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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
AUTOMATIC PART FEEDER
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours.
by
MUHAMMAD HELMI BIN JAMIL
FACULTY OF MANUFACTURING ENGINEERING
2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: AUTOMATIC PART FEEDER
SESI PENGAJIAN: 2009/10 Semester 2 Saya MUHAMMAD HELMI BIN JAMIL mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap:
Tarikh: _________________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi: Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Automatic Part Feeder” is the results of my own
research except as cited in references.
Signature : ………………………………………….
Author’s Name : …………………………………………
Date : …………………………………………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The member of the supervisory
committee is as follow:
(Signature of Supervisor)
………………………………
(Official Stamp of Supervisor)
i
ABSTRACT
A part feeder is a device that arranges works (machine and electronic parts, and
tablets, etc.), which are supplied in random posture from former process,
automatically in constant posture, and supplies them to the next process. In this
report we propose an automatic parts feeder of a new mechanism and show how it
can feed parts into a pressing machine. Based on the improving technology, the need
of automation is a must. This part feeder will also add safety for the machine, it will
uses microcontroller and it is cheaper than the ordinary part feeder. In addition, this
project is and industrial based project which is in collaboration with Selia-Tek
Industries.
ii
ABSTRAK
“Part feeder” merupakan alat/peranti yang berperanan dalam mengatur/menyusun
kerja (mesin dan bahagian elektronik, pil-pil dan sebagainya), yang dibekalkan oleh
proses terdahulu secara rawak atau berkedudukan tetap secara automatik. Ia juga
merupakan penghubung kepada proses yang seterusnya. Di dalam laporan ini, kami
mengusulkan “part feeder” automatik yang menggunakan mekanisma baru dan
menjelaskan bagaimana ia menyuap bahagian ke dalam mesin tekan. Berdasarkan
perkembangan teknologi yang kian membangun pada masa kini, automasi dilihat
sebagai satu keperluan. “Part feeder” ini juga dapat meningkatkan tahap keselamatan
terhadap mesin tekan tersebut dengan menggunakan pengawal mikro yang kosnya
jauh lebih murah berbanding dengan “part feeder” biasa yang ada di pasaran.
Tambahan pula, projek ini adalah berteraskan industri di mana ia adalah kolaborasi
dengan Selia-Tek Industries.
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DEDICATION
Specially dedicated to
my beloved parents and family who have encouraged,
guided and inspired me throughout my
journey of education
iv
ACKNOWLEDGEMENTS
Praise to Allah Almighty for giving me the chance to complete this report. I would
like to take this opportunity to express my deepest gratitude to my project supervisor
Mr. Mohd Hisham bin Nordin who has determinedly assisted me during the whole
course of this project. It would have been very difficult to complete this project
without the support and advice given by him. My outmost thanks also go to my
beloved parent and family who have given me support throughout my academic
years. I would like also to say thanks to all my friends. It is my greatest thanks and
joy that I have met these people. Thank you.
v
TABLE OF CONTENT
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List of Abbreviations xii
1 INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scope of Project 3
2 LITERATURE REVIEW 4
2.1 Introduction 4
2.2 Previous Work and Research 4
2.2.1 Part Feeder In Automated Assembly 4
2.2.2 Importance of Part Feeder 6
2.2.3 Flexible Part Feeding 7
2.2.4 Important Factor for Part Feeder 8
2.2.5 Types of Part Feeder 9
2.2.5.1 Barrel Feeder 9
2.2.5.2 Centrifugal Feeder 10
2.2.5.3 Drum Feeder 11
2.2.5.4 Shaker Feeder 12
2.2.5.5 Roll Feeder 12
2.2.5.6 Revolving-Plate Feeder 13
2.2.5.7 Gravimetric Feeder 14
vi
2.2.5.8 Linear Feeder 15
2.2.5.9 Vibratory Part Feeder 15
2.2.6 Sensors 18
2.3 Related Works 19
2.3.1 Design and Fabrication of an Agile Sorting and Feeding System 19
2.3.2 Novel Design and Development of An Active Feeder 20
2.3.3 A Methodology for Part Feeder Design 21
2.4 Conclusion 23
3 METHODOLOGY 24
3.1 Introduction 24
3.2 Planning Stage 24
3.2.1 Gantt Chart 25
3.2.2 Methodology Flowchart 26
3.3 Research Related to Project 27
3.4 Design Stage 28
3.5 Software Used 29
3.6 Material Selection 31
3.6.1 Aluminum Profile for Structure 31
3.6.2 Aluminum Sheet for Feeder 32
3.6.3 Electrical/Electronic Component 34
3.6.3.1 Microcontroller 34
3.6.3.2 Sensor 36
3.6.3.3 Relay 37
3.7 Testing and Analysis 37
3.8 Preliminary System Design 38
