Design, Modelling, Analysis and Prototyping of
Vertical Forming, Filling and Sealing Machine
Associate Prof. Dr. Mohamed Abdel Rahim Asy
Dr. Mohamed Hany Kazamal
Kareem Ahmed Fathy Essa
Mohamed Anwar Mohamed Abu-El Ela
Farah Tamer Abdel Hady Nasser
Maheitab Mahmoud El Waraky
Halah Moselhy Salama
Moamen Ahmed Taha Negm
Karim Adel Abbas Awdallah
Mostafa Zaghlol Hassan Sayed
Karim Mostafa Basha Zayan
Ahmed Afifi Mohamed Afifi
July 2022
VERTICAL FORMING, FILLING AND SEALING MACHINE
Acknowledgment
We would like to thank our supervisors, Dr. Mohamed
Abel Rahim Asy and Dr. Mohamed Hany Kazmal, for
bringing the weight of their considerable experience and
knowledge to this project. Their high standards have
made us better at what we do.
Thanks also to Eng. Mohab Asy and Eng. Asmaa Rashid,
who acted as our instructors in this project, and provided
invaluable guidance for all project stages.
We would also like to thank Hossam Hamady for his precious help in electric system, and programming of this
project and for bringing his experience and knowledge in
electric system to this project.
1
‫‪VERTICAL FORMING, FILLING AND SEALING MACHINE‬‬
‫اللـهِ الرَّحْمَـٰنِ الرَّحِيمِ‬
‫بِسْمِ َّ‬
‫س ُحواْ ِفى‬
‫يََٰٓأَيُّ َها ٱلَّ ِذ َ‬
‫ين َءا َمنُ َٰٓواْ ِإذَا ِقي َل لَ ُك ْم تَفَ َّ‬
‫ْ‬
‫ْ‬
‫ْ‬
‫ْ‬
‫َ‬
‫ح َّ‬
‫ٱَّللُ لَ ُك ْم ۖ َو ِإذَا قِي َل‬
‫س‬
‫ف‬
‫ي‬
‫ا‬
‫و‬
‫ح‬
‫س‬
‫ف‬
‫ٱ‬
‫ف‬
‫س‬
‫ل‬
‫ج‬
‫م‬
‫ٱل‬
‫ِ‬
‫ُ‬
‫ِ‬
‫َ‬
‫َ‬
‫َ‬
‫َ‬
‫َ‬
‫ِ‬
‫ين َءا َمنُواْ‬
‫ش ُزواْ فَٱن ُ‬
‫ٱن ُ‬
‫ش ُزواْ يَ ْرفَ ِع َّ‬
‫ٱَّللُ ٱلَّ ِذ َ‬
‫ين أُوتُواْ ْٱل ِع ْل َم دَ َر َج ٍۢت ۚ َو َّ‬
‫ٱَّللُ ِب َما‬
‫ِمن ُك ْم َوٱلَّ ِذ َ‬
‫ون َخ ِبير‬
‫ت َ ْع َملُ َ‬
‫صَدَقَ اهللُ العَظيمُ‬
‫‪2‬‬
VERTICAL FORMING, FILLING AND SEALING MACHINE
Abstract
At present, there are many kinds of process technologies that can be used in the field of packaging. This project aims to develop such a machine used in packing technology with minimum costs
to be available for youth startups and to be locally manufactured. The Vertical forming, filling,
and sealing machine is used for packing granule food in plastic or fiber bags. During this process
the accurate motion of filling mechanisms, sealing mechanism parts and film transport mechanism should be obtained.
Filling system mechanism motion smoothness depends on filling parts inclination angles, the
amplitude of vibration. Filling system accuracy is dependent on the load cell. Filling system
material selection is a critical part as in this study we aims to obtain minimum cost and selecting non toxic materials for direct contact parts with food.
Sealing mechanism accuracy depends on the study of the plastic film behavior in different
temperatures and pressures, to determine the stroke length, motor torque and parts lengths.
Sealing mechanism required different types of analysis because it is the continuous dynamic
part of the machine, and its motion is dependent on every part in it.
For film transport a simple system was selected to simplify the process and obtain the web
tension in the same time.
The chassis design and analysis depended on stiffness, ease of maintenance and allow all parts
access easily. The chassis should obtain low deformations and high stiffness with minimum
costs in the same time. also it should allow continuous monitoring for all machine parts without dust access.
For manufacture processes, minimum number of processes was used to reduce cost. Most of
machine is manufactured using sheet metal. Sheet metal processes was simplified to be done
in low cost. Most of bends are 90 degrees. Other parts were made using traditional machining
or Nontraditional machining but those parts number was minimized. Other parts were purchased as they were designed on standard commercial stock dimensions.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Table of Contents
Acknowledgment ......................................................................................................................... 1
Abstract ........................................................................................................................................ 3
Table of Figures ........................................................................................................................... 9
Table of Tables .......................................................................................................................... 18
1.
Introduction and literature survey ...................................................................................... 21
1.
Introduction.................................................................................................................... 21
2.
History of Food Packing ................................................................................................ 21
2.1.
Early Developments in Packaging ......................................................................... 21
2.2.
Post-World War II ................................................................................................. 22
2.3.
New Package Developments ................................................................................. 23
2.4.
Active Packaging ................................................................................................... 24
2.5.
New Package Developments ................................................................................. 25
3.
Machine History ............................................................................................................ 25
4.
Why VFFS? ................................................................................................................... 26
5.
6.
4.1.
VFFS Machines Manufacture is not Widespread in Egypt ................................... 26
4.2.
Experience ............................................................................................................. 27
4.3.
Suitable For Youth Startups................................................................................... 27
4.4.
Environmentally Friendly ...................................................................................... 27
VFFS types .................................................................................................................... 27
5.1.
Liquid filling machine: .......................................................................................... 27
5.3.
Vibratory Weigh Filling Machine ......................................................................... 29
5.4.
Positive Displacement Pump Filling Machine: ..................................................... 29
5.5.
Capsule Filling Machine ........................................................................................ 30
Surveys .......................................................................................................................... 31
6.1.
Types of Filling Systems ....................................................................................... 31
6.2.
Types of Bags ........................................................................................................ 31
6.3.
Sealing System Types ............................................................................................ 32
6.4.
Types of Sealing Mechanism................................................................................. 32
6.5.
Types of Film Transport Component System ........................................................ 36
6.6.
Collar (Bag Former) Types .................................................................................... 37
6.7.
Types of Chassis .................................................................................................... 39
6.8.
Material selection................................................................................................... 42
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VERTICAL FORMING, FILLING AND SEALING MACHINE
6.9.
Types of Electric Systems ..................................................................................... 46
7.
Machine Specification ................................................................................................... 48
8.
Final Selections .............................................................................................................. 48
2.
Design Considerations ........................................................................................................ 49
1.
Introduction.................................................................................................................... 49
2.
Calculations Required for The Filling System .............................................................. 49
2.1.
Filling Components Inclination Angle .................................................................. 49
2.2.
Filling Spring Calculations .................................................................................... 50
2.3.
Gate Motor Torque ................................................................................................ 51
3. Sealing Mechanism Calculations ....................................................................................... 52
3.1. Sealing Mechanism Requirements ............................................................................. 52
3.2. Sealing Mechanism Synthesis ..................................................................................... 53
3.3. Sealing Mechanism Static Force Analysis .................................................................. 57
3.4. Transmission Shaft Diameter ...................................................................................... 61
3.5. Sealing Mechanism Springs ........................................................................................ 62
3.6. Suitable Bag Dimensions ............................................................................................ 63
3.
Electricity and Programming.............................................................................................. 64
3.
Introduction.................................................................................................................... 64
4.
Arduino Mega 2560 ....................................................................................................... 64
4.1.
Board Specifications .............................................................................................. 65
5.
LCD ............................................................................................................................... 66
4.
Keypad ........................................................................................................................... 67
4.1.
5.
Keypad Specification ............................................................................................. 68
Load Cell ....................................................................................................................... 68
5.1. Amplifier .................................................................................................................... 70
6.
Vibrator .......................................................................................................................... 71
6.1. Motor Driver L298 Dual H-Bridge ............................................................................ 72
7.
Gate Servo Motor .......................................................................................................... 72
7.1. Gate Servomotor Specifications .................................................................................. 73
7.2. Servo Motor Connections ............................................................................................ 73
7.3. DC-DC Step Down Converter ..................................................................................... 74
8.
Pulleys motor RS555 ..................................................................................................... 75
2.
8.1. Encoder ................................................................................................................... 75
9.
Sealing Wiper Motor ..................................................................................................... 77
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VERTICAL FORMING, FILLING AND SEALING MACHINE
9.1. Wiper Motor -WD1160/1160-B Specifications .......................................................... 77
9.2. Wiper Motor Driver .................................................................................................... 78
10.
Heaters ....................................................................................................................... 80
10.1. Heat Sensors .............................................................................................................. 80
10.2. Relay module ............................................................................................................. 81
4.
Machine Modelling ............................................................................................................ 83
1.
Introduction.................................................................................................................... 83
2.
Filling System Modelling .............................................................................................. 83
2.1.
Vibratory System ................................................................................................... 83
2.2.
Filling System ........................................................................................................ 84
2.3.
Casing .................................................................................................................... 84
2.4.
Different Parts Iterations........................................................................................ 85
2.4.3.
Filling Pot Fixature Iterations ............................................................................ 86
2.4.4.
Load cell Fixture Iterations ................................................................................ 87
3.
Sealing System............................................................................................................... 88
3.1.
3.2.
Sealing Mechanism Modeling ............................................................................... 88
Sealing Jaws Modeling .............................................................................................. 89
3.3.
4.
Sealing Mechanism Fixation ................................................................................. 90
Chassis ........................................................................................................................... 91
4.1.
First Iteration ............................................................................................................. 91
4.2.
Second Chassis Iteration ............................................................................................ 95
5 . Machine Parts Analysis ........................................................................................................ 99
1.
Introduction.................................................................................................................... 99
2.
Filling System Static Analysis ....................................................................................... 99
2.1.
Filling Grid Analysis ............................................................................................. 99
2.1.2.
Filling Grid second Iteration Analysis ............................................................. 101
.2.2Load Cell Fixation Analysis ....................................................................................... 103
2.2.1.
First Iteration for Load Cell Fixation Analysis................................................ 103
2.2.2.
Second Iteration for Load Cell Fixation Analysis ........................................... 104
3.
Chassis Static Analysis ................................................................................................ 106
3.1.
First Iteration Analysis ............................................................................................ 106
3.1.1.
Aluminum (Al6063-T6) Analysis....................................................................106
3.1.2.
Stainless Steel 304 Analysis ............................................................................ 108
3.1.3.
Steel A36 Analysis .......................................................................................... 109
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VERTICAL FORMING, FILLING AND SEALING MACHINE
3.2.
Second Iteration Analysis ........................................................................................ 111
3.2.1.
Steel A36 ......................................................................................................... 111
3.2.2.
Stainless Steel 304 Analysis ............................................................................ 112
4.
Sealing Static Analysis ................................................................................................ 114
4.1.
Sheet Metal .............................................................................................................. 114
4.1.1.
C-SEC .............................................................................................................. 114
4.1.2.
The Backward and Forward plate ....................................................................119
4.2.
4.2.2.
Transvers Jaws .................................................................................................126
4.2.4.
Springs Analysis .............................................................................................. 131
4.3.
6.
Sealing Jaws Static Force Analysis .....................................................................123
Sealing Mechanism Kinematic Analysis .................................................................135
4.3.1.
The Analysis of Jaws and Back Plate .............................................................. 136
4.3.2.
The Crank Analysis ......................................................................................... 137
4.3.3.
Coupler Analysis ............................................................................................. 138
4.3.4.
The Rocker and Rocker With Rod Analysis .................................................... 140
Machine Manufacture and Assembly ............................................................................... 142
1.
Introduction.................................................................................................................. 142
2.
Sheet Metal Processes ..................................................................................................142
2.1.
Sheet Metal Processes for Chassis .......................................................................142
2.2.
Sheet Metal Bending for Filling System ............................................................. 150
TYPES OF WELDING USED FOR STAINLESS STEEL ................................................ 153
3.
3D Printing Processes in Filling System .....................................................................153
4.
Collar ........................................................................................................................... 155
5.
Sealing System Manufacture ....................................................................................... 156
5.1.
Sealing Jaws......................................................................................................... 156
5.2.
Knife .................................................................................................................... 156
5.3.
Mechanism links Manufacture ............................................................................ 157
.5.6Sealing Mechanism Assembly .................................................................................... 161
6.
7.
Machine Assembly ......................................................................................................162
Future Recommendations and Conclusions .....................................................................164
1. Introduction ..................................................................................................................... 164
2.
Filling System Conclusions and Recommendations.................................................... 164
3.
Sealing System Conclusions and Recommendations .................................................. 164
4.
Chassis Conclusions and Recommendations ............................................................... 164
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.
Film Transport System Conclusions and Recommendations ......................................165
References ................................................................................................................................ 166
Appendix A .............................................................................................................................. 169
(The Kinematic Analysis of Sealing Mechanism Tables) ................................................... 169
Appendix B .............................................................................................................................. 176
(MATLAB Figure Design for Comparison Between the Results) ......................................176
The Relation Between the Jaws Rod And The Back Plate Rod .......................................176
The Crank Analysis .......................................................................................................... 177
8.
