ICTS-The arrival of the actual conveyors

Enviro send over the CvB(6 foot), CvC (12 foot), and CvD (12 foot) yesterday. Infact they had an option not to send them yet as we agreed on terms that we can only get if the RM18K checkque is ready. However, since they trust us (Oversea), so they keep their promise to complete the job before end of the month and send it over even we are not ready yet. As a matter of facts, the payment has been arranged already. Its a matter of checkque signatures and quality inspection that delay the payment.

Anyway, after observing and testing the new conveyors, we found several discrepancies from the actual design. Here are they :
1- The width. The design width is 150mm including the sides aluminum profile. This is simply because the diagonal length of the big mooncake trays is about 130mm. Considering the aluminum profile sides is about 10mm each, so the total width should be about 150mm. However, the new built conveyor total width is 220mm. They fabricate a 150mm with belt with additional 30mm both sides as aluminum support profile, adding unnecessary 60mm width for a total width of 220mm. The good thing about this is we get a bigger conveyor for a small conveyor cost. This is OK for future expansion or product size variations. The bad thing is for this application, we have to add some sort of guides just to ensure that the mooncakes is aligned at respective position which is extra job for us.
* THIS PROBLEM IS DUE TO THE STANDARD SIZE OF THE END ROLLER THAT DOESNT REALLY MATCH OUR REQUIREMENT OF 150mm TOTAL WIDTH. THE NEXT SMALLER ONE IS LESS THAN 120mm REQUIRED BELT WHICH IS NOT WIDE ENOUGH FOR OUR APPLICATION.

2- The belt. As promised, this time we get a glossy white belt. The old conveyors are nonglossy green and a bit more sticky. While the green conveyors are a bit thicker and flat, the white glossy are thinner and not fully flat. Both sides of the white belt are wrinkled a bit and not smooth. What more the belt are not tighten yet.
* THE BELT SHOULD BE FLATTEN ENOUGH ONCE IT IS TIGHTEN ACCORDINGLY.

3- The speed. New conveyors run much faster than the previous conveyors. The the old one can run up to 13m/min, the new one should be more than 15m/min.
* THE ACTUAL TOP SPEED IS ATTAINABLE ONCE THE TEST IS BEING DONE.

4-The height. The old conveyors have one option to adjust a tolerance of about 50mm on top of the fixed height. The new once have 2 height tolerance adjustment for about 200mm on top of minimum height of 900mm. The required height is about 1030mm.
* THE OPTIMUM HEIGHT WOULD BE SET ONCE THE FINAL LAYOUT IS CONCLUDED.

5- The control power supply serial connection. Supposed they promised to add a connection so that we dont have to modify for the inverter power supply control. However upon inspection it seems like they forget to install that serial control connection. This means, we have to modify our own.
* THE AC POWER SUPPLY CONTROL FOR THE CONVEYOR WILL BE IMPLEMENTED USING AC SUPPLY SOCKET EXTERNAL WIRING.

6- The side nuts. They promised to supply for us for easier installation of the guides. They did put, but only a few. What more the sides aluminum profiles nuts rail are being blocked by the conveyor bodylock to the profiles.
This means that we have to install on our own few more nuts for better linkage with the conveyor cover.
* SEVERAL MORE NUTS WILL BE ADDED ACCORDINGLY

Next Stage Progressive Planning
Since the prototyping task is completed already where the objective is already met, so yesterday Mr Yu TT list out a few short terms task to do. They are :
1- Reproduction of the conveyor and pusher schematic diagram individually. This is to ensure that all members are capable of troubleshooting in case of machine faulty in future.
2- Assemble the new conveyors for production use according to the specified layout approval.
3- Prepare the necessary accessories for PLC control deployment to replace the current hardwires control system.
4- Analyse the optimum new conveyors speed, gap between mooncakes to match and syncronised with existed 45 unit per minute of the packaging machine running speed.
5- Arrange a necessary training on electrical and electronics as well as computer interfacing for Norjo so that he would have hands on experience more on instrumentation engineering job.
6- Complete the packaging machine block schematic diagram as soon as possible.
7- Arrange Brazer Engineering to prepare a troubleshooting manual and practical training for the Thermal Oil Heater.