3.81 Sketch 38
3.82 System Block Diagram 39
4 DESIGN AND DEVELOPMENT 40
4.1 Introduction 40
4.2 Part Feeder Prototype Development 40
4.2.1 Part Feeder Mechanical Part/Structure 41
vii
4.3 Part Feeder Electronic Circuit Development 44
4.4 Programming Development 46
4.4.1 Operational Flow Chart for Automatic Part Feeder 47
4.4.2 Programming for Automatic Part Feeder 48
4.4.3 Write Programming Using MikroC 49
4.4.4 PIC Programmer 51
4.5 Conclusion 53
5 RESULT AND DISCUSSION 54
5.1 Introduction 54
5.2 Result 55
5.3 Automatic Part Feeder Specification 56
5.4 Part Feeding Testing 60
5.5 Analysis 63
5.6 Discussion 65
6 CONCLUSION AND FUTURE WORK 66
6.1 Conclusion 66
6.2 Future Work 67
REFERENCES 68
APPENDIX
viii
LIST OF TABLES
2.1 Functions of feeder 15
3.1 Gantt chart for PSM 1 and PSM 2 24
3.2 Static friction coefficent of aluminum against other material 32
3.3 Static coefficent of steel against other material 32
4.1 Output pins and motor direction 48
4.2 Output pins and LED indication 48
ix
LIST OF FIGURES
2.1 Friction on incline track 8
2.2 Barrel feeder 9
2.3 Centrifugal feeder 10
2.4 Drum feeder 10
2.5 Shaker feeder 11
2.6 Roll feeder 12
2.7 Revolving-plate feeders 12
2.8 Gravimetric feeder 13
2.9 Linear feeder 14
2.10 Vibratory part feeder 14
2.11 Fabricated setup of agile feeder 18
2.12 Developement of an active feeder 19
2.13 Feeder design flowchart 21
3.1 Methodology flowchart 26
3.2 Design flowchart 28
3.3 SolidWorks logo 29
3.4 mikroC software icon 29
3.5 Proteus Isis 7 software icon 30
3.6 Aluminum profile 31
3.7 Aluminum sheet 32
3.8 Microcontroller chip 34
3.9 PIC16F877 microcontroller 35
3.10 Limit switch 36
3.11 Relay 37
3.12 Automatic part feeder sketch 38
3.13 System block diagram 39
x
4.1 Design of part feeder 40
4.2 Acrylic sheet 41
4.3 Cutting acrylic using jig saw 41
4.4 Finish product 41
4.5 Drilling acrylic 42
4.6 Slot on acrylic after drilling 42
4.7 Acrylic glue 42
4.8 Attaching acrylic together 42
4.9 Drilling aluminum bar 43
4.10 Tightening screw on the feeder leg 43
4.11 Circuit simulation using Proteus ISIS 7 44
4.12 Red LED is ON when the two switches is OFF 45
4.13 Green LED is ON when switch 1 is ON 45
4.14 Real electronic circuit 45
4.15 Operational flowchart for automatic part feeder 47
4.16 New project in mikroC 49
4.17 Select P16F877A as the device 50
4.18 Write the programming 50
4.19 Success build in mikroC 51
4.20 PIC burner 51
4.21 PICkit 2 programmer 52
4.23 Hex file successfully imported 52
4.24 Write programming 53
4.25 Programming successful 53
5.1 Automatic part feeder prototype 55
5.2 18 º angle of incline feeder track 56
5.3 Design showing the angle of the incline track 56
5.4 Feeder with limit switch station 56
5.5 Red LED indicate feeder is OFF 57
5.6 Green LED indicate feeder is ON 57
5.7 Electronic circuit of part feeder 57
5.8 6V dc geared motor 58
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5.9 Adjustable feeder wall 58
5.10 Feeder width of 4.5 cm 58
5.11 Feeder width of 4 cm 58
5.12 Electronic testing 59
5.13 Voltage supply to relay 59
5.14 9V battery length and width 60
5.15 9V battery height 60
5.16 Feeder gate holding down part from going down the track 61
5.17 Top view of part being hold by feeder gate 61
5.18 Part sliding down to the station 61
5.19 Part arrive at the station 62
5.20 Part on upper feeder 62
5.21 Feeder gate releasing one part 62
5.22 Incline surface angle and dimensions 63
5.23 Friction on inclined track 64
xii
LIST OF ABBREVIATIONS
PC - Personal Computer
MC - Microcontroller
DC - Direct Current
AC - Alternating Current
PIC - Programmable Interface Controller
PLC - Programmable Logic Controller
LED - Light Emitting Diode
1
CHAPTER 1 INTRODUCTION
1.1 Background
Parts feeders are machines that feed parts so that robots or other automated processes
can capture and use or package the parts or components. Applications range from
packaging pills in the pharmaceutical industry to sparkplug production in the
automotive industry. The main difference between parts feeders is their method of
directing the feed. The purpose of this project is to create an automatic part feeder for
pressing machine. This feeder will direct the part into the machine with the right
orientation. Operator will put the parts into the part feeder with large volume and the
feeder will let the part move one by one into the pressing machine. Automation
nowadays is a must for a manufacturing factory as it provides many benefits. The
advantages of part feeder to manufacturing nowadays as it reduce cost where factory
will not have to pay for operator. By using part feeder also it will increase the
manufacturing productivity because it reduces time and cost.