The Coupler Analysis ..................................................................................................177
The Rocker And Rocker With Rod Analysis ...................................................................178
8
VERTICAL FORMING, FILLING AND SEALING MACHINE
Table of Figures
Figure 1-1 Liquid filling machine.............................................................................................. 27
Figure 1-2 Powder Filling Machine ........................................................................................... 28
Figure 1-3 Vibratory Weight Filling Machine........................................................................... 29
Figure 1-4 Filling System of The Vibratory Filling Machine ................................................... 29
Figure 1-5 Positive Displacement Pump Filling Machine ......................................................... 30
Figure 1-6 Positive Displacement Pump Filling Machine ......................................................... 30
Figure 1-7 Types of Sealing Jaws .............................................................................................. 32
Figure 1-8 4 bar mechanism intial design.................................................................................. 33
Figure 1-9 4 Bar mechanism Design ......................................................................................... 33
Figure 1-10 Cam Shaft Mechanism Front View ........................................................................ 34
Figure 1-11 Cam Shaft Mechanism Main Parts ........................................................................ 34
Figure 1-12 A VFFS Machine with Pneumatic Sealing System ............................................... 35
Figure 1-13 Film Transport Using Friction Roll Mechanism .................................................... 36
Figure 1-14 VFFS with Shafts Transport System...................................................................... 37
Figure 1-15 Round Bag Former for Mechanism with Friction Roll ......................................... 37
Figure 1-16 Round Bag Former for Mechanism with Shafts only ............................................ 38
Figure 1-17 Rectangular Bag Former ....................................................................................... 38
Figure 1-18 Oval Bag Former ................................................................................................... 39
Figure 1-19 Space Frame ........................................................................................................... 40
Figure 1-20 Structural Members and Sheet Metal Frame ......................................................... 40
Figure 1-21 Sheet Metal Frame ................................................................................................. 41
Figure 1-22 Chart of Material Selection .................................................................................... 42
Figure 2-1 The Relation between Moisture Content and Coefficient of Friction of Hungry Rice
with Different Materials[11] ...................................................................................................... 49
Figure 2-2 Force-Displacement Graph For Plastic 15-35 At Dwell Time 1.5 S And Sealing
Temperature (A) 110 °C And (B) 130 °C[13] ........................................................................... 52
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 2-3 Mechanism Initial Drawing ..................................................................................... 54
Figure 2-4 Mechanism Synthesis Drawing................................................................................ 55
Figure 2-5 Crank Rocker Synthesis Mechanism Drawing in first Position............................... 56
Figure 2-6 Crank Rocker Synthesis Mechanism Drawing in second Position .......................... 56
Figure 2-7 Initial Mechanism Drawing Using Solidworks ........................................................ 57
Figure 2-8 Initial Mechanism Drawing Using GeoGebra ......................................................... 57
Figure 2-9 The Crank Slider O4CD Mechanism Drawing ......................................................... 58
Figure 2-10 The Crank Slider O2BF Mechanism Drawing ....................................................... 59
Figure 2-11 The Crank Rocker O2ABO4 .................................................................................. 60
Figure 2-12 Sealing Transmission Shaft Free Body Diagram ................................................... 61
Figure 3-1 The Board[14] .......................................................................................................... 65
Figure 3-2 1602A QAPASS 16×2 LCD display[15] ................................................................ 66
Figure 3-3 Codes For Rest Parameters Weight and Length ...................................................... 66
Figure 3-4 LCD Display Pin Diagram ....................................................................................... 67
Figure 3-5 Code for Input Data During Machining Time ......................................................... 67
Figure 3-6 Membrane Keypad 16 Keys Matrix (4*4) ............................................................... 68
Figure 3-7 Code for Calculating the Integrate Length and Weight ........................................... 68
Figure 3-8 Code for Calculating the Integrate Length and Weight ........................................... 68
Figure 3-9 Strain Gauge Load Cell Diagram ............................................................................. 69
Figure 3-10 More In-Depth Diagram of Strain Gauges on Bar Load Cells When Force is
Applied ...................................................................................................................................... 69
Figure 3-11 "Z" Formation Fixation For The Strain Gauge Load Cell ..................................... 69
Figure 3-12 Load Cell and HX711 Amplifier Connections ..................................................... 70
Figure 3-13 Code for Weight Affecting The Load Cell ............................................................ 70
Figure 3-14 RC-280 Vibration Motor........................................................................................ 71
Figure 3-15 Code for Controlling Speed in Vibrator Motor...................................................... 71
Figure 3-16 L298N H-Bridge .................................................................................................... 72
10
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-17 Servo Motor FS5103B[22] .................................................................................... 73
Figure 3-18 Servo Motor Code for Opening and Close the Cup Gate ...................................... 73
Figure 3-19 Servo Motor Connections ...................................................................................... 74
Figure 3-20 LM2596-XXE5/F5 DC-DC Step Down Converter ............................................... 74
Figure 3-21 Pulleys Motor RS555 ............................................................................................. 75
Figure 3-22 Pulley Motor Code for Roller Speed ..................................................................... 75
Figure 3-23 Rotary Encoder ...................................................................................................... 76
Figure 3-24 Rotary Encoder Code for Pully Speed Control ...................................................... 76
Figure 3-25 Encoder Connections Illustration ........................................................................... 76
Figure 3-26 Wiper Motor -WD1160/1160-B ............................................................................ 77
Figure 3-27 Wiper Motor Code for Speed Control ................................................................... 77
Figure 3-28 VNH2SP30 Motor Driver[24] ............................................................................... 78
Figure 3-29 VNH2SP30 Driver Pin Definitions ........................................................................ 79
Figure 3-30 Hall Sensor ............................................................................................................. 80
Figure 3-31 Hall Effect Sensor Code for Speed Control ........................................................... 80
Figure 3-32 Relay Module (1 Channel- 5V).............................................................................. 81
Figure 3-33 Code For Controlling The Longitudinal Jaws Temperature .................................. 81
Figure 3-34 Code For Controlling The Transverse Jaws Temperature ..................................... 82
Figure 3-35 Code For Controlling Sealing System Temperature ............................................. 82
Figure 4-1 Vibratory system ...................................................................................................... 83
Figure 4-2 Filling System .......................................................................................................... 84
Figure 4-3 Filling System Casing .............................................................................................. 85
Figure 4-4 Filling Pot first Iteration........................................................................................... 85
Figure 4-5 Filling Pot second Iteration ...................................................................................... 85
Figure 4-6 Vibratory System Fixature first Iteration ................................................................. 86
Figure 4-7 Vibratory System Fixature second Iteration ............................................................ 86
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-8 Filling Pot Fixature first Iteration ............................................................................ 86
Figure 4-9 Filling Pot Fixature second Iteration........................................................................ 87
Figure 4-10 Load cell Fixture first Iteration ............................................................................. 87
Figure 4-11 Load cell Fixture second Iteration ......................................................................... 87
Figure 4-12 Sealing Mechanism Initial Concept ....................................................................... 88
Figure 4-13 Sealing Mechanism Actual Design ........................................................................ 88
Figure 4-14 Modelling of Transverse Sealing Jaws .................................................................. 89
Figure 4-15 Modelling of longitudinal Sealing Jaws ................................................................ 89
Figure 4-16 Upper Sheet for Fixing Sealing Mechanism Modeling ......................................... 90
Figure 4-17 Lower Sheet for Fixing Sealing Mechanism Modeling ......................................... 91
Figure 4-18 C-Section for Fixing Sealing Mechanism Modeling ............................................. 91
Figure 4-19 Pulleys System First Iteration ................................................................................ 92
Figure 4-20 Chassis first Iteration Front View .......................................................................... 92
Figure 4-21 Isometric View for Chassis first Iteration without sides ........................................ 92
Figure 4-22 Isometric View For Chassis first Iteration With Sides .......................................... 93
Figure 4-23 Chassis first Iteration assembly Front View Without Transparency ..................... 93
Figure 4-24 Chassis first Iteration assembly Transparent Front View ...................................... 94
Figure 4-25 Isomeric View for Chassis first Iteration Assembly .............................................. 94
Figure 4-26 Pulleys Mechanism Second Iteration ..................................................................... 95
Figure 4-27 Chassis second Iteration Front View .................................................................... 96
Figure 4-28 Chassis second Iteration Isometric View ............................................................... 96
Figure 4-29 Chassis second Iteration Assembly ........................................................................ 97
Figure 4-30 Chassis second Iteration Assembly Showing electric Plate ................................... 97
Figure 4-31 Chassis second Iteration Assembly Front View .................................................... 98
Figure 5-1 Stress Results for Filling Grid first Iteration Analysis........................................... 100
Figure 5-2 Displacement Results for Filling Grid first Iteration Analysis .............................. 100
12
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-3 FOS Results for Filling Grid first Iteration Analysis ............................................. 101
Figure 5-4 Stress Results for Filling Grid second Iteration Analysis ......................................101
Figure 5-5 Displacement Results for Filling Grid second Iteration Analysis ......................... 102
Figure 5-6 FOS Results for Filling Grid second Iteration Analysis ........................................102
Figure 5-7 Stress Results for Load Cell Fixation first Iteration Analysis ............................... 103
Figure 5-8 Displacement Results for Load Cell Fixation first Iteration Analysis ................... 103
Figure 5-9 FOS Results for Load Cell Fixation first Iteration Analysis..................................104
Figure 5-10 Stress Results for Load Cell Fixation second Iteration Analysis ......................... 104
Figure 5-11 Displacement Results for Load Cell Fixation second Iteration Analysis ............ 105
Figure 5-12 FOS Results for Load Cell Fixation second Iteration Analysis ........................... 105
Figure 5-13 Stress Results for Chassis first Iteration Al6063-T6............................................ 106
Figure 5-14 Displacement Results for Chassis first Iteration Al6063-T6 ............................... 107
Figure 5-15 FOS Results for Chassis first Iteration Al6063-T6 ............................................. 107
Figure 5-16 Stress Results for Chassis first Iteration St 304 ................................................... 108
Figure 5-17 Displacement Results for Chassis first Iteration St 304.......................................108
Figure 5-18 FOS Results for Chassis first Iteration St 304 ..................................................... 109
Figure 5-19 Stress Results for Chassis first Iteration A36 ...................................................... 109
Figure 5-20 Displacement Results for Chassis first Iteration A36 .......................................... 110
Figure 5-21 FOS Results for Chassis first Iteration A36 ......................................................... 110
Figure 5-22 Stress Results for Chassis second Iteration A36 .................................................. 111
Figure 5-23 Displacement Results for Chassis second Iteration A36 .....................................111
Figure 5-24 FOS Results for Chassis second Iteration A36 .................................................... 112
Figure 5-25 Stress Results for Chassis second Iteration St 304 .............................................. 112
Figure 5-26 Displacement Results for Chassis second Iteration St 304 ..................................113
Figure 5-27 FOS Results for Chassis second Iteration St 304................................................. 113
Figure 5-28 C-section Modelling on ANSYS 19 ....................................................................114
13
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-29 C-section Analysis Displacement Results ........................................................... 115
Figure 5-30 C-section Analysis Equivalent Elastic Strain Results .......................................... 115
Figure 5-31 C-section Analysis Maximum Shear Strain Results ............................................ 115
Figure 5-32 C-section Analysis Equivalent stress Results ...................................................... 116
Figure 5-33 C-section Analysis Maximum Shear Stress Results ............................................ 116
Figure 5-34 Deformation for C-section Frequency Analysis .................................................. 117
Figure 5-35 Total Deformation of C-section Frequency Analysis and Static Load Analysis .117
Figure 5-36 C-section Solidworks Analysis Stresses Results ................................................. 117
Figure 5-37 C-section Solidworks Analysis Displacement Results ........................................118
Figure 5-38 C-section Solidworks Analysis Strain Results ..................................................... 118
Figure 5-39 C-section Solidworks Analysis FOS Results ....................................................... 118
Figure 5-40 Plate one modelling on Solidworks .....................................................................119
Figure 5-41 Plate One Solidworks Analysis Stress Results .................................................... 120
Figure 5-42 Plate One Solidworks Analysis Displacement Results ........................................120
Figure 5-43 Plate One Solidworks Analysis Strain Results .................................................... 120
Figure 5-44 Plate One Solidworks Analysis FOS Results....................................................... 121
Figure 5-45 Plate Two Solidworks Modelling ........................................................................121
Figure 5-46 Plate Two Solidworks Stress Results ...................................................................121
Figure 5-47 Plate Two Solidworks Displacement Results ...................................................... 122
Figure 5-48 Plate Two Solidworks Strain Results ...................................................................122
Figure 5-49 Plate Two Solidworks FOS Results .....................................................................122
Figure 5-50 Longitudinal Jaw Deformation Results Using ANSYS .......................................124
Figure 5-51 Longitudinal Jaw Stress Results Using ANSYS .................................................. 124
Figure 5-52 Longitudinal Jaw Strain Results Using ANSYS .................................................. 124
Figure 5-53 Longitudinal Jaw Stress Results Using Solidworks............................................. 125
Figure 5-54 Longitudinal Jaw Displacement Results Using Solidworks ................................ 125
14
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-55 Longitudinal Jaw Strain Results Using Solidworks............................................. 125
Figure 5-56 Transverse Jaw Deformation Results ANSYS .................................................... 126
Figure 5-57 Transverse Jaw Strain Results ANSYS ............................................................... 126
Figure 5-58 Transverse Jaw Stress Results ANSYS ............................................................... 127
Figure 5-59 Transverse Jaw Deformation Results Using Solidworks .....................................127
Figure 5-60 Transverse Jaw Strain Results Using Solidworks ................................................ 127
Figure 5-61 Transverse Jaw Stress Results Using Solidworks ............................................... 128
Figure 5-62 Temperature Distribution on Jaws ......................................................................128
Figure 5-63 Longitudinal Sealing Jaws Heat Analysis Deformation Results ......................... 128
Figure 5-64 Longitudinal Sealing Jaws Heat Analysis Strain Results ....................................129
Figure 5-65 Longitudinal Sealing Jaws Heat Analysis Stress Results ....................................129
Figure 5-66 Transverse Sealing Jaws Heat Distribution ......................................................... 129
Figure 5-67 Transverse Sealing Jaws Heat Analysis Deformation Results ............................ 130
Figure 5-68 Transverse Sealing Jaws Heat Analysis Strain Results .......................................130
Figure 5-69 Transverse Sealing Jaws Heat Analysis Stress Results .......................................130
Figure 5-70 Longitudinal Sealing Spring Deformation Results .............................................. 132
Figure 5-71 Longitudinal Sealing Spring Stress Results ......................................................... 132
Figure 5-72 Longitudinal Sealing Spring Strain Results ......................................................... 133
Figure 5-73 Transverse Sealing Spring Deformation Results ................................................. 134
Figure 5-74 Transverse Sealing Spring Stress Results ............................................................ 134
Figure 5-75 Transverse Sealing Spring Strain Results ............................................................ 134
Figure 5-76 Sealing Actual Mechanism .................................................................................. 135
Figure 5-77 Sealing Simplified Mechanism ............................................................................ 135
Figure 5-78 Sealing Simplified Mechanism on ANSYS ......................................................... 135
Figure 5-79 Jaws Relative Velocity Curve .............................................................................. 136
Figure 5-80 Back Plate Relative Velocity Curve ....................................................................136
15
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-81 Jaws Relative Acceleration Curve .......................................................................136
Figure 5-82 Back Plate Relative Acceleration Curve .............................................................. 136
Figure 5-83 Jaws Forces Curve ............................................................................................... 137
Figure 5-84 Back Plate Forces Curve ...................................................................................... 137
Figure 5-85 Crank Relative Velocity Curve ............................................................................ 137
Figure 5-86 Crank Relative Acceleration Curve .....................................................................137
Figure 5-87 Crank Forces Curve ............................................................................................. 138
Figure 5-88 The Angular Velocity of the Coupler Curve........................................................ 138
Figure 5-89 The Angular Velocity of Coupler with Rod Curve .............................................. 138
Figure 5-90 The Angular Acceleration of Coupler Curve ....................................................... 139
Figure 5-91 The Angular Acceleration of Couple With Rod Curve .......................................139
Figure 5-92 Total Force of The Coupler Curve .......................................................................139
Figure 5-93 The Total Force of Coupler With Rod Curve ...................................................... 139
Figure 5-94 The Rocker Angular Velocity Curve ...................................................................140
Figure 5-95 The Rocker with Rod Angular Velocity Curve ................................................... 140
Figure 5-96 The Rocker Angular Acceleration Curve ........................................................... 140
Figure 5-97 The Rocker with Rod Angular Acceleration Curve ............................................. 140
Figure 5-98 The Rocker Force Curve ...................................................................................... 141
Figure 5-99 The Rocker with Rod Force Curve ......................................................................141
Figure 6-1 Flatten Sheet Metal of Chassis Top and Front ...................................................... 143
Figure 6-2 DXF File of Chassis Flatten Pattern for Top and Front .......................................144
Figure 6-3 Chassis Sheet Metal During Laser Cut Process .................................................... 144
Figure 6-4 Chassis Sheet Metal During Laser Cut Process (Wider View) ............................. 145
Figure 6-5 Working Drawing for Chassis Top and Front Flatten Pattern ............................ 146
Figure 6-6 Working Drawing for Chassis Base Flatten Pattern ............................................. 146
Figure 6-7 Chassis Sheet Metal Installing Before Bending .................................................... 147
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-8 Chassis Sheet Metal After Bending .......................................................................147
Figure 6-9 Machine Parts During Painting process ............................................................... 148
Figure 6-10 chassis Front and Top After Cutting, Bending and painting ............................... 149
Figure 6-11 Sealing C-Section After Cutting, Bending and painting ......................................149
Figure 6-12 Chassis Base After Cutting, Bending, and painting ............................................ 149
Figure 6-13 Chassis After Manufacture (Assembled with Sealing Mechanism And Transverse
Sealing Jaws) ........................................................................................................................... 150
Figure 6-14 Casing Model before Flatten ............................................................................... 151
Figure 6-15 Casing Working Drawing After Flatten .............................................................. 151
Figure 6-16 Filling Grid Model before Flatten .......................................................................151
Figure 6-17 Filling Grid Working Drawing After Flatten ...................................................... 152
Figure 6-18 Filling Pot Model before Flatten ......................................................................... 152
Figure 6-19 Filling Pot Working Drawing After Flatten ........................................................ 152
Figure 6-20 CAD Model for Filling Cup Using Solidworks ................................................... 153
Figure 6-21 Cup Placement Using Machine Program............................................................ 154
Figure 6-22 Different 3D Printing Infills ................................................................................ 154
Figure 6-23 3D Printed Filling Cup ........................................................................................ 155
Figure 6-24 The Support or The Wasted Material to Reach the Required Design ................. 155
Figure 6-25 Purchased Collar.................................................................................................156
Figure 6-26 Different Knives Shapes and Types[30]............................................................... 157
Figure 6-27 Transverse Sealing Mechanism Assembly ........................................................... 162
Figure 6-28 Machine After Assembling Sealing with Chassis without Sides (side View) .......162
Figure 6-29 Chassis After Assembly without Electric Parts ................................................... 163
Figure 6-30 The Machine After Manufacture and Assembly .................................................. 163
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Table of Tables
Table 1-1 comparison between weight filling system and volumetric filling system [2], [3] ... 31
Table 1-2 Comparison Between Types of Sealing Mechanism ................................................. 35
Table 1-3 Comparison Between Types of Frames Used in VFFS Machines ............................ 41
Table 1-4 Comparison Between Different Types of Material alloys and their Chemical and
Physical Resistance [9] .............................................................................................................. 44
Table 1-5 The difference between different stainless-steel grades[10] ..................................... 46
Table 2-1 Typical Values of Angle Response[12] .................................................................... 50
Table 2-2 Different Spring Models Specifications .................................................................... 51
Table 2-3 Initial Data Used in Calculations .............................................................................. 54
Table 2-4 Crank Slider O4CD Mechanism Static Forces Calculations ..................................... 58
Table 2-5 Crank Slider O2BF Mechanism Static Forces Calculations ...................................... 59
Table 2-6 Crank Slider O2BF Mechanism Static Forces Calculations ...................................... 60
Table 3-1 Arduino Mega Board Specifications[14] .................................................................. 65
Table 3-2 RC-280 Vibration Motor Specifications ................................................................... 71
Table 3-3 RS555 Motor Electrical Specifications ..................................................................... 75
Table 3-4 Performance Data of Wiper Motor-WD1160/1160-B .............................................. 77
Table 5-1 Analysis Conditions and Results for C-section Plate .............................................. 114
Table 5-2 Conditions and Results of C-Section Frequency Test ............................................. 116
Table 5-3 Plates Steel Specifications ....................................................................................... 119
Table 5-4 Aluminum Alloy Specifications .............................................................................. 123
Table 5-5 Longitudinal Sealing Analysis Conditions and Results .......................................... 123
Table 5-6 Transverse Sealing Jaws Analysis Conditions And Results ...................................126
Table 5-7 Sealing Jaws Heat Analysis Results ........................................................................131
Table 5-8 Springs Steel Material Specifications .....................................................................131
Table 5-9 Longitudinal Sealing Spring Analysis Conditions And Results ............................. 131
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 5-10 Transverse Sealing Spring Analysis Conditions And Results .............................. 133
Table 6-1 Rods Standard tables[31] ........................................................................................ 158
Table 6-2 Standard Dimensions of Tie Rod Ends[32] ............................................................. 159
Table 6-3 Guide Ways Standard Dimensions Table[33] ......................................................... 161
Table 0-1 Input Data for Sealing Mechanism Kinematic Analysis ......................................... 169
Table 0-2 Jaws Relative Velocity Values ................................................................................ 169
Table 0-3 Back Plate Relative Velocity Values.......................................................................169
Table 0-4 Jaws Relative Acceleration Values ......................................................................... 169
Table 0-5 Back Plates Relative Acceleration Values .............................................................. 169
Table 0-6 Jaws Forces values ..................................................................................................170
Table 0-7 Back Plate Forces values ......................................................................................... 170
Table 0-8 Output Data For Jaws And Back Plates Kinematic Analysis Summary ................. 170
Table 0-9 Crank Relative Velocity Values ............................................................................. 171
Table 0-10 Crank Relative Acceleration Values ....................................................................171
Table 0-11 Crank Forces Values ............................................................................................. 171
Table 0-12 Crank Analysis Results Summary ......................................................................... 171
Table 0-13 The Angular Velocity of the Coupler Values ........................................................ 172
Table 0-14 The angular velocity of Coupler with rod Values ................................................. 172
Table 0-15 The Angular Acceleration of Coupler Values ....................................................... 172
Table 0-16 The Angular Acceleration of Coupler With Rod Values ......................................172
Table 0-17 Total Force of The Coupler Values .......................................................................172
Table 0-18 The Total Force of Coupler With Rod Values ...................................................... 172
Table 0-19 Output Data OF Coupler Analysis Summary ........................................................ 173
Table 0-20 The Rocker Angular Velocity Values ...................................................................174
Table 0-21 The Rocker with Rod Angular Velocity Values ................................................... 174
Table 0-22 The Rocker Angular Acceleration Values............................................................. 174
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 0-23 The Rocker with Rod Angular Acceleration Values ............................................. 174
Table 0-24 The Rocker Force Values ...................................................................................... 174
Table 0-25 The Rocker with Rod Force Values ......................................................................174
Table 0-26 Rocker and Rocker with Rod Analysis Output Summary.....................................174
20
Chapter One:
Introduction
and Literature
Survey
VERTICAL FORMING, FILLING AND SEALING MACHINE
1. Introduction and literature survey
1. Introduction
In this chapter, history of food packing machines is introduced through ages. Starting with first
package made at Napoleon Bonaparte life in early 1800s, passing through packing during
middle of 1800s and its final. Packing during world wars and industrial revolution are included. The new packing developments and active packing are described as well. Then the VFFS
history is mentioned in detail. Surveys are done for machine different types and systems. Filling system two common types volumetric filling and weighting filling are described. Surveys
done on sealing jaw types and sealing mechanisms. Different types of film transport and
chasses are mentioned in detail. The material selection criteria for the project was mentioned,
primary and secondary constrains are made. Then a group of materials was selected. The machine specification is mentioned and according to the specifications the final selections was
made.