Prototype Conveyor Syncronising Test Run II

We did a second syncronising test today using a new input data where this time we manage to get all running perfectly as planned. Here is the test data.
1- S1 and S2 gap = 160mm
2- S3 and S4 gap = 110mm(S3 to edge=80mm, S4 to edge=30mm).
3- CvB speed = full swing (mark 10, high, =>10.32m/min)
4- CvC speed = 4.1 mark (50mm for 5.3s, => 5.66m/min)
5- CvA speed = 45unit/min (11.16m/min)
6- CvA gap = 255 mm
7- CvB mooncake gap = 150mm
8- CvC mooncake gap = 50mm

Here is the video prooving that the used data are OK for the prototype conveyors.
As for the actual conveyors, we have to do the same test again.

ICTS-Prototype Conveyors Syncronising Test Run

We did the trial run for the new layout again today. For today trial run we set the S1 to S2 sensor gap to about 130mm, and S3 to S4 about 100mm. For S3 and S4 both are about 50mm from the conveyor edge. Here is the video shot during that test.

As we can see there is still some errors that require further test. They are:
1- Timer is not perfect replacement for cutter signal. It would only be triggered once the S1 is ON. Its timing is not that accurate enough due no no available equipment such as oscilloscope to measure the timing settings. What we use now is only a visual approximation only. Sometimes it it not syncronous that caused the mooncake to delay a bit from being push out to the packaging conveyor. We have to try using the actual signal to get the best result.
2- The prototype conveyors top speed are running at different velocity, CvB=10.32m/min, CvC=12.96m/min and CvA=11.16m/min. Indeed this condition had troubled us in deciding the best condition to syncronize the conveyors. What is more, all of the conveyors inverter speed controller just use a mark to indicate the speed, whereas the actual conveyor speed is not directly proportional to that mark. This definitely makes the setup task a bit tricky.
3- There is no prototype conveyor D to be used. As such we did the trial run based on the assumption that the CvD will supply the mooncakes to CvC from side by side condition. The variance in those two conveyors speed would create a gap on CvC about 50mm. A 50mm gap on CvC running at 30% mark would create a gap of 150mm on CvB. The packaging conveyor gap is 255mm.

Conclusion
The best settings would only be available and possible to be devised once the actual conveyors (CvB, CvC, CvD) and actual Cutter Signal are being applied. As long as these components are not ready, we cannot make the best trial run. This means that the syncronising part is best done when all are ready. As we can see, this project is halfway done. Many effort have been put onto this, and all are agreed that it will work. It just a matter of time and some precision work in setting up the speed, sensors position and gap between mooncakes.

ICTS-2nd Analysis of the trial run

Before Mr Yu TT going to China we did a brainstorming to analyze the possible problems that could happen with the existed design and oprational standard. Here are the issues discussed and feedbacks and as well as the suggestions for project improvement.
1- The layout change of the ICTS for smoother operation.
Indeed before changing to straight layout from 90 degree layout, we did a few mechanical sliders but all of them we cannot control the friction that causing the gap on CvB to out of specs. Of course we can use the same pusher concept, or even robotic arm or pick n place procedures. Notwithstanding, these alternatives are costly and time consuming. The best way is simply to change the layout of the process. Since we have ample space and the new layout doesnt affect the standard operating procedures, thus it is chosen among other ideas. Here are the new layout of the prototype conveyors from 2 angles. This is from one angle. Here is from another angle.
2- The positioning of the sensors for more efficient control of the gap between mooncakes.
To get the best result for speed and distance we decide to place the sensors S3 and S4 as close as possible to the edge of the conveyors CvB and CvC which is about 50mm.
3- The replacement of the 50mm actuator to 75mm actuator.

ICTS-Test Run 2 Analysis

We did the test run on 16/4/07 and here are the analysis:
1. We found error for S3 and S4 sequence where the CvC stop once S3 is ON. After troubleshooting we found that there is one missing condition. The condition is when S3 ON and S4 OFF, the CvC must continuosly running. Missing it meaning the CvC stop unnecessarily. Here is the new design.
2. The gap for each mooncake on CvB is slightly out of control. The reason is due to the 90 degree slider friction at S3 and S4 is beyond control. A few countermeasure is required prior to actual running of the project. They are : change the layout of the process, apply pneumatic pusher as S1 and packaging, or even improve the mechanical sliding jig there.
3. The actual gap S1 and S2 must be concisely measured to ensure smooth running of the CvB without stopping it while waiting for Cutter signal. The speed of CvB also needs to be constantly verifed. Currently it is running at 10.32m per minute. The actual new conveyor will give a maximum speed of 15 m per minute.
4. The actual gap for mooncakes on CvC must be calculated correctly to ensure smooth delivery to CvB. Smooth delivery will give accurate gap on CvB that later on will guarantee syncronisation with Packaging Conveyor.

