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complex engineering problem

Complex Engineering Problem
Subject: MT368L- Mechatronic System Design
Semester: Spring 2019
Total Marks: 100
Instructor: Engr Umer Farooq
Engr. Ahmad Abdullah
Engr. Adil Saeed
The aim of this complex engineering activity is to carry out research, analysis, design,
investigation, and implementation of a real-world mechatronics engineering project that has the
following objectives:
1.1 Main Objective
To design a bottle filling system that fills two different volumes at SME's production rates
1.2 Specific Objectives
To design an automated bottle filling system capable of filling 2 different volumes without
To design an automated transfer unit for the filled bottles.
To design and integrate control algorithm for the transfer unit and the filling system
1.3 Complex Engineering Problem Outcomes (CEAO):
The outcome of this activity is that the students may be able to partially attain some or all of
the following graduate attributes:
1. GA1: Engineering Knowledge
2. GA2: Problem Analysis
3. GA3: Design/Development of Solutions
4. GA4: Investigation
5. GA5: Modern Toll Usage
6. GA9: Individual and Teamwork
7. GA10: Lifelong Learning
But in the course, the activity is mapped CLO4 and CLO5 and your performance in this project
will play an important role in their attainment. CLO4 and CLO5 are reproduced:
Trace theoretical knowledge to develop a link between
theoretical foundations of Mechatronics Systems with the PLO5
programming using Modern Tools .
Organization of acquired knowledge by dividing a project into smaller
modules and effectively integrating them individually or in a team.
2. Problem Statement
In the design of the bottle filling machine the problem was summarized as follows: Liquid
processing Small and Medium Enterprises (SMEs) are not maximizing profits due to losses from
poor filling methods and low production outputs with the procurement and maintenance of state
of art being filling machines being cost prohibitive. The design task was then clarified and
described through the use of requirements. These requirements will also be used in the evaluation
of the final product. Table 1 shows the narrative requirements list.
It should fill bottles of different volumes (0.5L and 1L) and height (150mm and
300mm) at a rate of 0.083 l/s i.e. 1L in 12s.
It should fill 300 bottles of 1L in an hour and 600 bottles of 0.5L in an hour
The system should not operate if the bottle has been removed or fallen during
conveyance or filling.
The conveyor should move at 0.10m/s to avoid dynamic instability
Bottle detection and operation of the filling mechanism shall be within 2s-3s
The filling mechanism will have to extend for small bottles and retract for large
It shall be a microcontroller based system
It shall require 12V/24V DC power for operation
It should be able to count the number of filled bottles
It should have a total weight of 20-60Kg
The machine must be portable occupying a volume space of not more than 10m3
It should be below $1500 manufacturing cost
Target market should be small enterprises
To operate with Newtonian fluids only
It should be compatible with PEP, Metal and Glass bottles
It should have a continuous operation for 12 hours.
The system has two position sensors that detect the mouth of the bottle in
relation to their heights
3. Policy on Professional Ethics & Plagiarism
You are free to consult any book and online resources during the design and analysis phase, but you could
not copy from them. Your design and implementation must be your original effort and the same applies
to the source code. Remember that if anyone is found to copy from the Internet or other group members,
the group shall face severe penalty. You are not allowed to copy any material or code directly from the
web or elsewhere. Note that if you are found to violate this policy or it becomes obvious that the work
you have submitted is not your own or has been taken from some other source you shall be facing severe
The Formula that will be generously applied in all cases is:
Final Score = Raw Score – 2*CF*Total
Where CF is the Copying Factor. This means that even if you are found to copy only in 50% of the activity
deliverables, and you end up scoring 100% raw score, but your final score will be 0. Please follow the
principle that “Honesty is the Best Policy”.
4. Deliverables
1. You need to design a complete Mechatronic system according to given specification
2. The design process must be indicated and highlighted at each step
3. Each selection / choice must have a solid engineering logic behind it. Not being able to prove
that will results in an impression of plagiarism or casual attitude.
4. The selection criteria / calculations required for selection of each component must also be
defined clearly.
5. Calculations are required wherever necessary and must be included in the report. These include
conveyor, nozzle, pump, power supply, allied circuitry.
6. The conveyer motion must be encoder based and its encoder as well motor calculations must be
produced and verified using data sheet.
7. Flow Charts, Block Diagrams, system sketches, component diagrams and PCB Schematics for
power supply, sensors and allied circuitry along with PIN assignments on the controller must be
produced wherever necessary.
8. For the code, state machine based code must be provided and the state machine diagrams must
be provided for better understanding of code and logic.
9. You will be required to upload the solution within given time on Google Classroom.
10. The final Submission must be provided according to the following template
Complex Engineering Problem
Subject: MT368L- Mechatronic System Design
Semester: Spring 2019
Total Marks: 100
Instructor: Engr Umer Farooq
Engr. Ahmad Abdullah
Engr. Adil Saeed
Submitted by : ______________
Reg. ID :______________
Bottle Filling Plant
(Lab Midterm)
Department of Mechatronics Engineering
Air University Islamabad
April 05, 2019
Design Cycle
o Overall System Design (In light of Design Cycle)
o Mechanical Design
 Conveyor Calculations
 Conveyor Motor Calculation
 Conveyor Material
 Feedback Mechanism
 Pump Calculation
 Desired Flow
 Desired Total Dynamic Head
o TDH = pumping level + vertical rise + friction loss
 Consult Pump Curves
 Platform Design
 Sketch
 Material
 Attachment of the filling head and conveyor
o Electrical Design
 Component Selection
 Specification Sheets
 Power Supply Design
 Input / Output Circuits design
 State Machine Diagram
 Code flow
 Input and output
 Verification
o Conclusion