2. History of Food Packing
2.1.
Early Developments in Packaging
The Industrial Revolution brought the development of new manufacturing processes and new
materials. Although initially many of them were not intended for food products, they became
useful as food packaging materials. Metal cans were initially manufactured for snuff, for
which they provided an excellent barrier to maintain the moisture of the product as well as
providing protection for the flavor of the product. They later were used in the canning operation that was discovered by Nicholas Appert when he answered a challenge from French Emperor Napoleon Bonaparte to develop a method to preserve food for his army. Appert used
glass bottles with corks secured with wire as a closure to contain food while heating. The glass
bottles were fragile and were soon replaced with metal cans, allowing products to be heat processed much more readily to extend their shelf life and prevent spoilage. Paperboard was first
used to manufacture folding cartons in the early 1800s. Corrugated boxes that today are widely
used as a shipping container to hold a number of smaller packages were developed in the
1850s. Plastics including cellulose nitrate, styrene, and vinyl chloride were discovered in the
1800s but were not used in any packaging until well into the 20th century. Some of the first
uses were during World War II with commercialization for food packaging occurring after the
war.
One part of a package that was patented in 1892 played a significant role in the development
of the beverage industry. William Painter, the founder of what today is Crown Holdings, Inc.,
patented the crown cork. This was a metal cap that had a layer of cork inside that gave a good
seal against the top of a glass bottle. Prior to this invention, glass bottles could not be tightly
sealed with a convenient closure and did not provide protection for the products inside the bot21
VERTICAL FORMING, FILLING AND SEALING MACHINE
tles. Products were susceptible to deterioration due to the ingress of oxygen. As plastics and
other synthetic materials have been developed, they have replaced the cork to provide a more
uniform and tighter seal. In one study, it was found that ingress of oxygen using traditional
crown seals with various linears ranged from 0.58 to 1.2 μL per day.
Today, some of the liners in the crown have oxygen-absorbing ability built into them to remove residual oxygen from the headspace in the bottle to slow or eliminate oxidation of the
contents of the bottle.
Biscuits were the first products to be individually packaged and were first sold in the 1890s.
They were produced by the National Biscuit Co., which had recently been formed by the merger of several baking companies. They felt that they needed something new to draw attention
to the company and developed a biscuit which was lighter and flakier than anything else on the
market. Up until that time, biscuits had been packed in large barrels which sat open at the
market. People would pick out as much product as they wanted and put it in a paper bag to
take it home. This provided no protection for the quality of the product other than being a dust
cover. The new product needed moisture protection to maintain the light, flaky texture, and an
individual package was designed with an inner liner to provide that protection. While this may
not seem significant today, it was a major step forward in preserving product quality by
providing a barrier to moisture to keep the product crisp. This also provided protection from
contamination during distribution.[1]
2.2.
Post-World War II
After World War II, there was an increasing focus on food and food quality. Many materials
including plastics that were developed for war applications found their way into food packaging after the war. There have been a number of developments to improve food quality and allow for consumers to have a wide variety of foods year-round. Plastics are one area that has
seen major improvement in materials and their properties. Polyethylene was one of the first
plastics used widely for food packaging.
There are several types of polyethylene in use today including low-density (LDPE), highdensity (HDPE), linear low-density (LLDPE), and very low density (VLDPE). LDPE was the
first to be developed by Imperial Chemical Industries in 1933. The company received a patent
for production of the material that involved compressing ethylene gas and heating it to a high
temperature. The first plastic sandwich bag on a roll was introduced in 1957. By 1966, over
25%of all bread sold was in plastic bags made from LDPE. That package still is in wide use
for most bread products sold. Some companies have gone back to the use of paper bags for
bread to give it an artisanal feel; however, the paper bag does not keep the bread as well and
the quality deteriorates much more quickly than when the bread is stored in a plastic bag.
Although plastics have been more widely used as food packaging materials in the past 50-60
years, new developments in plastics have helped to increase the usage. Professor Giulio Natta
discovered isotactic polypropylene in 1954. The film is often oriented after the casting or
forming process by first stretching the material in the machine direction and then stretching it
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VERTICAL FORMING, FILLING AND SEALING MACHINE
in the crosswise direction to give oriented polypropylene (OPP). This stretching aligns the
molecules, making a film with a better moisture vapor barrier, better clarity, and more stiffness. It is widely used as an overwrap for snack foods.
One process that is used to improve barriers even further is metallization. In this process, an
aluminum wire is heated to 1700 BC in a large vacuum chamber. This vaporizes the aluminum, which deposits on the surface of the film as it is run through the chamber. In the case of
a 50-gauge polyester film, metallizing improves the moisture vapor transmission rate (MVTR)
from 2.0 g/ (100 in.2 3 24 h 3 90% RH) to 0.05, a 40-fold improvement.
One process that has improved overall properties of plastic films is coextrusion, developed in
1964 by Hercules. In this process a film with two or more layers of different types of plastic
can be made in one step without the need to laminate the layers together with an adhesive,
eliminates the use of solvents, and produces a film in one step instead in needing multiple
steps.
Because different types of resin or resin blends are being used, it requires careful control of the
melt properties and viscosity to ensure the appropriate thickness of each distinct material. It is
possible to make structures with much thinner layers than can be made when laminating. Multiple-layer films offer better protection for products as some films are better moisture barriers
and others offer better barriers to gases. One example is polyester film, which provides a better
gas barrier, whereas polypropylene and ethylene vinyl alcohol (EvOH) films are better moisture barriers. These three can be combined readily in one structure to give protection from
both moisture and oxygen permeation.
In the past 15-20 years, only one new plastic has been approved for food contact and that material is polyethylene naphthalene (PEN), which received FDA clearance in 2000. Although
other new plastics have been developed, the process for clearance from FDA in the form of a
letter of no objection is difficult to obtain as extensive safety and environmental evaluations
must be performed. It should be noted that PEN has not seen any widespread use in food
packaging, due to the high cost of the material. There are a large number of new additives and
processing aids that have been allowed.[1]
2.3.
New Package Developments
In addition to broad developments in materials, there have been a number of specific packages
that have both created new food categories and changed the way that we can deliver a product
to the consumer. Metal cans, now typically made of tin-plated steel, have been in use since the
early 1800s. It was not until the 1950s that aluminum cans were first manufactured and used.
Today, aluminum cans are widely used, particularly for carbonated beverages. The first aluminum cans were opened with a can opener, like the way other metal cans are opened. The first
ring pull was introduced in 1963. This facilitated opening a can and being able to drink directly from it. The first ring pulls were not attached to the can and caused concern that someone
could choke on them. It was not until 1975 that what is called the stay tab was introduced,
which is a ring tab that stays attached to the can.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Another package widely used by the carbonated beverage industry is the 2 L plastic beverage
bottle made of polyethylene terephthalate (PET). The concept for the bottle was introduced by
Pepsi in 1970, with a patent on the bottle issued in 1973.
It is interesting to note that this is one of the few packages in the United States that uses a metric size as its standard. The challenge in using PET is that it must provide a barrier to both carbon dioxide and flavors while not contaminating the product with components of the PET that
can migrate from the package to the product. Acetaldehyde is one residual component that can
be present in PET and can create undesirable flavors in the product if it is not tightly controlled. The challenge for smaller bottles was that the carbonation would be lost via permeation through the PET as a smaller bottle has a larger surface to volume ratio. Smaller bottles
are in use today but most of these are either multilayer or have a coating to add the barrier
needed.[1]
2.4.
Active Packaging
There are different types of active packaging. One type, referred to as a susceptor, is used for
microwave foods, including popcorn. The first bag of microwave popcorn was sold in 1971.
The package was a simple paper bag. It was not until the package including a microwave susceptor was introduced in the mid-1980s that the product became a large success. The package
consists of two layers of paper with a metalized PET film (susceptor) laminated between the
layers of paper in a position so that it lies on the floor of the microwave oven. The metallized
film is produced in the same way described earlier but with a thinner layer of metal that interacts with the microwave energy and heat to temperatures of 200 BC or higher (a thicker layer
such as that used for packaging for overwrap would reflect microwave energy instead of absorbing it). The heat generated gives the energy needed to get the kernels to pop. Without the
susceptor, the product will have a large number of unpopped kernels. One initial patent for the
popcorn bag was issued in 1988. In a later legal challenge, the patent was invalidated due in
part to failure to site all the appropriate prior art in some communication with the patent office
as the patent and its continuations were being prosecuted. This technology is used for other
microwave products including pizza, hand-held sandwiches, and French fries. For these products, it helps the surface to dry and enhances browning and crisping.
In addition to the technical challenge of stabilizing the metallized film on a paper substrate,
there was concern about the safety of the packaging materials. The package got to a higher
temperature than was anticipated by any FDA regulations. The FDA was concerned about the
possibility for migration from the package and the potential for components of the package to
degrade during heating, creating low molecular weight unknown compounds that could also
migrate into the food in the package. Industry came together to develop analytical methodology to measure the potential for migration of both volatile and nonvolatile components from the
susceptor packaging. Although FDA had issued an advanced notice of proposed rulemaking
(ANPR) in 1989, it eventually abandoned the ANPR as industry had provided the necessary
data to show the safety of the package.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
One other type of active packaging material is one that can absorb oxygen. As was mentioned
earlier in relation to the liners of crowns for beer bottles, oxygen absorbers can be built into
packaging to remove residual oxygen from around product or a sachet with material (typically
iron oxide) can be placed inside the package.
Some companies are exploring means of incorporating flavors into packaging to maintain the
quality of the flavor and have it release at the time of consumption. One package has been developed by Lee Reedy. Flavors and nutritional supplements are sealed into the cap for a bottle.
When the cap is twisted to open the bottle, a small plastic blade cuts the seal and releases the
nutrients and flavor into the beverage. This preserves the quality and freshness of the flavors
and supplements until the time of consumption.[1]
2.5.
New Package Developments
Another package that has created a new category in the supermarket is the film used for freshcut vegetables. The vegetables are still respiring so the film needs to be breathable to both carbon dioxide and oxygen while providing a barrier to moisture. Different vegetables respire at
different rates, requiring films with different permeabilities. This is just one type of controlled
atmosphere packaging. There are many others where the atmosphere around the product is
specifically changed to prolong the shelf life of the food. Any time the atmosphere is modified
or controlled, the appropriate packaging material must be used to maintain the desired atmosphere and not allow the gases to permeate through the package. The Tetra Pack Co. was
founded in 1951 in Sweden. The main product of the company is a laminated packaging material that combines paperboard for rigidity, foil for a light and gas barrier, and plastic as both a
barrier and sealant layer. The package is formed on a special machine that also fills the product into the formed package. The product can fill aseptically, resulting in a product with the
shelf life of a canned product but much less heat stress. The package is used for some products
in the United States but has found much greater acceptance in other countries. An entirely new
way of presenting a product was introduced by Dean Foods in 1998. Known as the Dean’s
milk chug, this package is a high-density polyethylene blow-molded bottle with a screw cap.
Although milk had been sold in large containers with a screw cap, this was the first company
to launch single-serving containers with a screw cap. In addition to making milk a portable
beverage, a significant advantage is that the HDPE bottle provides a light barrier to help prevent deterioration in the flavor of the milk.[1]
3. Machine History
The first Vertical Form/Fill/Seal (VFFS) machine was patented in 1936 by Walter Zwoyer
whilst working at “Henry Heide Candy Company”. Walter” & “Heide” formed the “Transparent Wrap Machine Co.” to build and sell VFFS machines. At that time, modified cellophane
was the main flexible packaging material and Walter named his machines “Transwrap” to reflect that.
25
VERTICAL FORMING, FILLING AND SEALING MACHINE
The demand for “Transwrap” machines grew fast. Stokes & Smith also started manufacturing
machines for Walter under a license. Walter had patented many new inventions up till the
1950’s, those included important improvements to the VFFS machines and infeed machines /
automating weighing machines to insert product into VFFS machines.
As they say, ‘success has many fathers’. Walter was not left alone and was embroiled in many
court cases during the later years of his life. Walter Zwoyer’s patent on VFFS expired in 1954
and the Package Machinery Company purchased the Transparent Wrap Machine Company. At
that time, few of the key employees of Transparent Wrap Company joined Hayssen Manufacturing Company. There was a long court case, where Package Machinery Company tried to
claim money from Hayssen Manufacturing for using their trade secrets, but it could not be
proved in the court of law. The sudden death of Walter Zwoyer didn’t help the Package Machinery case and even after Walter’s death, his family had to go through court cases to claim
money & royalty for his inventions.
During the same time (the 1950’s), the Woodman Company started venturing into the VFFS
machines market. Kawashima (Japan) also built their first machine in 1961.
From the second half of the 1950s to the 1970’s was the time of rapid proliferation of VFFS
machines worldwide with the advent of new materials and technologies and high market demand. Rovema (Germany), Ricciarelli (Italy), Hayssen, Hassia Redatron, Bosch and many
other current leaders of packaging industry started manufacturing VFFS at that time. Ishida
came into the mix in 1970’s and came to the forefront because of their advanced technology
on VFFS machines and leadership position in the multi-head weighing machines category.
TNA started in 1982 and soon made its presence felt in VFFS machines category.
Walter Zwoyer’s “Transwrap” brand for the VFFS machines remained in the packaging industry for about 50 years and eventually became the part of Bosch.
As it usually happens, the life cycle of innovations can possibly be described using the Scurve, which maps growth of revenue or productivity against time. The s-curve of technological innovation summarizes four major stages in the evolution of a product which are emergence, rapid improvement, declining improvement, maturity.
The current stage of the VFFS machines life cycle may be debatable, but it would be in the
rapid improvement stage.
4. Why VFFS?
4.1.
VFFS Machines Manufacture is not Widespread in Egypt
VFFS machines are manufactured in small number in factories in Egypt. Most of these factories just assembly the machine parts and does not manufacture it is parts. Most of VFFS machines are imported. Studying how to manufacture the VFFS machine by minimum cost and
26
VERTICAL FORMING, FILLING AND SEALING MACHINE
parts made in Egyptian workshop. This will lead to more job opportunities and reduce costs of
imports. Then if this machine is mass produced it can be exported.
4.2.
Experience
This project includes most of knowledge learned during university period. This will give
members more experience by applying all this science in a real-life application and qualify
them to their career. In this project the team members used design principles, forming and machining technologies, industrial safety, material science…etc.
4.3.
Suitable For Youth Startups
Most of youth are searching for small projects to improve their income or to start their careers.
The VFFS machine is a very suitable startup project which does not cost a large initial cost
and has a suitable income. The machine can be easily used in small places so there is no additional costs. The VFFS machines does not require skilled labors because it is user friendly and
does not require more than one operator. Since manufacturing this machine reduced its cost
compared to imported machine this will help more youth to start their project.
4.4.
Environmentally Friendly
The VFFS machines are electrical machines does not require any source of fuel. It is manufacture as well depends totally on electrical machines e.g., laser cut machines, bending machines,
3D printing machines…etc. this machine does not produce any type of harmful gases for the
environment.
5. VFFS types
5.1.
Liquid filling machine:
Figure 1-1 Liquid filling machine
27
VERTICAL FORMING, FILLING AND SEALING MACHINE
Liquid filling machines, also known as flow filling machines, are commonly used in the beverage industry. It dispenses the exact amount of liquid-based products needed for different
containers such as bottles, cartons, cans, or cups. An example of liquid filling machines is
shown in Figure 1-1.
-
This type of filling machine can handle a wide range of liquids, including water, alcoholic beverages, and carbonated drinks. It can even be utilized to fill packaging food
items such as sauces, cooking oil, soup, and salad dressing [2]
5.2.Powder Filling Machine:
Figure 1-2 Powder Filling Machine
Powder filling machines are designed with a spiral feeding and light control technology that
ensures high-filling accuracy and zero-drip operation. This type of filling machine is suitable
for filling both free-flowing and non-free-flowing powdered or granulated products.
Free flowing simply refers to powdered products that cannot maintain its shape even when extra pressure is added. Examples include granulated sugar or table salt. In contrast, non-freeflowing products, such as powdered milk and brown sugar, can be compressed and keep their
shape.
Powder filling machines are usually used in pouring additives, starch, feed, condiments, and
pesticides into different types of packaging. As such, they are commonly seen in the food and
beverage, cosmetics, and chemical industries. An example of powder filling machines is
shown in Figure 1-2. [2], [3]
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.3.
Vibratory Weigh Filling Machine
Figure 1-3 Vibratory Weight Filling Machine
Figure 1-4 Filling System of The Vibratory Filling Machine
This type of filling machine as shown in Figure 1-3 is designed with multiple vibrating trays to
carefully dispense products into a weigh bucket. Once the required weight is achieved, the
bucket would empty the product into a container.
Vibratory weigh filling machines are commonly used in the controlled distribution of products
that are unsuitable for traditional powder filling machines. They are capable of filling dry
granular substances that require precise weighing., making them extremely essential in industrial and chemical industries. The filling system of this machines is shown in Figure 1-4.[2]
5.4.
Positive Displacement Pump Filling Machine:
This type of filling machine is designed with a positive displacement pump head that
can easily handle a wide range of substances, As shown in Figure 1-5.
29
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 1-5 Positive Displacement Pump Filling Machine
It is mainly used in filling high-viscosity liquids such as gels, creams, and lotions. However, it
is also capable of pouring water-thin and heavy-paste products. This includes shampoo, hair
conditioners, hair gels, cosmetic creams, honey, heavy sauces, paste cleaners, and car wax
among many others.
Filling machines are commonly used for packaging food and beverage products but they can
also be applicable in other industries. Remember these 5 different types of filling machines to
have a rough idea of which machine to invest in.[2]
5.5.
Capsule Filling Machine
Instead of filling containers by weight, this type of filling machine relies on pouring
substances by piece or number, As shown in Figure 1-6.
Figure 1-6 Positive Displacement Pump Filling Machine
capsule filling machines are commonly used for pharmaceutical purposes as medicines are
very crucial to people’s health. They are capable of accurately counting soft and hard gelatin
capsules, tablets, coated tablets, and pills.
Aside from the pharmaceutical and food industry, this filling machine is also used in agriculture, health care, and chemical engineering applications.[2]
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VERTICAL FORMING, FILLING AND SEALING MACHINE
6. Surveys
6.1.