5. The simulated Cutter Signal is not perfect. While the actual signal is a pulse with 1.333s tact time, the current circuit is giving a clock cycle of about 1.333s which means the pulse is half of it that is about 0.655. Indeed the actual pulse is even shorter than that. Here is the hardware t o generate the pulse timer.

ICTS-Conveyor C Hardwire Design

Today I designed the control system by hardwire for controlling the conveyor C so that it would turn on and off automatically based on the sensors installed on conveyor B, and conveyor C themselves. I use two MY4N relays and 1 LY2. MY4N are meant for photosensors E3Z-D62 and LY2 is for AC on off of the inverter. Here is the sketched design.


Look at the crcuit diagram, I misstype the S3 and S4 sensors. They should be the other way around as the Ladder diagram.

As for the speed controlling concept, here is the data as obtained by Mr Norjo on 16/4/07.
Packaging Conveyor, CvA
Its usage is at 45 unit/minute
Therefore the average tact time for 20 data is 1.345s.
Thus for 25cm distance, the average speed is 0.186m/s
Hence the standard speed is 11.16m/minute

Feeder Conveyor, CvB
Average tact time, 1.74s
Thus for 30cm distance, the Average speed, 0.172m/s
Hence the standard speed is 10.32m/minute

Input Conveyor, CvC
Average tact time, 1.39s
Thus for 30cm distance, the Average speed, 0.216m/s
Hence the standard speed is 12.96m/minute

** From above data, thus it can be conclude that whatever the speed of the conveyor, the average speed of CvB > CvA at all times so that the process can be syncronised.

Since CvA tacttime is 60/45=1.333s or by hand 1.345s,
Thus for every 1.345s the distance travelled is 250.17mm

This position can be achieved by existed CvB by positioning S1 and S2 at a distance of 150mm. By doing so, then the travelled time from S2 to S1 is (150x60/10320)=0.872s. This is infact 0.473s faster than CvA. This about half second difference indeed is good enough for Cutter to transmit signal so that a mooncake can be released syncronously to the packaging conveyor CvA.

ICTS-Hardwire Test Analysis part1

Yesterday we did the actual packaging room condition test for the hardwires circuit using the control system below. Here are the result and the analysis of the test.

1- Three conveyors (Cv-B, Cv-C, Cv-D) are required to feed the mooncake into packaging machine conveyor (Cv-A). Cv-B is the main one where most control are placed there such as sensors and pneumatic valve. Its speed must be faster than the Cv-A to avoid packaging of empty pack, and to ensure continuos supply to pusher area while waiting for cutter signal. Cv-C is the feeder to Cv-B where its main function is to create permissible gap for mooncake once it connects with Cv-B. This conveyor would run at medium speed. The last conveyor, Cv-D would run at slowest speed to allow the feeder operator to place the mooncake side by side. Once this Cv-D connect to the Cv-C, a small gap would be created to ensure no unnecessary pushing at the L-junction of the Cv-C and Cv-B. This would eliminate the misrotation of the mooncake once it fall from the L-junction slider.


2- The positioning of the sensor 1 and sensor 2 must be modified. The reasons are to avoid collision in case of the 2 consecutive mooncakes at S1 and S2 where S1 is not properly pushed out due to cutter signal mistiming. The sensors must be 130mm higher than the moving conveyors as the best working condition for E3Z-D62 is from 100mm to 2000mm distance. Next, while shorten the gap between S1 and S2 will ensure no collision as the conveyor Cv-B would stop if it detects both S1and S2 presence simultaneoulsy (1.5 tray gap), it also ensures continuos supply of mooncake at S1 on time prior to cutter signal.
3- The pneumatic pusher stopping arm needs modification. It seems that if there is mistiming between S1 and cutter signal, the mooncakes would keep on pushing the pusher arm as the Cv-B keeps on running filling the empty space on Cv-B. This indirectly built up unnecessary pressure that might damage or bend the pneumatic rod in a long run. To avoid this from happening, the arm would be dismantle leaving the L-shape pusher only. A new wall stopper would be designed to replace it that act as a guide as well.
4- Pneumatic pusher stroke of 50mm will be replaced be 75mm. This is simply because the mooncake base is about 100mm. Since the snowy mooncake require soft push to avoid damage, so longer stretch or or soft push is needed to feed the moving Cv-A so that the quality of the mooncakece can be preserved.
5- Feeder side guide installation is required to ensure the mooncake reached S1 area in right orientation. Right orientation will ensure smooth delivery to the Cv-A moving conveyor. Next it also will avoid unnecessary accident at S1 area or the mooncake tumble out of the slider that might hamper the packaging proceess.
6- Installation of the S3 and S4 sensors to the existed hardwires so that a more complete test can be done. These two sensors would act as a safety and control device. They would stop Cv-C if the Cv-B is full. This would avoid accident for oversupply of the mooncakes at the L-junction there.