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1.2 Problem Statement
Nowadays, automated manufacturing needs are changing from large-volume, single-
product runs to small-size, customer-specific lots. There is also a continuing pressure
for higher quality, lower cost, and shorter design cycles.
The parts for the pressing machine need to be inserted manually by operator, so there
is no safety element. The hands of the operator might be pressed by the pressing
machine while inserting the part. To avoid any accident, this automatic part feeder
will replace the inserting part job with the feeder feeding the part automatically to the
pressing machine.
With the use of operator to insert the part and at the same time to control the pressing
machine is quite hard. So with this automatic part feeder, it is easier to use. The
operator will just put the part into the part feeder in large volume, and the feeder will
let go the part one by one, so operator just have to control the pressing machine and
not to repeat inserting the part into the machine.
The disadvantage of the normal part feeder as it is expensive. This automatic part
feeder wills cost cheaper than the normal part feeder because it uses cheaper material
for building it. This automatic part feeder also will use microcontroller to control all
the sensors and actuators on the automatic part feeder.
3
1.3 Objectives
The objectives of the project are:
a) To develop an automatic part feeder for pressing machine.
b) To added safety element to the pressing machine to avoid any accident.
c) To create a cheaper and easier to use part feeder than the normally part feeder
that is available in the market.
1.4 Scope of project
In order to complete this project, the following tasks are required:
a) Design the part feeder mechanical structure.
b) Develop the prototype of the feeder.
c) Program the feeder using microcontroller.
d) Test and analysis.
4
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction
This chapter reviews some of the previous works that have been done in the field of
feeder technology. This section highlighted the needs of part feeding in automated
assembly systems, the common applications of automatic feeder, types of conveying
in part feeder, analysis on the part feeding system as well as design of effective traps
for a typical type of part feeder.
2.2 Previous Work and Research
2.2.1 Part Feeder in Automated Assembly
Nowadays industrial sector have been using automated assembly line which come in
bulk, so the use of part feeder is essential as it will orientiate and transport the part.
Some of the previous work will be discussed to support the need of the part feeder.
Boothroyd (1992) states that an automated assembly system has the purpose of
combining multiple components into a single entity through a sequence of automated
assembly operations. The single quantity can be a final product or a subassembly for
a larger product.
5
The components are usually joined one at a time and are completed progressively.
An automated assembly system consists of the following subsystem:
a) One or more workstations at which the assembly steps are performed.
b) Parts feeding devices that deliver the individual components to the workstations.
c) A work handling system for the assembled product.
Prior to starting any automation project, it is important to set goals and determine
why the automating process is necessary Philip (1998). The following are the few
possible reasons:
a) Increase productivity
Many times the use of automation will allow an operator to perform more than
one task. In other situations, the automation device can actually assist in an
operation, resulting in increased productivity.
b) Labor savings
Automation usually performs tasks that are very repetitive,which can lead to
fatigue and boredom if performed manually. Automation can free a worker to
perform additional, more highly-skilled assembly functions. One type of
automated parts handling system consists of a storage supply hopper, vibratory
parts feeder, an in-line track, and a part placing device. This system reduces the
requirement for a full time employee to hand load the machine. Assuming one
shift operation, payback for this system would be less than one year. In multiple
shift operations, payback can be little as four months.
c) Quality
Automation can lead to increased consistency and quality. In general, automatic
systems require a higher quality supply of parts than that required for hand
assembly.
d) Safety
Some types of automation devices are ideal for use in hazardous environments. In
addition, automation often results in a reduction of work-related injuries,
especially chronic problems, such as carpel tunnel syndrome an back injuries.