Types of Filling Systems
Table 1-1 comparison between weight filling system and volumetric filling system [2], [3]
Weight Filling Machine
Volumetric Filling Machine
weight machines utilize scales to weigh
containers and fill until the determined
weight is reached. These machines have
less product contact and are easier to
clean than volumetric machines. These
machines will typically return about half
the speed of a volumetric machine for
containers 1 gallon and smaller. With the
latest innovative technology, our net
weight filling machines are ideal for customers who require data tracking or require highly accurate fills.
volumetric filling machines are available with
either 1 gallon or 5-gallon double acing positive displacement volumetric piston pumps.
Double acting pumps have product on both
sides of the piston which keeps the cylinder
walls and seals lubricated and increases the life
of the pump. These machines are fast, accurate,
easily adjustable, and simple to clean. They are
ideal for customers who prefer a less technologically complicated setup and who prioritize
speed.
6.2.
Types of Bags
6.2.1. Bag Making
In theory, all vertical packaging machines work the same. A flat web of film, originating from
a large roll of film at the start of the machine, is shaped into a tube. This tube is closed at the
bottom: this is the bottom of the new bag. As soon as the product is dispensed into the bag, the
top side is also closed. The time and steps that are needed to make one bag are collectively
called a machine cycle.
6.2.2. Bag Types
In principle, VFFS machines produce three types of bags. Within these main types, there are
countless possible variations in model, length and width.
•
•
Products such as fresh vegetables, chips or candy are usually packaged in a pillow bag. This bag shape is also called a flat bag.
A common variation on the pillow bag is the gusset bag and it is usually presented in combination with a carton or box around it. It is commonly used for
packaging breakfast cereals.
31
VERTICAL FORMING, FILLING AND SEALING MACHINE
•
•
6.3.
A bag that can stand up with a flat bottom, often referred to as a block bottom
bag and is used for cookies or coffee, for example.
The doy bag, is another form of stand-up bag, and is often referred to as a stand
up pouch. [2], [3]
Sealing System Types
As shown Figure 1-7 in there are different types of sealing jaws as:
•
•
•
•
•
•
•
•
•
Fin Seal Roller
Small Rotary Flow Wrap Sealing Jaw without Knife
Rotary Flow Wrap Sealing Jaw with Hole Punch Cut-outs
Rotary Flow Wrap Sealing Jaw Complete with Removable Insert
Vertical Bagging Sealing Jaw Complete with Heated Euro Punch and Anvil
Rotary Flow Wrap Sealing Jaw with Reduced Sealing Area
Vertical Bagging Sealing Jaw
Rotary Flow Wrap Quad Sealing Jaw
Rotary Flow Wrap Sealing Jaw Complete with Removable Heated Euro Punch
System [4], [5]
Figure 1-7 Types of Sealing Jaws
6.4.
Types of Sealing Mechanism
6.4.1. Bar Mechanism Transmission System
Using 4bar Mechanism as a source of transmission as shown in Figure 1-8
32
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 1-8 4 bar mechanism intial design
•
4bar mechanism the main motion for the transverse sealing; but the assist motion for
the longitudinal sealing by contacting with the shaft
The process
Figure 1-9 4 Bar mechanism Design
From Figure 1-9:
•
•
•
The longitudinal jaws are behind the collar (forming shoulder) and forming tube to seal
the film along the process.
The transverse jaws are fixed in two plates which moving by 4bar mechanism to seal
the product bag.
The relation between the (longitudinal and transverse sealing) end of transverse sealing
starts a new longitudinal seal.
6.4.2. Cam System with Mechanical Piston Cylinder
•
•
Cam shaft system: the cam shaft is the source of the transmission system which contact
with ( rod and
two pully contact with two cam inverse
in position )
two springs above the rod to control in transverse system motion as linear motion (
back and forward )
at the top of the cam shaft another (pully , cam and rod) especially for the longitudinal
sealing
system
the rod fixed with the longitudinal gate by bolts it’s motion from pully and cam
33
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 1-10 Cam Shaft Mechanism Front View
The main parts
Figure 1-11 Cam Shaft Mechanism Main Parts
Variables of the sealing systems
Longitudinal sealing system
•
•
•
One Jaw in front of the forming tube contact with the upper pully.
Its internal mechanism from two rods as a drag (pull) system.
The sealing jaw has no teeth as the longitudinal sealing occur from impact between the
jaw and forming tube.
Transvers sealing system
•
two jaws one of them contact directly with the rod ( the external jaw )
34
VERTICAL FORMING, FILLING AND SEALING MACHINE
•
the internal jaw contact directly by the pully and on the rod by two circular guide
ways the spring acting it’s role by controlling in the transvers sealing motion ( external jaw related to the internal )
6.4.3. Pneumatic system
•
•
•
•
•
Pneumatic Type VFFS machine used for liquid & semi liquids more than powder
depends on pneumatic circuits design
Required valves and compressor
it’s the same parts of cam system put the motion system difference as it machined by
pneumatic circuits put the other machined by mechanical cam system
Supported by piston cylinder
The difference type of sealing
1) The longitudinal sealing
the jaw take its linear motion from the high pressure which generated by the pneumatic
cylinder which fixed on front of the jaw fixture .
2) The transvers sealing
Works by two pneumatic piston cylinder The high pressure generate the motion
Figure 1-12 A VFFS Machine with Pneumatic Sealing System
Comparison between 3 systems
Table 1-2 Comparison Between Types of Sealing Mechanism
P.O.C
4 Bar Mechanism
Mechanical Cam
System
Pneumatic System
Accuracy
Good
High
High
Productivity
Good
high
High
Used for
Low quantity
High productivity
High productivity
35
VERTICAL FORMING, FILLING AND SEALING MACHINE
Design
simple
complex
Simple
Cost
The minimum cost
compared to other
systems
High cost
High cost
Wasted Cost
No wasted cost
High wasted cost
No wasted cost
Maintenance
At different time intervals
Requires good follow
up of the parts constantly
Requires good follow
up of the parts constantly
Spare Parts
available
Hard to get
Hard to get
Parts Machinability
Good and always
available
Takes long time and
high cost
Requires high quality
and take long time
manufacturing
Friction
Low Friction
High Friction because the contact between the parts and
each other
High because the
contact between piston cylinders
6.5.
Types of Film Transport Component System
6.5.1. Film Transport Using Friction Roll Mechanism
This film transport system consists of friction rollers as shown in Figure 1-13 to keep the film
straight without bends. The pulley and belt are used to pull the film downwards and control the
bag shape regularity. It keeps bag with equal diameter. The mechanism controls the film flow
velocity.
Figure 1-13 Film Transport Using Friction Roll Mechanism
36
VERTICAL FORMING, FILLING AND SEALING MACHINE
6.5.2. Film Transport System Using Shafts only
As shown in Figure 1-14, in these machines a simple film transport system is used. The film
roll is hanged on a shaft. This shaft rotates when the film is pulled downward. The film is
pulled downward using pulleys. The already longitude sealed part is the only part of the film
pass through pulleys. The pulleys controls film flow velocity. By controlling film velocity bag
size is determined.
Figure 1-14 VFFS with Shafts Transport System
6.6.
Collar (Bag Former) Types
6.6.1. Round Bag Former
•
•
•
•
High standard raw material.
Easy to use with good precious
Excellent film tracking
Can be custom designed to any packing machine models
Figure 1-15 Round Bag Former for Mechanism with Friction Roll
The round forming shoulder is the most commonly used on vertical packing machine. The
structure is relatively simple, and the machining accuracy is easy to guarantee. It is suitable for
37
VERTICAL FORMING, FILLING AND SEALING MACHINE
most of the packing requirements, it runs efficiently and steadily on continuous high-speed
machines. It has two different types according to the type of film transport system the first
type as shown in Figure 1-15 used with machines with film transports system using friction
rolls. The second type as shown in Figure 1-16 used with film transport systems using shafts
only
Figure 1-16 Round Bag Former for Mechanism with Shafts only
6.6.2. Rectangular Bag Former
• High standard raw material.
• Easy to use with good precious
• Excellent film tracking
• Can be custom designed to any packing machine models
As shown in Figure 1-17, The forming tube with a rectangular collar edge radius is ideal for
forming bag with square bottom without the need to mark the corners and therefore without
subjecting to tension the film.
Figure 1-17 Rectangular Bag Former
38
VERTICAL FORMING, FILLING AND SEALING MACHINE
When producing the Four-side Edge or when film size is larger, normally use square forming
shoulder.
6.6.3. Oval Bag Former
• High standard raw material.
• Easy to use with good precious
• Excellent film tracking
• Can be custom designed to any packing machine models
Oval Forming Set is for the forming of bags with wide band, the possible creation of wrinkles
in the implementation of the film is significantly reduced.
When the material is special, or the zipper bag uses an Oval forming shoulder, easy help to
form.
Oval forming sets are provided with oval collars.
If you required Oval Type Forming Shoulders, we also can produce[6].
Figure 1-18 Oval Bag Former
6.7.
Types of Chassis
6.7.1. space frame
As shown in Figure 1-19 space frame is a machine frame that made from structural members
only. Most of time has square or rectangular cross-section. This reduces raw material, which
reduces material cost as well. But it requires many welds which makes its total manufacture
cost increase. Also, it is hard to design because it requires additional brackets compared to designs contains sheet metal. And it is hard to be modified after manufacture compared to sheet
39
VERTICAL FORMING, FILLING AND SEALING MACHINE
metal. In addition to the internal components will be exposed to external environment which
reduces its working life and make it requires more maintenance.
Figure 1-19 Space Frame
6.7.2. Structural members and sheet metal frame.
In Figure 1-20, two examples of structural members chassis covered with sheet metal. This is
the stiffest chassis which make it the best choice for large machines and heavy-duty machines.
In contrast with space frame, it protects machine components from external environment
which reduce maintenance requirements. But it is raw materials cost and manufacture cost is
high. As it combines between sheet metal processes (laser cut, bending, welding…etc.) and
structural member processes (manual or laser cutting, welding…etc.)
Figure 1-20 Structural Members and Sheet Metal Frame
6.7.3. Bended sheet metal chassis
As shown in Figure 1-21, bended sheet metal depends on sheet metal only. The stiffness depends on the sequenced bends made in sheet metal, it does not require welding and can be as40
VERTICAL FORMING, FILLING AND SEALING MACHINE
sembled using bolts. It does not require brackets for assembling components to it. The filling
mounting is more stable than that in space frame. It is cost in minimum compared to the space
frame and structural members with sheet metal chassis. It is easily modified after manufacture
and can be assembled with additional components. It is stiffness is lower than the chassis containing additional structural members. But it is suitable for small applications with low loads.
Figure 1-21 Sheet Metal Frame
Table 1-3 shows a comparison between the three chassis types from cost of raw materials and
manufacture, types of process done, time required to design…etc.
Table 1-3 Comparison Between Types of Frames Used in VFFS Machines
P.O.C
Space frame
Structural
members Bended sheet metal
and sheet metal
Raw material Low cost
cost
High cost
Medium cost
Manufacture
cost
Medium cost
High cost
Low cost
Manufacture
less hard than structural Hard to manufacture
members with Sheetmetal
The easiest to manufacture
Welding
Yes
Yes
No
Bending
No
Yes
Yes
Design
time scale
to Hard to design and takes Less hard than space The easiest to design
time
frame and takes less and require less time
41
VERTICAL FORMING, FILLING AND SEALING MACHINE
time
••
Total
6.8.
•
•••
Material selection
Material selection process depends on the following chart shown in Figure 1-22.[7]
Figure 1-22 Chart of Material Selection
6.8.1. Applying primary constrains
According to the chart in Figure 1-22, there is only one main primary constrain for the machine components material. The main constrain is being suitable for food industry. These materials should have the properties of compatibility, workability, and related hygiene features.
From the above constrains a subset of candidate materials were selected
•
Stainless steel is the preferred general use metal for food contact surfaces because of
its corrosion resistance and durability in most food applications. However, not all
stainless steel is equal. In general, the properties of the stainless-steel alloy are related
42
VERTICAL FORMING, FILLING AND SEALING MACHINE
to its relative composition with regard to chromium and nickel level. Corrosion resistance varies with chromium level, and structural strength varies with nickel level.
The relative levels of these components are often given as a ratio. For example, the American
Iron and Steel Institute (AISI) 300 Series Stainless Steel, commonly recommended for food
contact surfaces is also termed 18/8 indicating that it is 18% Cr and 8% Ni. 3A Sanitary
Standards require 316 (or 18/10) stainless steel for most surfaces. They allow the use of 304
stainless steel only for utility usage (e.g. pipes), and restrict the use of 303 stainless steel. 3A
Standards also provide specifications regarding alloys and other coatings used in fabrication.
The properties of stainless steel can change with continued use, especially under conditions
where the chromium oxide layer is altered (e.g. incompatible cleaners, abrasive cleaners, abrasive cleaning pads, or chlorine and related sanitizers). Therefore, it is recommended that surfaces be passivated (using nitric acid or other strong oxidizing agents) initially and on a regular frequency thereafter, to maintain a passive (non-reactive) oxide film on the surface. Passivation of stainless-steel food contact surfaces is recommended after any surface repair, polishing, or working.
Other metals are limited by application as follows:
•
•
•
•
Copper is primarily used for equipment used in the brewing industry, with some use
for cheese vats in Swiss cheese manufacture, due to tradition. Care should be used with
copper equipment when processing acid products, as copper residues can leach into the
product.
Aluminum is used in certain parts and components where lighter weight is desired.
However, aluminum has poor corrosion resistance and can become pitted and cracked
with continued use. Care should taken when cleaning and sanitizing aluminum components as oxidizing chemicals can accelerate the pitting of the metal. In most food contact applications, aluminum must be coated with an acceptable material. Plastic coatings such as polytetrafluorethylene (PTFE or Teflon®)are common.
Carbonized metal and cast iron are only used for frying and cooking surfaces, and
similar applications in food service.
Non-metals
A variety of non-metal materials are used as food contact surfaces in specific applications of food equipment (e.g., probes, gaskets, membranes). These materials should
meet the same sanitary design and cleanability requirements as metals when used in
these applications as described in 3 A Sanitary Standards and other standards. Nonmetal surfaces, in general, lack the corrosion resistance and durability of metal surfaces, therefore, maintenance programs should include frequent examination for wear and
deterioration under continued use, and replacement as
appropriate.
Non-metal materials used in food contact surfaces include:
43
VERTICAL FORMING, FILLING AND SEALING MACHINE
•
•
•
•
•
•
Plastics, rubber, and rubber-like materials that should be food grade and should
meet the requirements designated under 3A Sanitary Standards (18-03 and 20-20).
Multi-use plastics, rubber, and rubber-like materials may also be considered as indirect food additives under FDA regulations.
Ceramics are used primarily in membrane filtration systems. They may also be
used in other limited applications if wear resistance is necessary.
Glass may be used as a food contact surface. These applications are limited due to
the potential for breakage. Specially formulated glass materials such as Pyrex®
have proven successful. When glass is used, it must be durable, break resistant or
heat resistant glass.
Some applications where glass is used are light and sight openings into vessels and
in very limited glass piping applications.
Paper has been used over the years as a gasket material in piping systems designed
for daily disassembly. Paper is considered a single use material.
Wood, which is highly porous and difficult to clean, should be avoided as a food
contact surface. Wood is restricted in food service applications by most regulatory
agencies, with the exception of hardwood cutting boards and tight grain butcher
blocks.[8]
Table 1-4 Comparison Between Different Types of Material alloys and their Chemical and
Physical Resistance [9]
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VERTICAL FORMING, FILLING AND SEALING MACHINE
6.8.2. Applying secondary constrains
•
•
•
•
•
•
•
Stiffness
Low cost
Low vibrations
High heat resistance
High corrosion resistance
Low toxicity for packed food
Available in the local market and easily machined
From the secondary constrains a range of different materials are selected according to their
different functions and place
45
VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 1-5 The difference between different stainless-steel grades[10]
•
•
•
•
6.9.
Aluminum is also available in the Egyptian market but for sheet metal it requires
good heat treatment to increase stiffness and reduce vibrations, but it is suitable for
casted parts.
Steel A36 is the most common structural steel grade in the local market, it is non
toxic material but it is exposed to rust so it needs coating. It is not preferred to use
with parts directly touch food but it can be used in structures of the machines.
Hard chrome is suitable material for mechanism parts as it does not touch food
and is not exposed to rust.
Plastics that should be food grade and should meet the requirements designated
under 3A Sanitary Standards is used. Because it is easily used material with 3d
printing parts, also acrylic sheets are suitable for some structural parts.
Types of Electric Systems
6.9.1. PLC
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a
custom program to control the state of output devices.
Almost any production line, machine function, or process can be greatly enhanced using this
type of control system. However, the biggest benefit in using a PLC is the ability to change
and replicate the operation or process while collecting and communicating vital information.
Another advantage of a PLC system is that it is modular. That is, you can mix and match the
types of Input and Output devices to best suit your application.
46
VERTICAL FORMING, FILLING AND SEALING MACHINE
PLC main limitation is the cost. PLC components cost is about 4 times compared to Arduino
components. And it is programming language is advanced. In addition to data leakage about it
is programming which makes it harder to learn and use.
6.9.2. ECS
The embedded system is a type of system that is very powerful, fast, and small size in nature
so that it can easily fix in other systems and perform their task. The embedded system can be
categorized as a computer system but they do not perform the operations performed by computer systems. The embedded systems can be used in mobile phones, medical devices, or any
other manufacturing equipment. Various types of operations and functions can perform by
embedded systems and used to control smaller parts of a larger system. The embedded system
is generally a combination of software and hardware system and other components parts so
that a particular operation can be executed.
When the embedded system is designed the functions cannot be changed once it is designed on
another hand in a computer system this functionality of replacing components and software is
possible. From the embedded system one single function or multiple functions can be performed but once it is designing the functionality cannot be changed for the embedded systems.
The microprocessor is the key component of an embedded system.
The embedded system can be used to execute an operation or can help in executing tasks in a
repetitive manner.
In addition to the unchanged functionality, it is hard to program ECS. ECS also became uncommon control system in VFFS. It is hard to get the code or design it.
6.9.3. Arduino
Arduino is an open-source platform used for building electronics projects. Arduino consists of
both a physical programmable circuit board (often referred to as a microcontroller) and a piece
of software, or IDE (Integrated Development Environment) that runs on your computer, used
to write and upload computer code to the physical board.