7- Cutter signal automation design. As for the time being we are still using a manual cutting signal to avoid wastage of the Oxygen Absorber. Since the actual cutter signal would be in sequence with the packaging machine Cv-A that runs about 45 unit per minute (1.33s gap), so a pacemaker signal seems adequate as a replacement signal.
Those are the issues that we have to deal with until end of next week.

PLC Set
We also received the items required as control system yesterday as well. They are :
1-CPMA0056D - Omron CPM1A-30CDR-A-V1 CPU Unit (18/12)
2- CPM10018A - Omron CPM1A-CIF01 RS232 Adapter
3- CX010080B - Omron CXONE-AL01C-EV2-UPSP Software
4- S8J1649R - Omron S82J-02512D AC100/240 12V(2.1A)
5- S8JX0062F - Omron S8JX-05024C AC240 24V(2.1A)
6- E39 217G - Omron E39-L104 Bracket
7- RS232 - Omron RS232 PC-PLC/NT 3M (9F-25M-9PIN)

There is one more items not delivered which is another photosensor for S5 location that would only be available by end of this month.

ICTS - Hardwire Test for Conveyor B, and PLC set purchase

Yesterday after a meeting to discuss the ICTS and process flow got approval, Mr Yu approved the purchase for additional automation parts like Omron PLC set that cost about RM3553.5, and conveyors (1 6 ft, and 2 12 ft) that cost another RM18000 from Enviro. The PLC set would be delivered latest by next week while the conveyors would take about 2 to 3 weeks to fabricate.

As for the time being, the circuit for testing the conveyor B by hardwires had been designed. It would be tested this week. Here is the circuit.

Click here to download the pdf image.

ICTS - Standard Operation for process flow

Up to this point, we have concluded that the project would go on as plan. Now we are in the process of getting the best quotation for conveyors as well as the control system. For the time being negotiations have been going on with Enviro for conveyors and Autovation for PLC and some other automation instruments. If everything goes on perfectly, the whole project should cost about RM40K, and should be finished by middle of next month.

As for the conveyor, currently we are looking into fabricating one 6 foot, and one 24 foot or 2 times 12 foot or 4 times 6 foot. The idea of curve conveyor has been scrapped due to extensive cost required. Whatever combinations it is, it would be a L-shape as we did for prototype. The width would be 150mm and the height would be about 1030 mm.

As for the control system, chances are great that we might use the Omron CPM1A 30 I/O PLC with computer software. Up to this point we are waiting the best offer by Omron vendor.

We are also discussing the standard operation of the new process flow in the packaging room once the project would takes place later on. This is simply because one main objective of this project is to reduce the manpower and upgrade the process flow. A few adjustment needs to be done before this conveyor project is to be installed, such as The packaging machine needs to be rearrange to allow more space and facilities constraints inside the room. The actual proposed process flow would be ready in a few days as Mr Khow is preparing it now.

Click here to download the new process flow.

ICTS-Photosensors Application

Omron delivered the sensors, switches, and relays on 2 of April 07. This time they gave the 12vdc NPN 3 wires sensor that capable of detecting up to 2 metres of diffused object. This is the said sensor.

Since it is NPN type so I have to add one MY4N relay to send a relay signal that deliver 12VDC to the auto sachet feeder cutter sensor. They were arranged in that manner (series) so that the SMC solenoid valve would only be triggered if both the sensors are ON. Once the wiring assembly is completed, then the circuit was assembled at the packaging conveyor and tested automatically.

The result was quite outstanding as the process runs smoothly once the feeder conveyor speed was adjusted to be syncronised with the packaging conveyor.