0.6%) was
observed for 1000, 1500, 2000, 2500 & 3000 grams weight measurement. This could be further minimized by altering the position of reader limit switch and by tuning of storage hopper gate open speed, feed speed and close rapid speed parameters. Weight measurements on the dispensed material under repeatability
conditions produced results within 0.22% of displayed set weight for 3000,3500,4000,4500 and 5000 grams. Repeatability of greater than 0.22% was observed for 1000, 1500, 2000 and 2500 grams displayed set weights which were due to material weighing speed. Improve in repeatability limit could be possible by slowing down weigh up cycle.
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Table 1. Comparison of set weight and measured weight of wheat Weight set (Grams) Sl. No. 1000 1500 2000 2500 3000 3500 4000 4500 5000
Measured values (Grams) 1 2 3 4 5 6 7 8 9 10 Max. Min. Average Standard Deviation Error (%) p-value Fcrit Fstat df Repeatability 1016.2 1000.6 1006.8 4.8 0.6 0.0002 4.414 20.289 19 13.3 1510.6 1493.7 1499.8 5.1 0.26 0.889 4.414 0.019 19 14.14 2015.1 1980.2 1991.5 9.2 0.57 0.009 4.414 8.423 19 25.5 2508.9 2483.9 2494.8 6.6 0.28 0.023 4.414 6.103 19 18.3 3016.6 3000 3008.3 4.8 0.27 3.2E-05 4.414 30.273 19 13.3 3511.6 3495.1 3502.6 4.3 0.1 0.068 4.414 3.766 19 11.91 4010.5 3999.6 4005.5 3.8 0.13 0.001 4.414 20.244 19 10.53 4504.4 4488 4495 4.8 0.13 .003 4.414 11.055 19 13.30 5015.9 4988.2 5001.1 7.0 0.2 0.48 4.098 0.507 39 19.40
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4.0
Conclusion The results of studies carried out for the Design & Development of low cost,
servo based PLC operated grain / grain products automatic weigher indicated that the equipment could be used as weigher in Flour mills. Statistical analysis indicated that there was no significant difference in mean value of measurements from set weights (1500, 3500, 5000 grams) and measured weights at the 95% probability level. Minimum average percentage error (< 0.2%) was observed for 3500, 4000, 4500 and 5000grams weight measurements. Weight measurements on the
dispensed material under repeatability conditions produced results within 0.22% of displayed set weight for 3000,3500,4000,4500 and 5000 grams revealed that weighing of product by auto grain weigher is very precise. Automatic weighing
equipment can be successfully used for weighing and dosing of any granular products into bags, containers in automated production processes.
Acknowledgements The project team thanks Ministry of Food Processing Industries for partial funding of the project. Thanks to Director, CFTRI for encouragement and permission to carry out the project work.
5.0
References
Bubulis, A., Jurenas, V., & Kranclukas, R., (2005). Research and development of dosage devices for powdery products. Mechanika 6, 56. Efremenkov, V.V., Subbotin, K.Yu., & Khaimovich, M.M., (2001). A system for dosed feeding of batch and cullet into a glass-melting furnace, Glass and Ceramics 58, 195-196. Efremenkov, V.V., Subbotin, K.Yu., Klimychev, V. N., Ruchkin, V.V., & Khaimovich, M.M., (2003). Upgrade of Electric weighing cars. Glass and Ceramics 60, 129-130.
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Gustavo Gonzalez, A., & Angeles Herrador, M., (2007). The assessment of electronic balances for accuracy of mass measurements in the analytical laboratory. Accredited quality assurance 12, 21-29. Halimic, M., Balachandran, W., & Enab, Y., (1996). Fuzzy logic estimator for dynamic weighing system. IEEE Xplore 0-7803-3645-3/96. Jafaripanah, M., Al-Hashimi, B.M., & White, N.M. (2004). Design consideration and implementation of analog adaptive filters for sensor response correction.In Proceedings of the ICEE, Iran. Okada., & Shimauchi., (2001). Automatic grain weighing machine, JP20011657562001-06-22. Shimauchi., (2000). Feed shutter for automatic grain weigher, JP2000053101-200002-22. Udo, M., (2002), http://www.imeko.org/publications/tc3-2002/IMEKO-TC3-2002-
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http://www.hiwin.com/pdf/lg/0809/HiwinLinearGuidewayCatalog_G99TE13-0809.pdf
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ANNEXURE III
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Project Team 1. 2. 3. 4. Mr. G.H. Gangadharappa Dr. P Prabasankar Mr. Basavaraj Mundalamani Mr. R. Prashanth Principal Investigator Co-Investigator Team member Project Assistant
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