The Arduino platform has become quite popular with people just starting out with electronics,
and for good reason. Unlike most previous programmable circuit boards, the Arduino does not
need a separate piece of hardware (called a programmer) in order to load new code onto the
board -- you can simply use a USB cable. Additionally, the Arduino IDE uses a simplified
version of C++, making it easier to learn to program. Finally, Arduino provides a standard
form factor that breaks out the functions of the micro-controller into a more accessible package.
This makes Arduino a simple method for the machine control system. Arduino is also affordable controlling system as its components costs less than the other methods. And it is easily
modified unlike ECS. So it was the most suitable controlling system for the project.
47
VERTICAL FORMING, FILLING AND SEALING MACHINE
7. Machine Specification
After studying the available machines in the market specifications and making surveys
about different types. The following specifications was selected.
•
Speed: 15: 20 bags/min
•
Filling weight: 1:100 gm
•
Accuracy: ±0.2-1 gm based on raw material
•
Bag material: heat sealing film
•
Sealing type: three side
•
Machine size: 155 cm*42cm*50 cm
8. Final Selections
According to the machine specification, the following selections are done:
•
•
•
•
•
•
•
•
•
For filling system, it is required high accuracy, and small size filling and speed is relatively low. The most suitable system is weight filling system
Filling bag selected is bag with 3 sealing two transverse and one longitudinal.
Sealing mechanism selected is 4 bar mechanism as it is suitable for small size machines and gives suitable accuracy.
Sealing jaws selected are Vertical Bagging Sealing Jaw
For film transport system, film transport system with shafts is selected as it is suitable
with low-speed machines and small size bags.
Round bag former is selected because it is easy to use with high accuracy.
Chassis selected is bended Sheetmetal chassis as loads on this machine is relatively
low and machine size is small.
Material final selection will be done during modelling, analysis, and manufacture processes.
Electrical system used is Arduino because it is easy programmed system and will give
satisfying results.
48
Chapter Two:
Design
Considerations
VERTICAL FORMING, FILLING AND SEALING MACHINE
2. Design Considerations
1. Introduction
In this chapter mathematical calculations are done. These Calculations are the base of our mechanical design. The Calculations includes selecting suitable inclination angle for some parts,
spring selection, forces affecting on parts, parts dimensions…etc. These calculations are used
in chapter three for selecting suitable motors. And used in chapter 4 for modelling the system.
2. Calculations Required for The Filling System
2.1.
Filling Components Inclination Angle
According to R. Nwaba et al. the friction coefficient of hungry rice varies according to the material. The material used in the filling system is stainless steel 304. But it would be considered
mild steel to take the greatest friction coefficient, as shown in Figure 2-1.
Figure 2-1 The Relation between Moisture Content and Coefficient of Friction of Hungry Rice
with Different Materials[11]
According to his curve:
Max angle to move = 45°
𝜇 = 𝑡𝑎 𝑛 𝜃 = 0.946
(2.1)
𝜃 = 43.41°
(2.2)
According to Al-Hashemi et al. literature review on the angle of repose of granular material. The
largest angle of response for different grains is 45 As shown in Table 2-1. [12]
Angles selected for the filling system should be larger than 45. Larger angles provide smoother
motion.
49
VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 2-1 Typical Values of Angle Response[12]
2.2.
Filling Spring Calculations
Based on common spring dimensions and spring material available in Egypt , shown in Table
2-2.
𝐺. 𝑑4
𝐾=
8. 𝐷3 . 𝑛
(2.3)
Substitute values in equation (2.3)
2.03 ∗ 106 ∗ (1.4)4
𝑁
= 7.26
3
8 ∗ (11.5) ∗ 10
𝑐𝑚
𝐾=
𝐾𝑒𝑞 = 𝐾 ∗ 𝑁𝑜. 𝑜𝑓 𝑠𝑝𝑟𝑖𝑛𝑔𝑠
(2.4)
Substitute values in equation (2.4)
𝐾𝑒𝑞 = 7.26 ∗ 4 = 29.048
𝑇=
50
𝑃
𝜔
𝑁
𝑐𝑚
(2.5)
VERTICAL FORMING, FILLING AND SEALING MACHINE
𝜔 = 2𝜋𝑓
(2.6)
Substitute values in equation (2.5) and (2.6)
5
10−4 𝑁
= 2.65 ∗
2 ∗ 𝜋 ∗ 3000
𝑚
𝑇=
𝑇 =𝐹∗𝐿
(2.7)
Substitute values in equation (2.7)
𝐹=
𝑇
= 2.65 ∗ 10−4 ⁄8 ∗ 10−2 = 3.3125 ∗ 10−3 𝑁
𝐿
𝑋(𝑡) = 𝐹⁄𝐾𝑒𝑞 ∗ sin(𝜔. 𝑡)
(2.8)
According to equation (2.8) spring amplitude can be calculated
Table 2-2 Different Spring Models Specifications
2.3.
Gate Motor Torque
Gate has two main positions the first position is closed position. In this case the forces
affecting on the gate are:
1) The grains mass in the cup. Maximum 100 gm.
2) The gate masses
Gate mass is assumed to be 40 gm as it would be made from plastic material. Second position
is when the gate is open only gate mass assumed on it.
𝐹 = 𝑚 ∗ 𝑔
(2.9)
𝑇 = 𝐹 ∗ 𝐿
(2.10)
Substitute the numbers in the equation (2.9) and (2.10) in the first position and second position.
51
VERTICAL FORMING, FILLING AND SEALING MACHINE
2.3.1. First Position:
𝐹 = 0.1 ∗ 9.8 = 0.98 𝑁
𝑇 = 0.98 ∗ 8 = 7.84 𝑁. 𝐶𝑚
𝐹 = 0.04 ∗ 9.8 = 0.3924 𝑁
𝑇 = 0.3924 ∗ 5 = 1.962 𝑁. 𝐶𝑚
𝑇 𝑡𝑜𝑡𝑎𝑙 = 7.84 + 1.962 = 9.802 𝑁. 𝐶𝑚
2.3.2. Second Position:
𝐹 = 0.04 ∗ 9.8 = 0.3924
𝑁
𝑇 = 0.3924 ∗ 4 = 1.5696 𝑁. 𝐶𝑚
𝑇 = 1.5696 𝑁. 𝐶𝑚
Select motor depending on the first position.
1. 3. Sealing Mechanism Calculations
3.1. Sealing Mechanism Requirements
Figure 2-2 Force-Displacement Graph For Plastic 15-35 At Dwell Time 1.5 S And Sealing
Temperature (A) 110 °C And (B) 130 °C[13]
The Plastic 15-35 experienced a similar fluctuation with poor sealing quality at 100 °C samples. The average sealing strength was about 0.35 N and all these samples behaved similarly
regardless of the dwell time. At 110 °C, the sealed samples showed an easy peel with an enhanced seal strength of about 10 N. At this stage the polymer molecules are thought to have
interdiffusion of chains across each other. Above 120 °C, the material breaks at the edge of the
laminated film as demonstrated figure 18. The laminated film failed to tear because the seal
strength exceeds the laminated bon
52
VERTICAL FORMING, FILLING AND SEALING MACHINE
The load displacement graphs for Plastic 15-35 sealed at 1.5s dwell time with a sealing temperature at (a) 110 °C and (b) 130 °C . Figure 1 (a) has two fluctuating peaks with an average
seal strength of about 22.5 N. The first peak was lower than the second peak by about 5 N.
This is because the second surface area has higher sealing surface pressure due to the geometry of Tool 2. At higher temperatures, above 120 °C shown in figure 20 (b), the graph increased sharply with no transition between the two sealing layers. The increase of temperature
resulted in bonding molecules to be stressed and adhering the two surface areas into one layer
(Hishinuma 2009, p. 156). The high-tension force lead to breaking of the laminated film at the
edge of the seal . This concludes that the strength of the laminated seal is stronger than material structure.There are several key factors to achieve a good seal. When the two adhesive layers
are in contact, it requires high temperature to melt the molecular chains in crystalline form and
to diffuse across the interface. Gradually, upon cooling, these molecules form entanglements
and recrystallize after sealing. Dwell time is another reasonable factor to increase the diffusion
coefficient. This phenomenon was only achieved over range of temperature exceeding 110 °C
for fiber-based material, 120 °C for Plastic 15-35 and 140 °C for Plastic 50 with 1.5 s dwell
time. Therefore, the suggested optimum processing parameter is to use sealing temperature
130 °C with 1.5s dwell time for production.
It is clear the fiber-based material had attractive results than the thermoplastic polymer. The
Fiber 120 recorded a higher seal strength than Fiber 85. This is because the Fiber 120 has
thicker lamination which poses stronger inter diffusion of adhesives molecules across the laminated layer. The cellulose polymer joints play primarily important role in strengthening the
paper materials. The paper materials delivered desired outcome as compared to the OPP films.
According to Clark and Wagner, the OPP is a non-conductive material which induces static.
He concluded that the film distorts causing unattractive sealing at high temperatures above 145
°C. This was not the case with the thermoplastic polymers used in this experiment. For example, the Plastic 15-35 showed sealing distortion above 120 °C[13].
According to the Above the requirements are:
•
•
•
•
•
stroke =40mm
initial rpm=40 rpm
force = 30N
torque = 32 kg.cm
temperature= (100: 130 C)
3.2. Sealing Mechanism Synthesis
3.2.1. Synthesis Conception
•
•
•
•
This is C-R mechanism with slider used for the machine, it transmit motion from
the motor to the sealing system.
calculate the lengths of the parts
Start with the 4 bar mechanism ( C-R) , then the crank slider
work on 2 positions.
53
VERTICAL FORMING, FILLING AND SEALING MACHINE
o first: 𝛾𝑚 when the angle between R1 and R2 equals 0
o second: 𝛾𝑥 when the angle between R1 and R2 equals 180
Figure 2-3 Mechanism Initial Drawing
Table 2-3 Initial Data Used in Calculations
Input
Output
Data
Assumed
Δ1
Ѳ4
R3 , R2
Δ2
L4
R1
3.2.2. Crank Rocker Synthesis
Data: Δ1 = 30̊, Δ2 = 60 ̊
Assume that: Ѳ4 = 95 ̊, L4 = 4 cm
𝛾𝑚 = 90 – 𝛥1 = 60
54
(2.11)
VERTICAL FORMING, FILLING AND SEALING MACHINE
𝛾𝑥 = 90 + 𝛥2 = 150
(2.12)
Use the date Above to draw:
Figure 2-4 Mechanism Synthesis Drawing
Results
𝑅3 = 9.4 𝑐𝑚 , 𝐿𝑚 = 8.2 𝑐𝑚
𝐿𝑥 = √𝑅32 + R42 − 2 ∗ 𝑅3 ∗ 𝑅4 ∗ 𝑐𝑜𝑠𝛾𝑥 = 16.9 𝑐𝑚
𝑅2 =
𝐿𝑥 + 𝐿𝑚
= 2.4 𝑐𝑚
2
(2.13)
(2.14)
𝑅1 = 2.4 + 8.2 = 10.6 𝑐𝑚
3.2.3. crank Slider Mechanism
Initial Position
The angle between R2 & R3 = 180,
𝑎 = 5.2 𝑐𝑚 , 𝛼1 = 117 ̊
𝑅6 = √𝑎2 + 𝑅52 + 2 ∗ 𝑎 ∗ 𝑅5 ∗ 𝑐𝑜𝑠𝛼1
55
(2.15)
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 2-5 Crank Rocker Synthesis Mechanism Drawing in first Position
Final position:
the angle between R2 & R3 = 0 ,
a + x = 88 cm
x = 36 cm , 𝛼2 = 49 ̊
𝑅6 = √(𝑎 + 𝑥 )2 + 𝑅52 + 2 ∗ (𝑎 + 𝑥) ∗ 𝑅5 ∗ 𝑐𝑜𝑠𝛼2
Figure 2-6 Crank Rocker Synthesis Mechanism Drawing in second Position
From equation (2.18) and (2.19)
𝑅5 = 3.1 𝑐𝑚
𝑅6 = 7.16 𝑐𝑚
56
(2.19)
VERTICAL FORMING, FILLING AND SEALING MACHINE
3.3. Sealing Mechanism Static Force Analysis
Static force Analysis is done on this mechanism. with the same mechanism lengths for simplifying the solution. The input data as follow:
AO2 = 17.5 mm, AB = 83 mm, BO4 = CO4 = 30 , DC = 70 mm , BF = 225 mm , O2G = 35
mm
∅1 (O4DC)= 26 ° , ∅2(O2FB) = 7.8°
Mass of slider D = 1.25kg, Mass of slider F = 1.25kg , 𝜇 (𝑓𝑟𝑖𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡) = 0.2
Figure 2-7 Initial Mechanism Drawing Using Solidworks
Figure 2-8 Initial Mechanism Drawing Using GeoGebra
Sealing mechanism consist of 3 mechanisms
•
•
•
Crank Slider O4BF
Crank Slider O4CD
Crank Rocker O2ABO4
57
VERTICAL FORMING, FILLING AND SEALING MACHINE
To facilitate the solution, the mechanism is divided into the previous three mechanisms.
3.3.1. The Crank Slider O4CD
Figure 2-9 The Crank Slider O4CD Mechanism Drawing
Table 2-4 Crank Slider O4CD Mechanism Static Forces Calculations
The
Link
Free Body Diagram
Force Polygon
Calculations
mg = 1.25 * 10 =
12.5 N
𝑚𝑔
12.5
F = tan(𝜙) = tan 26
= 25.6N
F = Fn + (frictional
force) 𝜇𝑚𝑔 = Fn +
2.5 = 25.6N
Fn = 23.1N
F56 = 26.7 N
The
slider
D
The
Link
CD
---
The
Crank
58
F54 = - F56 = F45
= 26.7 N
M41 = F45 * O4C
M41 = 26.7* 3
= 80 N.cm
VERTICAL FORMING, FILLING AND SEALING MACHINE
3.3.2. The Crank Slider O2BF
Figure 2-10 The Crank Slider O2BF Mechanism Drawing
Table 2-5 Crank Slider O2BF Mechanism Static Forces Calculations
The
Link
Free Body Diagram
Force Polygon
Calculations
mg = 1.25 * 10 =
12.5 N
𝑚𝑔
12.5
F = tan(𝜙) = tan 7.8
= 91.25 N
F = Fn + (frictional
force) 𝜇𝑚𝑔 = Fn +
2.5 = 91.25N
Fn = 88.75N
F78 = 92.1 N
The
slider
D
The
Link
BF
--
F78 = - F74 = F47 =
92.1 N
M42 = F47 * O4B
M42 = 92.1 * 3 =
267.3 N
--
The
Crank
59
The total torque of
Rocker = M41 +
M42 = 80+ 267.3 =
356.3 N.cm
VERTICAL FORMING, FILLING AND SEALING MACHINE
3.3.3. The Crank Rocker O2ABO4
Figure 2-11 The Crank Rocker O2ABO4
Table 2-6 Crank Slider O2BF Mechanism Static Forces Calculations
The
Link
Free Body Diagram
Calculations
M4 = F43 * O4B = F43 * 3 = 356.3 N.cm (Total Torque of The Rocker)
The
Rocker
F43 = 356.3 / 3 = 118.8 N
The
Link AB
F32 = - F34 = F23 = 118.8 N
M2 = F23 * O2A = 118.8 * 1.75 = 207.8 N.cm
The Total Working Torque Required = M2 *
S.F
The
Crank
207.8 * 3 = 311.8 ~320 N.cm
= 32 Kg.cm
60
VERTICAL FORMING, FILLING AND SEALING MACHINE
3.4. Transmission Shaft Diameter
m
m
37.
m
5
m
13
5
m
m
62
Figure 2-12 Sealing Transmission Shaft Free Body Diagram
Data
𝑇 = 3563 𝑁. 𝑚𝑚
𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑓𝑟𝑜𝑚 𝑆𝑡𝑎𝑡𝑖𝑐 𝐹𝑜𝑟𝑐𝑒 𝐴𝑛𝑎𝑙𝑦𝑠𝑖𝑠
𝜏 = 36 𝑀𝑃𝐴
𝑎𝑠𝑠𝑢𝑚𝑝𝑒𝑑 𝑡ℎ𝑎𝑡 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑖𝑠 𝑠𝑡𝑒𝑒𝑙
𝜎𝑏 = 56 𝑀𝑃𝐴
𝑎𝑠𝑠𝑢𝑚𝑝𝑒𝑑 𝑡ℎ𝑎𝑡 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑖𝑠 𝑠𝑡𝑒𝑒𝑙
3.4.1. Vertical Loads
𝑅𝑐𝑣 + 𝑅𝐵𝑣 = 30.75
Taking moment of c:
𝑅𝐵𝑣 ∗ 135 = 30.75 ∗ 197
𝑅𝐵𝑣 = 45 𝑁
𝑅𝐶𝑣 = 14.25 𝑁 ( 𝑖𝑛 𝑡ℎ𝑒 𝑜𝑝𝑝𝑜𝑠𝑖𝑡𝑒 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛 )
𝑀𝐴𝑣 = 𝑀𝐷𝑣 = 0
𝑀𝐵𝑣 = 30.75 ∗ 62 = 1906.5 𝑁. 𝑚𝑚
𝑀𝐶𝑣 = 0
61
VERTICAL FORMING, FILLING AND SEALING MACHINE
3.4.1. Horizontal Loads
𝑅𝐶ℎ + 𝑅𝐵𝐻 = 115.45
Taking moment of c:
114.75 ∗ 197 − 𝑅𝐵ℎ ∗ 135 = 0.7 ∗ 37.5
𝑅𝐵ℎ = 176.25 𝑁
𝑅𝐶ℎ = 51.8 𝑁 ( 𝑖𝑛 𝑡ℎ𝑒 𝑜𝑝𝑝𝑜𝑠𝑖𝑡𝑒 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛 )
𝑀𝐴ℎ = 𝑀𝐷ℎ = 0
𝑀𝐵ℎ = 114.75 ∗ 62 = 7114.5 𝑁. 𝑚𝑚
𝑀𝐶ℎ = 0.7 ∗ 37.5 = 26.25 𝑁. 𝑚𝑚
Taking the largest moment.
2
2
𝑀𝐵 = √𝑀𝐵𝑣
+ 𝑀𝐵ℎ
= √1906.52 + 7114.52 = 7365.5 N. mm
(3.20)
𝑇𝑒 = √M 2 + T 2 = √7365.52 + 35632 = 8182 N. mm
(3.21)
8182 =
𝜋
𝜋
∗ 𝜏 ∗ 𝑑3 =
∗ 36 ∗ 𝑑 3
16
16
(3.22)
𝑑 = 10.5 𝑚𝑚
𝑀𝑒 = 0.5 ∗ ( 𝑀 + 𝑇𝑒 ) = 7773.75 𝑁. 𝑚𝑚
(3.23)
𝜋
𝜋
∗ 𝜎𝑏 ∗ 𝑑 3 =
∗ 56 ∗ 𝑑 3
32
32
(3.24)
7773.75 =
𝑑 = 11.3 ≈ 12 𝑚𝑚
Taking the largest value.