6
Before any automated solution to be considered, focused attention must be given to
the part. The shape, size, weight, composition and condition of the part must be
evaluated to determine if an automated solution is achieveable. To effectively feed
and orient a part, the shape of the part must be consistent so that an orientation
method can be properly design. Quality of the part handled is very important success
to part feeding. Part size and weight also play a big role in the evalution process of
part feeding. The equipment size will determined by the part size, feed rate,
complexity of part shape, as well as part compostion .
2.2.2 Importance of Part Feeder
The importance of part feeder is to maximize productivity in industry in order to
satisfy increasing labour cost and increasing demand for finished goods. In his
proceedings, Natarajan (2007), points out that assembly accounts for up to 50% of
the total manufacturing cost so it is quite mandatory that we opt for a mechanized
assembly. It shows that we should use other method because assembly will cost alot
and then we have to pay for the workers. By this, part feeder became and important
solutions, where cost of workers can be cut.
Another work that points out the important of part feeder is shown in an article by
Sprovieri (2005), as he tried to disassemble his hard drive from his computer when
he encountered problems while using the computer. In his article, he state that,
Seagate Technology (Scotts Valley, CA), one of the largest manufacturers of hard
drives, assembled more than 80 million of the devices lastyear alone. If each of those
drives contains only half the number of fasteners in his old drive that amounts are
more than 6 million screws per day. Furthermore, he explained that human operators
cannot orient the small screws in such an amount. The operators cannot pick, orient
and control them to be assembled on the part. Tooling or machines have to be
developed to solve ths problem. His article is actually encouraging the development
of part feeder to handle the buIk screws which is complex to separate by human
operators. This part feeder reduce error in orienting the screw in the right condition
before they are assembled to the product, and reduce production time in assembling a
product in his case the hard drive.
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2.2.3 Flexible Part Feeding
Automated manufacturing needs are changing from large-volume, single-product
runs to small-size, and customer-specific lots according to Branicky et.al. (1999).
This shows that factory doesn’t need a big and flexible part feeder that can orient all
part and feed it to one machine, but the growing needs of small and cheaper part
feeder is higher. Moreover, a continuing pressure for higher quality, lower cost, and
shorter design cycles for part feeder makes one lot-specific part feeder more better
than the flexible part feeder that can feed many part. However as it can feed many
part, it will also decrease the feed rate and thus make the feeding process slower than
the one lot-specific part feeder.
Sprovieri (2004) discussed about flexibility in automated assembly operations.
Usually, manufacturing engineers would like to feed part A today, part B tomorrow
and part C next month. But, when they realize that such flexibility will decrease the
feed rate and increase the cost and complexity of the system, suddenly flexibility
doesn't seem like such a good idea. Flexibility involves three of the manufacturing
biggest needs which are automating more processes, reducing changeover time, and
spreading the cost of equipment investment over multiple products. This shows that
flexibility is depends on what the company needs, if the company produces variety of
product and want the equipment cost to be low, the use of flexible part feeder is
important, but then, if the company only produces two or three product, the needs of
flexible part feeder is lower as the one lot-specific feeder gives you lower cost,
shorter design cycle and a better quality.
Most of the new flexible feeders do not try to orient parts. Instead, they merely
separate the parts and allow them to seek a natural, stable state. Stable means that,
they should come to rest very quickly, if the handfuls of parts are dropped on a flat
surface.
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2.2.4 Important Factor for Part Feeder
To build an automatic part feeder, speed, flexibility and ease of integration must all
be considered according to Weber (2001). However the method to use to build the
part feeder depends on part configuration and its complexity. Variables such as size,
shape, density and material will determine how effectively a part can be positioned.
The speed of the part depends mostly from the inclined surfaces of the part feeder.
The coefficient friction of the incline surface on the part feeder will also affect the
speed of the part going through the part feeder. So the use of the right material is
important for the part feeder. The friction between part and the surface of the feeder
must be low to prevent part from damage or scratch because of the friction.
Figure 2.1: Friction on incline track
Where, θ - angle of inclination of track
m - mass of part
g - acceleration of gravity
μ - coefficient of friction