𝑑 = 12 𝑚𝑚
The Suitable Shaft Size is 12 mm.
3.5. Sealing Mechanism Springs
Hooke's law states that the force F needed to extend or compress a spring by distance X is
proportional to that distance. That is:
𝑓 =𝑘∗𝑥
62
(3.25)
VERTICAL FORMING, FILLING AND SEALING MACHINE
where k is a constant factor characteristic of the spring: its stiffness, and X is small compared
to the total possible deformation of the spring. The spring constant K is measured in newtons
per meter (N/m)
3.5.1. Longitudinal Sealing Spring
The impact force F = 20 N , X (Stroke) = 0.45 cm =4.5 mm
𝑓 =𝑘∗𝑥
So, The Stiffness
𝑓
(3.26)
𝐾=𝑋
𝐾=
20
= 4.5 𝑁/𝑚𝑚
4.5
3.5.2. Traverse Sealing Spring
The impact force (F) = 20 N , X = 0.45 cm =4.5 mm
𝑓
𝑓 = 𝑘 ∗ 𝑥 So, The Stiffness 𝐾 = 𝑋
𝐾=
40
= 6 𝑁/𝑚𝑚
6.5
3.6. Suitable Bag Dimensions
3.6.1. Bag Length Calculations
The Length of Bag should not exceed longitudinal sealing length to have a sealed bag. The
Longitudinal jaw length=120mm which equals maximum Bag length.
3.6.2. Bag Width Calculations
Bag width depends on collar Diameter. And a little clearance between longitudinal sealing and
collar
Data:
tube diameter =18mm, clearance =2.5mm
𝑀𝑎𝑥. 𝑏𝑎𝑔 𝑤𝑖𝑑𝑡ℎ =
𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑡𝑢𝑏𝑒
+ 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒
2
𝑊𝑖𝑑𝑡ℎ = 3.14 ∗ 18 + 2.5 = 30.77𝑚𝑚 ≈ 31 𝑚𝑚
63
(3.27)
Chapter Three:
Electricity And
Programming
VERTICAL FORMING, FILLING AND SEALING MACHINE
3. Electricity and Programming
3. Introduction
As mentioned in chapter 1 the used system is embed controller system. The machine has the
following working flow, first of all the Lcd screen Works and keyboard enabling the user to
reset the values and input required package mass and bag length. The input data and instructions are viewed on the Lcd screen. Then the system starts working. The heaters and the load
cell starts working parallel with the system motors and drivers. The load cell keeps measuring
the mass continuously, and the heaters working with temperature 100C. Heater’s temperatures
are measured using temperature sensor. The electrical system works parallel with the load cell
and heaters as follow, The vibrator motor starts working to vibrate the filling grid. When the
filling grid vibrates, the grains began to fall into the filling cup which is fixed on the load cell.
The load cell keeps measuring the mass until it matches the input mass. When the input mass
equals the mass in the cup, the servo motor of the cup gate works and open the gate. The
grains start to fall into the collar. The wiper motor of sealing mechanism starts working to
close the transverse sealing jaws to seal the plastic film from the bottom. The longitudinal
sealing jaws closes as well as the motion is transmitted using shaft. To the longitudinal sealing
mechanism. The closure of longitudinal sealing jaw seals the plastic film longitudinally. The
next step is pulleys motor, the pulleys motor rotates the pulleys to transfer film after sealing to
make another seal by the same method. The next seal closes the bag top and seals the next bag
bottom to repeat the same process. In this chapter, the electric components used for this process, their selection, codes, and features are discussed.
4. Arduino Mega 2560
The Arduino Mega 2560 is a microcontroller board based on the ATmega2560. It has 54 digital input/output pins (of which 14 can be used as PWM outputs), 16 analog inputs, 4 UARTs
(hardware serial ports), a 16 MHz crystal oscillator, a USB connection, a power jack, an ICSP
header, and a reset button. It contains everything needed to support the microcontroller; simply
connect it to a computer with a USB cable or power it with a AC-to-DC adapter or battery to
get started. The Mega is compatible with most shields designed for the Arduino Duemilanove
or Diecimila[14].
It has greater number of inputs compared to Arduino uno which makes it suitable for the machine system. As the machine requires 4 motors in addition to their drivers, heaters and different sensors.
Arduino Mega memory is larger than Arduino Uno. The ATmega2560 has 256 KB of flash
memory for storing code (of which 8 KB is used for the bootloader), 8 KB of SRAM and 4
KB of EEPROM. Figure 3-1 shows the board, pins types and locations, power supply and
USB interface locations[14].
64
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-1 The Board[14]
4.1.
Board Specifications
Table 3-1 Arduino Mega Board Specifications[14]
Microcontroller
ATmega2560
Operating Voltage
5v
Input Voltage (recommended)
7-12V
Input Voltage (limits)
6-20V
Digital I/O Pins
54 (of which 14 provide PWM output)
Analog Input Pins
16
DC Current per I/O Pin
40 mA
DC Current for 3.3V Pin
50 mA
Flash Memory
256 KB of which 8 KB used by bootloader
SRAM
8 KB
EEPROM
4 KB
Clock Speed
16 MHZ
65
VERTICAL FORMING, FILLING AND SEALING MACHINE
5. LCD
LCD is used to view the required mass to be packaged and bag length. Also, it helps in reset
process and gives instructions to input data.
It is only required to view short instructions or mass and length, so a small LCD 16*2 is selected as shown in Figure 3-2.
Figure 3-2 1602A QAPASS 16×2 LCD
display[15]
Figure 3-3 Codes For Rest Parameters Weight and
Length
The LCD screen is made of 2 rows of 16-character spaces each. It is also built with 16 pins (16
channels) to connect to other devices and display the desired messages. As shown in Error!
Reference source not found., The interface for the 1602A QAPASS consists of the following
pin:
•
•
•
•
•
•
•
•
Pin 1: VSS, Ground (0V).
Pin 2: VDD, power (+5V).
Pin 3: V0, display contrast control through a potentiometer (0 to 5V).
Pin 4: RS, register select that toggles between instruction and data register (0: instruction mode, and 1: data mode).
Pin 5: RW or R/W, Read/Write (0: Write, 1: Read).
Pin 6: E, Enable, active high to enable operations.
Pins 7-14: D0-D7, in that order representing either data or instruction sequences.
Pins 15,16: A, K, anode and cathode of the backlight LED, respectively.
66
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-4 LCD Display Pin Diagram
Figure 3-5 Code for Input Data During Machining Time
• 4-bit and 8-bit Mode of LCD:
The LCD display can work in a 4-bit mode and an 8-bit mode.
•
•
4-bit mode: Only 4 bits of data are processed at a time. If the data is represented by a
byte, then the high order nibble and then the low-order nibble will be handled to show
the required character, by using shifting of data in the register. This more complicated
process is desired only when the number of I/O pins needed from the Arduino Uno is
not sufficient to handle an 8-bit sequence simultaneously.
8-bit mode: the entire 8-bit sequence is processed through the 8-bit data lines of the
LCD display and 8 lines from the Arduino Uno. If another Arduino board with a lot
more I/O ports is used, then the 8-bit mode would lead to simpler programming and
faster execution[15].
4. Keypad
Keypad is used to reset the program, insert required packed mass and bag length. the only buttons needed are numbers and a button to reset and another one to enter data. The suitable keypad to this application is membrane keypad 16 key matrix (4*4) shown in Error! Reference
source not found.
67
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-6 Membrane Keypad 16 Keys Matrix (4*4)
Figure 3-8 Code for Calculating the Integrate Length and Weight
Figure 3-7 Code for Calculating the Integrate
Length and Weight
4.1.
•
•
•
•
•
•
•
•
Keypad Specification
Pad Size: 77 x 70 x 0.8mm
Cable Length: 3-1/3″ or 85mm
Weight: 9g
Connector: Dupont 8 pins, 0.1″ (2.54mm) Pitch
Mount Style: Self-Adherence
Max. Circuit Rating: 35VDC, 100mA
Insulation Spec.: 100M Ohm, 100V
Operation Temperature: -20 to +40 °C[16]
5. Load Cell
A load cell is a physical element (or transducer if you want to be technical) that can translate
pressure (force) into an electrical signal. There are different types of loadcells e.g., hydraulic
load cell, pneumatic load cell, strain gauge load cell. Strain gauge load cell is selected as it is
the most common type and suitable to the small masses packed by the machine. Strain gauge
68
VERTICAL FORMING, FILLING AND SEALING MACHINE
load cell is shown in Error! Reference source not found.. Strain gauge load cell, which is a
mechanical element of which the force is being sensed by the deformation of a (or several)
strain gauge(s) on the element. In bar strain gauge load cells, the cell is set up in a “Z” formation, as shown in Error! Reference source not found. and Error! Reference source not
found.. So that torque is applied to the bar and the four strain gauges on the cell will measure
the bending distortion, two measuring compression and two tension. When these four strain
gauges are set up in a Wheatstone bridge formation, it is easy to accurately measure the small
changes in resistance from the strain gauges[17].
Figure 3-9 Strain Gauge Load Cell Diagram
Figure 3-10 More In-Depth Diagram of Strain Gauges on Bar Load Cells When Force is Applied
Figure 3-11 "Z" Formation Fixation For The Strain Gauge Load Cell
69
VERTICAL FORMING, FILLING AND SEALING MACHINE
Load cells varies according to the masses. There is load cell measures between 0~1000 gm,
another measures starting from 0.5 kg~ 5 kg, this type can measure less masses but the accuracy does not suit these small masses. There are another load cells that measures 50 kg, 100
kg…etc. the selected load cell is 1 kg load cell that measures masses starting from 0 gm to
1000 gm.
5.1. Amplifier
In most Load cells and weight sensors the output range of a strain gauge is very small and thus
the signal needs to be amplified before processing to prevent introduction of errors.
This 24-bit analog to digital and signal conditioning module is designed specifically for weight
scales, weight sensor and industrial control applications to interface directly with a bridge sensor. The module is based on HX711 chip. This module is used for amplifying the weight sensor and converting its analog sensor to digital one, therefore increasing the measurement accuracy. The output to your micro-controller /Ardunino is serial. The module can be connected to
2 weight sensors at the same time. The module also provide power directly to sensors through
out+ pin[18]. Error! Reference source not found. shows loadcell and HX711 connections.
Figure 3-12 Load Cell and HX711 Amplifier
Connections
Figure 3-13 Code for Weight Affecting The Load
Cell
5.1.1. HX711 Features
•
•
•
•
•
•
Two selectable differential input channels
On-chip active low noise PGA with selectable gain of 32, 64 and 128
On-chip power supply regulator for load-cell and ADC analog power supply
On-chip oscillator requiring no external component with optional external crystal
On-chip power-on-reset
Simple digital control and serial interface: pin-driven controls, no programming needed
70
VERTICAL FORMING, FILLING AND SEALING MACHINE
•
•
•
•
•
•
Selectable 10SPS or 80SPS output data rate
Simultaneous 50 and 60Hz supply rejection
Current consumption including on-chip analog power supply regulator: normal operation <
1.5mA, power down < 1uA
Operation supply voltage range: 2.6 ~ 5.5V
Operation temperature range: -40 ~ +85℃
16 pin SOP-16 package[19]
6. Vibrator
For vibratory motion of the filling grid, A DC motor is used with a flywheel. The usage of
flywheel makes imbalance which produces the vibratory motion. The selected motor is RC280 Vibration Motor, shown in Error! Reference source not found.. The motor specifications
are shown in Table 3-2. This motor requires a drive to control the direction of motion and
speed of rotation. The driver used is L298 Dual H-Bridge shown in Figure 3-16 L298N HBridge.
Figure 3-14 RC-280 Vibration Motor
Figure 3-15 Code for Controlling Speed in
Vibrator Motor
Table 3-2 RC-280 Vibration Motor Specifications
Motor Model
NFP-R280C-09450-45DVP
Motor Diameter
24mm
Motor Length
30mm
Nominal Voltage
6V DC
Rated Speed
5,000rpm
Ecc. Weight Radius
6.5mm
Ecc. Weight Length
6mm
71
VERTICAL FORMING, FILLING AND SEALING MACHINE
Amplitude
13G
6.1. Motor Driver L298 Dual H-Bridge
Figure 3-16 L298N H-Bridge
This driver module is based on L298N H-bridge, a high current, high voltage dual full bridge
driver manufactured by ST company. It can drive up to 2 DC motors 2A each. It can also drive
one stepper motor or 2 solenoids. The driver can control both motor RPM and direction of rotation. The RPM is controlled using PWM input to ENA or ENB pins, while of rotation direction is controlled by suppling high and low signal to EN1-EN2 for the first motor or EN3-EN4
for second motor. This Dual H-Bridge driver is capable of driving voltages up to 46V.
6.1.1. Features
•
•
•
•
•
•
•
•
Dual H bridge drive (can drive 2 DC motors)
Chip L298N
Logical voltage 5V
Drive voltage 5V-35V
Logic current 0mA-36mA
Drive current 2A(For each DC motor))
Weight 30g
Size: 43*43*27mm[20]
7. Gate Servo Motor
Servo motor is selected because it is Unlike dc motors, with servo motors you can position the
motor shaft at a specific position (angle) using control signal. The motor shaft will hold at this
position as long as the control signal not changed. This is very useful for controlling robot
arms, unmanned airplanes control surface or any object that you want it to move at certain angle and stay at its new position[21].
72
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-17 Servo Motor FS5103B[22]
Figure 3-18 Servo Motor Code for Opening
and Close the Cup Gate
As mentioned in chapter two, the Maximum torque of the gate is 9.702 N. Cm, which equals
0.99 Kg.cm. by taking factor of safety 3. Then the required motor of torque 3 kg.cm. The selected motor is Servo Motor Standard (180) 3.2 kg.cm Plastic Gears (FS5103B) shown in Figure 3-17 Servo Motor FS5103B[22].
7.1. Gate Servomotor Specifications
•
•
•
•
•
•
•
•
•
•
•
•
Dimensions: 40.8 × 20.1 × 38 mm
Weight: 40 g
Operating Speed : 0.18sec/60degree (4.8V) or 0.16sec/60degree (6V)
Stall Torque : 3kg.cm (4.8V) or 3.2kg.cm (6V)
Operating Voltage : 4.8V~6V
Control System: Analog
Direction: CCW
Operating Angle: 180degree
Bearing Type: 2 Ball Bearing
Gear Type: Plastic
Motor Type: Metal Brush Motor
Connector Wire Length: 30 cm[22]
7.2. Servo Motor Connections
As shown in Error! Reference source not found. , the Servo motor has three wires: Black
wire: GND (ground), RED wire:+5v and Colored wire: control signal. The third pin accept the
control signal which is a pulse-width modulation (PWM) signal. It can be easily produced by
all micro- controllers and Arduino board. This accepts the signal from your controller that tells
it what angle to turn to. The control signal is fairly simple compared to that of a stepper motor.
73
VERTICAL FORMING, FILLING AND SEALING MACHINE
It is just a pulse of varying lengths. The length of the pulse corresponds to the angle the motor
turns to.[21]
Figure 3-19 Servo Motor Connections
7.3. DC-DC Step Down Converter
The power supply used has 12 voltages while Servo motor works on 6 voltages. It is required
to use step down converter, to reduce volts input to the servomotor from the power supply.
The selected converter is LM2596-XXE5/F5 shown in Error! Reference source not
found.20.
Figure 3-20 LM2596-XXE5/F5 DC-DC Step Down Converter
7.3.1. Features of LM2596-XXE5/F5 Converter
•
•
•
•
•
•
•
•
•
•
•
•
•
3.3V, 5V, 12V, and adjustable output versions
Adjustable version output voltage range, 1.3V to 37V±4% max over line and load conditions
150kHz±15% fixed switching frequency
TTL shutdown capability
Operating voltage can be up to 40V
Output load current:3A
TO220-5L and TO263-5L packages
Low power standby mode.
Thermal shutdown and current limit protection.
High efficiency
Built-in switching transistor on chip
Requires only 4 external components
Use readily available standard inductors
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VERTICAL FORMING, FILLING AND SEALING MACHINE
8. Pulleys motor RS555
The motor selected is a DC motor with high torque as the torque is required is 15.14 mN.m as
mentioned in chapter 2. According to the electrical specification shown in Table 3-3, the selected motor is RS555-SH-4033.
The same As vibrator motor it is required to use driver to control speed and direction of rotation. The selected motor driver is L298N the same as vibratory motor.
Figure 3-22 Pulley Motor Code for Roller
Speed
Figure 3-21 Pulleys Motor RS555
Table 3-3 RS555 Motor Electrical Specifications
2. 8.1. Encoder
It is required to monitor the rotation of the shaft, rotary encoder is used, shown in Error! Reference source not found.. The Keyes KY-040 rotary encoder is a rotary input device (as in
knob) that provides an indication of how much the knob has been rotated AND what direction
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VERTICAL FORMING, FILLING AND SEALING MACHINE
it is rotating in. A rotary encoder has a xed number of positions per revolution. These positions
are easily felt as small “clicks” you turn the encoder.[23]
Figure 3-23 Rotary Encoder
Figure 3-24 Rotary Encoder Code for Pully
Speed Control
8.1.1. Encoder Connections
Figure 3-25 Encoder Connections Illustration
The module is designed so that a low is output when the switches are closed and a high when
the switches are open.
The low is generated by placing a ground at Pin C and passing it to the CLK and DT pins
when switches are closed.
The high is generated with a 5V supply input and pullup resistors, such that CLK
This website uses cookies to enhance your experience. By continuing to visit this and DT are
both high when switches are open.
Not previously mentioned is the existence of of push button switch that is integral to the encoder. If you push on the shaft, a normally open switch will close. The feature is useful if you
want to change switch function. For example, you may wish to have the ability to between
coarse and fine adjustments[23].
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VERTICAL FORMING, FILLING AND SEALING MACHINE
9. Sealing Wiper Motor
Sealing mechanism requires a powerful motor, because the motor is used for both transverse
sealing and longitudinal sealing mechanisms. The required torque is about 32 Kg.cm as mentioned in chapter 2. The selected motor is Wiper Motor -WD1160/1160-B shown in 3-26.
Figure 3-26 Wiper Motor -WD1160/1160-B
Figure 3-27 Wiper Motor Code for Speed
Control
9.1. Wiper Motor -WD1160/1160-B Specifications
The motor has the following Specifications:
•
•
•
•
•
12VDC
Aluminum Diecasting Gearbox
Rolled Steel Housing Construction
Dual Speed Design
Dynamically Balanced Rotor
The performance data is shown in the Table 3-4.
Table 3-4 Performance Data of Wiper Motor-WD1160/1160-B
The same as pulleys motor, wiper motor requires a rotary encoder. The same encoder used for
pulleys motor is used with the wiper motor. It requires a motor driver.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
9.2. Wiper Motor Driver
The driver selected was VNH2SP30 shown in Figure 3-28. As it is a high-power dc motor
driver based on VNH2SP30 chip from ST. It is designed for high power dc motor control applications with peak current up to 30A and continuous current of 14A. The module is easy to
use with Arduino or any other microcontroller. The motor driver also has thermal shutdown
capability for protection of overheating, it also have current sensing and overvoltage protection. It is very similar to spark fun Monster motor driver, the only difference is that this module drive only one motor at a time [24].
Figure 3-28 VNH2SP30 Motor Driver[24]
9.2.1. Features
•
•
•
•
•
•
•
•
Voltage max: 16V
Maximum current rating: 30 A
Practical Continuous Current: 14 A
Current sensing available to Arduino analog pin
MOSFET on-resistance: 19 mΩ (per leg)
Maximum PWM frequency: 20 kHz
Thermal Shutdown
Undervoltage and Overvoltage shutdown
9.2.2. Specifications
•
•
•
•
•
•
•
Max. Input Voltage: 16VDC
Max. Current Rating: 30A
Practical Continuous Current: 14A
MOSFET on-resistance: 19 mΩ per leg
Max. PWM Frequency: 20 kHz
Weight: 25g
Size: 53 x 22mm
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VERTICAL FORMING, FILLING AND SEALING MACHINE
9.2.3. Pin Definitions
As shown in Error! Reference source not found. the pin definitions as follows:
•
•
•
•
•
•
Out A, Out B: Motor Power
PWR (+/-): Power Supply Voltage
PWM: Pulse Width Signal (control the motor speed)
INA, INB: Rotation direction and brake control
CS: Current Sensor (optional)
EN: Status of switches output (Analog pin - Optional)[24]
Figure 3-29 VNH2SP30 Driver Pin Definitions
5.3.4. Hall sensor
wiper motor requires monitoring using sensor. the sensor is used to check wiper motor complete revolution. every revolution gives a complete bag. Linear Hall Magnetic Module that detect any magnets (can define the S , N poles) so you can use it also as an module to measure
the speed of rotation magnet. This Module detects the presence of a magnetic field supplying
at the output a voltage related to the intensity and the orientation at the same time. Very easy
to connect to Arduino board[25].
Features:
•
•
•
•
•
Adjustable sensitivity (potentiometer)
Voltage comparator LM393
LED Signal output indicator
Analog & Digital output
Based on hall sensor # 49E
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-30 Hall Sensor
Figure 3-31 Hall Effect Sensor Code for Speed
Control
10. Heaters
Heaters are used to seal the film. It heats the sealing jaws till it seals together. It is required to
work with temperature 100C. a heat sensor is used to monitor the heat and a relay is used to
control the temperature.
10.1. Heat Sensors
The DS18B20 sensor is used as it does not require any external calibration or trimming to
provide typical accuracies Multiple thermometers can be connected on the same wire because
everyone has its own internal address. The used version is a pre-wired and waterproofed version of the DS18B20 sensor.
10.1.1. Heat Sensor Features
•
•
•
•
•
•
•
•
Usable temperature range: -55 to 125°C (-67°F to +257°F)
9-to-12-bit selectable resolution
Unique 64-bit ID burned into chip
Multiple sensors can share one pin
±0.5°C Accuracy from -10°C to +85°C
Temperature-limit alarm system
Usable with 3.3V to 5V power/data
Waterproof
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VERTICAL FORMING, FILLING AND SEALING MACHINE
10.1.2. Pin Connections
The Output leads are classified as follow:
•
•
red (VCC)
blue or yellow (DATA)
•
black (GND)[26]
10.2. Relay module
The relay is used to control the temperature. The relay module selected is (1 Channels - 5V) as
shown in Error! Reference source not found.. This relay module consists of 1 relays. Each
relay is connected to a current buffer so that it is connected directly to a Microcontroller or
Arduino.
Figure 3-32 Relay Module (1 Channel- 5V)
Figure 3-33 Code For Controlling The Longitudinal Jaws Temperature
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 3-34 Code For Controlling The Transverse Jaws Temperature
Figure 3-35 Code For Controlling Sealing System
Temperature
Using these relays can easily control high power devices or appliances using Arduino or microcontrollers, the relay is rated for 230V 10Amps.
10.2.1. Specifications
•
•
Rating: 10A (250V AC or 30 V DC)
Input (Control) voltage: 5V DC[27]
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Chapter Four:
Machine
Modelling
VERTICAL FORMING, FILLING AND SEALING MACHINE
4. Machine Modelling
1. Introduction
In this chapter modelling is done for various machine elements. The model is built based on
design considerations mentioned in chapter two. More than one iteration is done for different
parts. First system in the modelling is filling system. Filling system iterations are made to simplify manufacture processes. And other modifications are made to reduce system volume.
Both types of modifications are made to reduce cost. For sealing system mechanism is modelled and mechanism plates has two designs, the first is two separated plates and the second
consists of one connected c-section. For chassis two iterations were made the first one for trial
and analysis. The second iteration to improve assembly and reduce cost by reducing volume.
2. Filling System Modelling
2.1.
Vibratory System
Vibratory system consists of 3 main parts with a support plate. Starting from the filling
grid which is used to hold suitable amount of the desired material to be filled. It is designed to aid the material flow by giving a narrower partition, whenever the material is
close to the end. It can hold up to 500-600 g. filling grid is fixed with the supporting
base, which is the second part. It has two main functions. The first function is fixing
the filling grid. The second function is used as fixation for the vibrator. Giving the filling grid the desired inclination angle to aid the material flow. The third part is the vibrator. It is the main part for the material flow process, giving the suitable amplitude
for vibrating the filling grid. The system is supported using springs to give the required
tolerance for the system to vibrate. Springs are supported on a plate connected to the
main base. The main base is fixed to the casing. This connection maintain the system
required stability.
Figure 4-1 Vibratory system
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2.1.1. first Iteration
•
•
Using two L section parts, to hold the springs to the main base. but they did not
maintain the required stability. L section parts were hard to assembly with the
main base. L section required many manufacture steps.
System dimensions and volume were large compared to the required function.
This leads to higher cost during manufacture
2.1.2. second Iteration
•
•
2.2.
L section was replaced by a plate, it required more material compared to first
iteration but required less manufacture steps.
The dimensions are reduced to reduce material used.
Filling System
Filling system as shown in Figure 4-2, has two main parts. The cup, it is used to receive the material to be weighted. The cup is designed with an angle of inclination
more than 45 degree as mentioned in chapter two, to let the material flow to the next
step. The cup is closed with an electric powered gate. The gate is opened when the load
cell gives signal that the weight in the cup equal to the input weight. When gate is
opened material flow to the output part to start the next process in the filling process.
The output part is designed on basis of design to manufacture, and it has two ways of
fixation either welding or bolting. The system fixation depends on how the cup is set
on the loadcell; the fixation is c-section welded with loadcell mounting.
Figure 4-2 Filling System
2.3.
Casing
Casing design as shown in Figure 4-3 is more like a cube to achieve simplicity. It can
be manufactured with dimensions which achieve accessibility to all parts inside. Filling
part is connected to the casing by bolting. This method gave flexibility in material selection. As the filling part and casing can be made from different materials and bolted
without requirement for complex welding methods.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-3 Filling System Casing
2.4.
Different Parts Iterations
2.4.1. Filling pot iterations
Figure 4-4 Filling Pot first Iteration
Figure 4-5 Filling Pot second Iteration
As shown in Figure 4-4and Figure 4-5, second iteration is easily manufactured compared to
the first iteration. The second iteration is manufactured using bending and welding. first iteration is manufactured by rolling which gives low dimension accuracy and more expensive.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
2.4.2. Vibratory System Fixature Iterations
Figure 4-6 Vibratory System Fixature first Iteration
Figure 4-7 Vibratory System Fixature second Iteration
As shown in Figure 4-6, the first iteration, many parts were used to achieve stability and the
inclination angle for the filling grid. These parts can be replaced with two parts only as shown
in the second iteration in Figure 4-7. second iteration provides higher stability and more accurate inclination angle.
2.4.3. Filling Pot Fixature Iterations
Figure 4-8 Filling Pot Fixature first Iteration
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-9 Filling Pot Fixature second Iteration
As shown in Figure 4-8, the first iteration all parts are made from one material so the filling
pot can be welded. But in the second iteration as shown in Figure 4-9, a small part is added to
fix the pot with the casing using bolts instead of welding. As welding different materials require complex steps before welding and after. This gave allowance of manufacturing the casing and pot from different materials.
2.4.4. Load cell Fixture Iterations
As shown in Figure 4-11, In the first iteration, the loadcell mounting was loading on the cell
itself which causes error in the reading. In the second iteration, as shown in Figure 4-10 the
mounting was cut to prevent loading on the load cell and gives accurate reading.
Figure 4-10 Load cell Fixture first Iteration
Figure 4-11 Load cell Fixture second Iteration
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3. Sealing System
3.1.
Sealing Mechanism Modeling
3.1.1. Transverse Sealing Mechanism
The transverse sealing mechanism gives the main motion of the system. It consists of 4 bar
mechanism with an additional link to control jaws motion.
3.1.2. Longitudinal Sealing Mechanism
The longitudinal sealing mechanism gives the secondary motion. It takes its motion from the
4-bar mechanism. Motion is transmitted by the shaft that connects the two mechanisms to each
other. The shaft transfers the motion to the pully. The Pulley transfers the motion to the two
rods via two links. The two rods transfer the motion to the jaws. The jaws motion leads to bag
longitudinal sealing.
Initial Concept
Figure 4-12 Sealing Mechanism Initial Concept
Actual Design
Figure 4-13 Sealing Mechanism Actual Design
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3.2.
Sealing Jaws Modeling
There are two pairs of sealing jaws. a transverse sealing jaws pair and longitudinal sealing
jaws pair. Jaws are a solid part used in filling and packaging machine with automatic sealing
systems. It acts an important role in the sealing process as it’s the main unit of sealing. Jaws
can be manufactured from many metallic material such as aluminum, copper, silicon, magnesium alloys. By using aluminum heaters inserted into jaws, the sealing process is done. Aluminum is selected for its manufacture for the following reasons:
•
•
•
Aluminum is commonly alloyed with copper, zinc, magnesium, silicon, manganese,
and lithium. small additions of chromium, titanium, zirconium, lead, bismuth, and
nickel are used as well, and iron presents in small quantities.
Electrical conductivity of aluminum is near to the electric conductivity of the copper.
Aluminum has an electrical conductivity high enough to be used as an electrical conductor. The conductivity of the common used conducting alloy (1350) is around 62%
of annealed copper.
Aluminum density is third copper density. It can conduct twice electric quantity compared to copper of the same weight.
3.2.1. Transverse Sealing Jaws
Figure 4-14 Modelling of Transverse Sealing Jaws
3.2.2. Longitudinal Sealing Jaws
Figure 4-15 Modelling of longitudinal Sealing Jaws
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VERTICAL FORMING, FILLING AND SEALING MACHINE
3.2.3. Material Specification
Property
Value
Atomic Number
13
Atomic Weight (g/mol)
26.98
Valency
3
Crystal Structure
FCC
Melting Point (°C)
660.2
Boiling Point (°C)
2480
Mean Specific Heat (0-100°C) (Cal/g.°C)
0.219
Thermal Conductivity (0-100°C) (Cal/cms. °C)
0.57
Co-Efficient of Linear Expansion (0-100°C) (x10-6/°C)
23.5
Electrical Resistivity at 20°C (Ω.cm)
2.69
Density (g/cm3)
2.6898
Modulus of Elasticity (GPa)
68.3
Poisson’s Ratio
0.34
3.3.
Sealing Mechanism Fixation
For Sealing Mechanisms Fixation Modeling There Are Two Different iterations of Fixations
3. Two Plates of sheet metal
• Upper Plate
• Lower Plate
4. C-Section Sheet Metal
3.3.1. Upper Sheet
Figure 4-16 Upper Sheet for Fixing Sealing Mechanism Modeling
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VERTICAL FORMING, FILLING AND SEALING MACHINE
3.3.2. Lower Plate
Figure 4-17 Lower Sheet for Fixing Sealing Mechanism Modeling
3.3.3. C-Section Modeling
Figure 4-18 C-Section for Fixing Sealing Mechanism Modeling
4. Chassis
4.1.
First Iteration
First chassis iteration was made as a trial for design and analysis. Electrical components were
not taken in consideration. The design of film transport system mechanism was depending on
a handle that keeps the pulleys in their place and when the handle is turned the pulleys opens
as Shown in Figure 4-19.
The collar used in this design was 30 cm length. Collar length effects the distance between the
longitudinal sealing jaws and transverse sealing jaws.
The filling system base area is 35 cm*30 cm. by taking all this consideration and add clearances. The first chassis iteration was made as shown in Figure 4-20, Figure 4-23, Figure 4-24,
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-23, Figure 4-24, and Figure 4-25. The sides are made from the same chassis metal
with bends.
Figure 4-19 Pulleys System First Iteration
Figure 4-20 Chassis first Iteration Front View
Figure 4-21 Isometric View for Chassis first Iteration without sides
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-22 Isometric View For Chassis first Iteration With Sides
Figure 4-23 Chassis first Iteration assembly Front View Without Transparency
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-24 Chassis first Iteration assembly Transparent Front View
Figure 4-25 Isomeric View for Chassis first Iteration Assembly
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.2.
Second Chassis Iteration
In this iteration, the control system was determined. The electric components sizes were
known. Film transport mechanism changed into a new mechanism that controls the distance
between pulleys using the bearing bolt as shown in Figure 4-26.
Collar size was reduced to reduce chassis size and reduce used material. The length of the
new collar was 25 cm. this reduced the distance between the sealing longitudinal jaws and
sealing transverse jaws.
The heaters wires, and sensors wires was taken in consideration. This lead to increase the sealing jaws openings for both longitudinal and transverse sealing. A bended sheet metal plate was
added next to the sealing c-section for electrical components.
Holes for assembling the electrical component plate and sealing c-section with the chassis
was made. There are two new openings for keypad and led screen to control machine inputs.
The sides changed from bended sheet metal to transparent acrylic to monitor the process without requirement for removing sizes and this gave more aesthetic look.
The distance between the chassis bottom and transverse sealing opening was reduced by 7 cm
to reduce the cost and material used.
These changes reduced the mass and volume by 26.7% from the first iteration. The lengths
reduction reduced laser machining time. Which reduced cost too as sheet metal cost depends
on mass and laser machining time. The chassis is modeled as shown in Figure 4-27, Figure
4-28, Figure 4-29, Figure 4-30, and Figure 4-31.
Figure 4-26 Pulleys Mechanism Second Iteration
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-27 Chassis second Iteration Front View
Figure 4-28 Chassis second Iteration Isometric View
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-29 Chassis second Iteration Assembly
Figure 4-30 Chassis second Iteration Assembly Showing electric Plate
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 4-31 Chassis second Iteration Assembly Front View
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Chapter Five:
Machine Parts
Analysis
VERTICAL FORMING, FILLING AND SEALING MACHINE
5. Machine Parts Analysis
1. Introduction
Analysis is the most important step before manufacture. It is done to check the stresses on the
parts are normal or exceeding the yield strength. Also, it is important to check deformation
happened to the parts. Analysis playing an important role in selecting material and checking
this selection. If the design is safe, it would avoid many problems after manufacture. In this
chapter analysis is done on all parts subjected to loads. Different types of analysis are done
e.g., static analysis and kinematic analysis. The static Analysis is done using Solidworks 2017
for filling system parts, solidworks 2020 for chassis and ANSYS 19 for sealing plates, springs.
The Kinematic analysis is done using ANSYS 19. The Kinematic Analysis checks the velocities, accelerations and forces at every joint in the sealing mechanism.
2. Filling System Static Analysis
The Analysis in first was done on the first iteration then after modification another analysis
was done for checking the results and confirming the stiffness of the parts.
2.1.
Filling Grid Analysis
Material selected was stainless steel 304 because:
•
•
•
•
•
safe
Durable, corrosion-resistant, and nonabsorbent.
Sufficient in weight and thickness to withstand repeated washing.
Finished to have a smooth, easy-to-clean surface.
Resistant to pitting, chipping, crazing, scratching, scoring, etc.
For example, if a given manufacturing process uses a lot of salt, using a “food-safe” metal
that is weak to pitting corrosion from exposure to chlorides could result in the metal rusting. Then, that rust could contaminate the food being prepped.
The following considerations was used for analysis:
•
•
•
•
Maximum load is about 1kg
Taking in consideration a factor of safety =3 then the applied load in analysis is 3 kg
The fixtures are at the holes as they are bolted with another part
The load is distributed on the grid
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VERTICAL FORMING, FILLING AND SEALING MACHINE
2.1.1. Filling Grid first Iteration Analysis
2.2.2.1.Stress Results
Figure 5-1 Stress Results for Filling Grid first Iteration Analysis
2.2.2.1.Displacement Result
Figure 5-2 Displacement Results for Filling Grid first Iteration Analysis
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VERTICAL FORMING, FILLING AND SEALING MACHINE
2.2.2.1.Factor of Safety Results
Figure 5-3 FOS Results for Filling Grid first Iteration Analysis
2.1.2. Filling Grid second Iteration Analysis
The same considerations and fixations done in the first iteration is used in the second iteration.
2.2.2.1.Stress results
Figure 5-4 Stress Results for Filling Grid second Iteration Analysis
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VERTICAL FORMING, FILLING AND SEALING MACHINE
2.2.2.1.Displacement Results
Figure 5-5 Displacement Results for Filling Grid second Iteration Analysis
2.2.2.1.Factor of Safety Results
Figure 5-6 FOS Results for Filling Grid second Iteration Analysis
In the first iteration stress varies between 5.837 ∗ 103 𝑁/𝑚2 and 3.298 ∗ 107 𝑁/𝑚2 . In the
second iteration it varies between 6.702 ∗ 103 𝑁/𝑚2 and 2.548 ∗ 107 𝑁/𝑚2 . Both of results
are satisfying as the yield strength of stainless steel 304 is 2.08 ∗ 108 𝑁/𝑚2 . But the second
iteration has less stresses which makes it preferred in addition to its advantages mentioned in
modeling chapter.
By comparing displacement in the first iteration and second iteration. The displacement in first
iteration varies between 0.0001 and 0.082 mm. In the second iteration it varies between 0.0001
and 0.004108 mm. the second iteration has less deformation. The deformation of the second
iteration is acceptable as it does not exceed 1 mm.
Factor of safety in the first iteration varies between 0.5 to 3. In the second iteration the maximum value is the same as the first iteration while minimum value is 1.5. That makes second
iteration better.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
2.2.
Load Cell Fixation Analysis
The mass of the cup and gate is 209 gm, the mass of the servo motor used is 40 gm, and the
maximum mass weighted is 100 gm. The total mass is 349 gm. Applying 500 gm for more
safety. These masses are on the load cell end. The load applied on the load cell fixation will be
as reaction in the opposite direction (upwards) as mentioned in chapter 3. The fixation is applied to the bottom holes made for bolting.
2.2.1. first Iteration for Load Cell Fixation Analysis
Stress Results
Figure 5-7 Stress Results for Load Cell Fixation first Iteration Analysis
Displacement Results
Figure 5-8 Displacement Results for Load Cell Fixation first Iteration Analysis
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Factor Of Safety Results
Figure 5-9 FOS Results for Load Cell Fixation first Iteration Analysis
2.2.2. second Iteration for Load Cell Fixation Analysis
The same Fixation and Load applied in the first iteration is repeated in the second iteration.
Stress Results
Figure 5-10 Stress Results for Load Cell Fixation second Iteration Analysis
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Displacement Results
Figure 5-11 Displacement Results for Load Cell Fixation second Iteration Analysis
Factor of Safety Results
Figure 5-12 FOS Results for Load Cell Fixation second Iteration Analysis
As shown in the analysis the minimum factor of safety for both iterations is 11.5. this means
this fixation is safe. The maximum deformation for both iterations is 0.036 mm. That means
the Design is approximately not deformed.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
3. Chassis Static Analysis
From the range of materials selected in chapter one, the most suitable material for chassis was
Aluminum (AL6063-T6) , stainless steel grade 304 and steel A36. These alloys are selected
because they are the most common structural material in the Egyptian market.
Static analysis was done at first for the first chassis iteration using the following constrains
•
•
•
•
•
•
•
•
•
•
•
•
The main load affecting the chassis is filling system mass
The filling system mass is 7 Kg
For more safe design apply 2.5 times the mass
The applied load will be a distributed mass of 17.5 kg
The fixtures are at the bottom edges of the base
Sealing system mass is about 8.5 kg
The mass is not equally distributed and it is hard to determine the accurate reactions
It will be assumed that the chassis acts as fixed-fixed support
The reactions are equal on both sides
For more safe design apply 2.5 times of the mass
The mass will be 21.25 kg
The reaction on each side will be 10.625 kg
3.1.
first Iteration Analysis
3.1.1. Aluminum (Al6063-T6) Analysis
Stress Result
Figure 5-13 Stress Results for Chassis first Iteration Al6063-T6
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Displacement Results
Figure 5-14 Displacement Results for Chassis first Iteration Al6063-T6
Factor of Safety Results
Figure 5-15 FOS Results for Chassis first Iteration Al6063-T6
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VERTICAL FORMING, FILLING AND SEALING MACHINE
3.1.2. Stainless Steel 304 Analysis
Stress Results
Figure 5-16 Stress Results for Chassis first Iteration St 304
Displacement Results
Figure 5-17 Displacement Results for Chassis first Iteration St 304
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Factor Of Safety Results
Figure 5-18 FOS Results for Chassis first Iteration St 304
3.1.3. Steel A36 Analysis
Stress Results
Figure 5-19 Stress Results for Chassis first Iteration A36
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Displacement Results
Figure 5-20 Displacement Results for Chassis first Iteration A36
Factor of Safety Results
Figure 5-21 FOS Results for Chassis first Iteration A36
For Stress Results, the stress varies between 6.27 ∗ 107 𝑁/𝑚2 and 8.156 ∗ 102 𝑁/𝑚2 . The
factor of safety for aluminum varies between 2.405 𝑎𝑛𝑑 2.175 ∗ 105 as the yield strength
equals 2.068 ∗ 108 𝑁/𝑚2. The factor of safety is satisfying.
The factor of safety for stainless steel 304 varies between 2.14 and 6.486 ∗ 104 . the factor of
safety for steel A36 varies between 2.53 and 8.705 ∗ 104 .
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VERTICAL FORMING, FILLING AND SEALING MACHINE
By comparing results Aluminum maximum deformation is about 9.261 mm. stainless steel deformation and steel A36 deformation are approximately equal 3.6 mm. while the factor of
safety of aluminum is higher than Stainless steel and steel. But its deformation is about 3
times the deformation of steel A36 and stainless steel 304. According to these result Aluminum is excluded because of its high deformation.
3.2.
second Iteration Analysis
3.2.1. Steel A36
Stress Results
Figure 5-22 Stress Results for Chassis second Iteration A36
Displacement Results
Figure 5-23 Displacement Results for Chassis second Iteration A36
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Factor Of Safety Results
Figure 5-24 FOS Results for Chassis second Iteration A36
3.2.2. Stainless Steel 304 Analysis
Stress Results
Figure 5-25 Stress Results for Chassis second Iteration St 304
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Displacement Results
Figure 5-26 Displacement Results for Chassis second Iteration St 304
Factor Of Safety Results
Figure 5-27 FOS Results for Chassis second Iteration St 304
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VERTICAL FORMING, FILLING AND SEALING MACHINE
For both stainless steel and steel, the minimum factor of safety is relatively low as it equals
1.045. But since the forces applied is 2.5 times the actual forces. This makes factor of safety
acceptable.
By comparing the results of stainless steel and steel they are approximately equal in strength
and displacement. Which makes both suitable choices.
4. Sealing Static Analysis
4.1.
Sheet Metal
4.1.1. C-SEC
•
•
•
•
It carries and fixes the two sealing mechanisms and guideways used for rods which
transfer the motion to the jaws in traverse sealing
It is a bended plate in the form of C section
Analysis done on A36 steel
The loads are applied as distributed masses with a large factor of safety to simplify
analysis.
4.1.1.1.C-Section Analysis
Figure 5-28 C-section Modelling on ANSYS 19
Table 5-1 Analysis Conditions and Results for C-section Plate
Object Name
Minimum
Total Deformation
Equivalent
Elastic Strain
0. mm
5.5428e-008
mm/mm
3.034e-008
mm/mm
4.1065e-003 MPa
2.3338e-003
MPa
1.4586e-004
mm/mm
2.0032e-004
mm/mm
27.916 MPa
15.409 MPa
Maximum 0.16931 mm
Maximum Shear
Equivalent Stress
Elastic Strain
114
Maximum
Shear Stress
VERTICAL FORMING, FILLING AND SEALING MACHINE
Average
3.4165e-002
mm
1.4378e-005
mm/mm
1.4312e-005
mm/mm
1.977 MPa
Figure 5-29 C-section Analysis Displacement Results
Figure 5-30 C-section Analysis Equivalent Elastic Strain Results
Figure 5-31 C-section Analysis Maximum Shear Strain Results
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1.1009 MPa
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-32 C-section Analysis Equivalent stress Results
Figure 5-33 C-section Analysis Maximum Shear Stress Results
Frequency Analysis
Table 5-2 Conditions and Results of C-Section Frequency Test
Total
Object
DeforName
mation
Total
Deformation
2
Total
Deformation
3
Total
Deformation
4
Minimum
Total
Deformation
5
Total
Deformation
6
Total
Deformation
7
Total
Deformation
8
Total
Deformation
9
Total
Deformation
10
0. mm
Maxi- 46.291
mum
mm
54.793
mm
54.551
mm
55.379
mm
55.424
mm
63.385
mm
102.6
mm
117.49
mm
60.678
mm
71.633
mm
Aver- 14.636
age
mm
14.401
mm
13.79
mm
11.564
mm
14.777
mm
12.844
mm
8.0074
mm
8.1975
mm
15.648
mm
12.915
mm
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-34 Deformation for C-section Frequency Analysis
Figure 5-35 Total Deformation of C-section Frequency Analysis and Static Load Analysis
Compering With Solidworks
Figure 5-36 C-section Solidworks Analysis Stresses Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-37 C-section Solidworks Analysis Displacement Results
Figure 5-38 C-section Solidworks Analysis Strain Results
Figure 5-39 C-section Solidworks Analysis FOS Results
The factor of safety is 2 according to Figure 5-39. While the deformation is 0.246 mm which
is acceptable. The design is safe and does not require any modifications.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.1.2. The Backward and Forward plate
•
•
It is used to fixed the bearing with rods and fixed the turnbuckles of mechanism
Manufactured from (A36)
4.1.2.1. Material Specifications
Table 5-3 Plates Steel Specifications
Young's
Temperature C Modulus Poisson's Ratio
MPa
2.e+005
0.3
-0.106
0.213
Shear Modulus MPa
1.6667e+005
Strength Coef- Strength
Ductility Ductility
ficient MPa Exponent Coefficient Exponent
920
Bulk Modulus MPa
Cyclic Strength
Coefficient MPa
-0.47
76923
Cyclic Strain Hardening Exponent
1000
Yield Strength Mpa
0.2
Tensile Ultimate Strength MPa
500
207
Figure 5-40 Plate one modelling on Solidworks
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-41 Plate One Solidworks Analysis Stress Results
Figure 5-42 Plate One Solidworks Analysis Displacement Results
Figure 5-43 Plate One Solidworks Analysis Strain Results
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Figure 5-44 Plate One Solidworks Analysis FOS Results
Figure 5-45 Plate Two Solidworks Modelling
Figure 5-46 Plate Two Solidworks Stress Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-47 Plate Two Solidworks Displacement Results
Figure 5-48 Plate Two Solidworks Strain Results
Figure 5-49 Plate Two Solidworks FOS Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
According to analysis results plates deformation is accepted. The stress does not exceed the
yield strength. The factor of safety very high. But it is used to reduce sheet metal manufacture
costs. As it is better to use a sheet metal from the same thickness as the other machine parts.
4.2.
Sealing Jaws Static Force Analysis
LONGITUDINAL JAWS
o Used for the longitudinal sealing of the bag
o Analysis done on Aluminum alloy with specifications shown in Table 5-4
TRAVERSE JAWS
o Used for the upper and lower sealing of the bag
o Analysis done on Aluminum alloy with specifications shown in Table 5-4
Table 5-4 Aluminum Alloy Specifications
Temperature
C
Young's Modulus
MPa
Poisson's Ratio
71000
0.33
Bulk Modulus MPa
Shear Modulus MPa
69608
Yield Strength Mpa
26692
Tensile Ultimate Strength MPa
310
280
4.2.1. Longitudinal JAWS
4.2.1..1.
4.2.1.1. Analysis using Ansys
Table 5-5 Longitudinal Sealing Analysis Conditions and Results
Object Name
Total Deformation
Equivalent Stress
Equivalent Elastic Strain
Minimum
0. mm
3.6277e-005 MPa
5.1095e-010 mm/mm
Maximum
2.1172e-004 mm
0.50044 MPa
7.2055e-006 mm/mm
Average
4.3352e-005 mm
4.0165e-002 MPa
5.9181e-007 mm/mm
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-50 Longitudinal Jaw Deformation Results Using ANSYS
Figure 5-51 Longitudinal Jaw Stress Results Using ANSYS
Figure 5-52 Longitudinal Jaw Strain Results Using ANSYS
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.2.1..2.
Comparing Analysis with Solidworks
Figure 5-53 Longitudinal Jaw Stress Results Using Solidworks
Figure 5-54 Longitudinal Jaw Displacement Results Using Solidworks
Figure 5-55 Longitudinal Jaw Strain Results Using Solidworks
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.2.2. Transvers Jaws
4.2.2..1.
Analysis Using ANSYS
Table 5-6 Transverse Sealing Jaws Analysis Conditions And Results
Object Name
Total Deformation
Equivalent Elastic Strain
Equivalent Stress
Minimum
0. mm
1.9126e-008 mm/mm
1.3405e-003 MPa
Maximum
5.289e-005 mm
3.8054e-006 mm/mm
0.26915 MPa
Average
2.8898e-005 mm
5.9294e-007 mm/mm
3.832e-002 MPa
Figure 5-56 Transverse Jaw Deformation Results ANSYS
Figure 5-57 Transverse Jaw Strain Results ANSYS
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-58 Transverse Jaw Stress Results ANSYS
4.2.2..2.
Compering With Solidworks
Figure 5-59 Transverse Jaw Deformation Results Using Solidworks
Figure 5-60 Transverse Jaw Strain Results Using Solidworks
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-61 Transverse Jaw Stress Results Using Solidworks
4.2.3. The Effect of Heat with The Impact Force
4.2.3.1. Longitudinal Jaws Heat Analysis
Figure 5-62 Temperature Distribution on Jaws
Figure 5-63 Longitudinal Sealing Jaws Heat Analysis Deformation Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-64 Longitudinal Sealing Jaws Heat Analysis Strain Results
Figure 5-65 Longitudinal Sealing Jaws Heat Analysis Stress Results
4.2.3.2. Transverse Jaws Heat Analysis
Figure 5-66 Transverse Sealing Jaws Heat Distribution
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-67 Transverse Sealing Jaws Heat Analysis Deformation Results
Figure 5-68 Transverse Sealing Jaws Heat Analysis Strain Results
Figure 5-69 Transverse Sealing Jaws Heat Analysis Stress Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 5-7 Sealing Jaws Heat Analysis Results
Object Name
Total Deformation
Equivalent Elastic Strain
Equivalent Stress
Results
Minimum
0. mm
1.7966e-006 mm/mm
0.11764 MPa
Maximum
9.0486e-002 mm
5.9253e-003 mm/mm
365.66 MPa
Average
4.7722e-002 mm
6.7876e-004 mm/mm
44.293 MPa
Results
Minimum
0. mm
3.6234e-007 mm/mm
2.0423e-002 MPa
Maximum
0.13474 mm
5.6627e-003 mm/mm
295.46 MPa
5.588e-002 mm
4.4937e-004 mm/mm
30.03 MPa
Average
4.2.4. Springs Analysis
•
•
•
It's an elastic object that stores the mechanical energy after the jaws impact
Its helical type
Analysis done on steel with material specifications shown in Table 5-8
Table 5-8 Springs Steel Material Specifications
Temperature
C
Young's Modulus MPa
1.93e+005
Shear
Bulk Modulus MPa Modulus
MPa
Poisson's
Ratio
0.31
1.693e+005
Tensile Yield Strength MPa
Tensile Ultimate Strength MPa
207
586
73664
4.2.4.1. Longitudinal Sealing Spring Analysis
Table 5-9 Longitudinal Sealing Spring Analysis Conditions And Results
Object Name
Total Deformation
Equivalent Stress
Coil Diameter
10 mm
Number of coil
5
Diameter of thread
2.5
131
Equivalent Elastic Strain
VERTICAL FORMING, FILLING AND SEALING MACHINE
Stiffness
4.5 N/mm
Length
28 mm
Results
Minimum
0. mm
0.15544 MPa
1.9566e-006 mm/mm
Maximum
2.9457 mm
328. Mpa
1.7693e-003 mm/mm
Average
0.97199 mm
103.44 Mpa
6.991e-004 mm/mm
Figure 5-70 Longitudinal Sealing Spring Deformation Results
Figure 5-71 Longitudinal Sealing Spring Stress Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-72 Longitudinal Sealing Spring Strain Results
4.2.4.2. Transverse Sealing Spring Analysis
Table 5-10 Transverse Sealing Spring Analysis Conditions And Results
Object Name
Total Deformation
Equivalent Stress
Coil Diameter
10 mm
Number of coil
5mm
Diameter of thread
2.5 mm
Stiffness
6 N/mm
Length
Equivalent Elastic Strain
20
Results
Minimum
0. mm
0.1943 MPa
2.4458e-006 mm/mm
Maximum
3.6821 mm
410. MPa
2.2117e-003 mm/mm
Average
1.215 mm
129.29 MPa
8.7387e-004 mm/mm
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-73 Transverse Sealing Spring Deformation Results
Figure 5-74 Transverse Sealing Spring Stress Results
Figure 5-75 Transverse Sealing Spring Strain Results
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.3.
Sealing Mechanism Kinematic Analysis
Sealing actual mechanism as shown in Figure 5-76 is complicated to analysis. A simplified
mechanism with the same length is used as shown in Figure 5-77 and Figure 5-78. This mechanism simplified analysis process and its results.
Figure 5-76 Sealing Actual Mechanism
Figure 5-77 Sealing Simplified Mechanism
Figure 5-78 Sealing Simplified Mechanism on ANSYS
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VERTICAL FORMING, FILLING AND SEALING MACHINE
4.3.1. The Analysis of Jaws and Back Plate
Figure 5-79 Jaws Relative Velocity Curve
Figure 5-80 Back Plate Relative Velocity Curve
Figure 5-81 Jaws Relative Acceleration Curve
Figure 5-82 Back Plate Relative Acceleration
Curve
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-84 Back Plate Forces Curve
Figure 5-83 Jaws Forces Curve
In the forward path "impact moment of the jaws" the maximum velocity of the jaws rod meets
the minimum speed of the back plat rod.
The minimum acceleration of the back plate rod meets the maximum acceleration of the jaws
rod.
The force of the jaws rod reaches its maximum value at the impact moment then it begins to
decrease.
4.3.2. The Crank Analysis
Figure 5-85 Crank Relative Velocity Curve
Figure 5-86 Crank Relative Acceleration
Curve
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Figure 5-87 Crank Forces Curve
4.3.3. Coupler Analysis
Figure 5-88 The Angular Velocity of the
Coupler Curve
Figure 5-89 The Angular Velocity of Coupler
with Rod Curve
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-90 The Angular Acceleration of Coupler Curve
Figure 5-91 The Angular Acceleration of
Couple With Rod Curve
Figure 5-92 Total Force of The Coupler Curve
Figure 5-93 The Total Force of Coupler
With Rod Curve
At the maximum angular velocity of the coupler the rod stop momentarily as its angular velocity equal zero.
The maximum angular acceleration of the rod meet the minimum angular acceleration of the
coupler (at the impact moment of the jaws)
At the impact moment of the jaws both of them reach to its maximum force value but the
coupler's force is much more the rod force.
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4.3.4. The Rocker and Rocker With Rod Analysis
Figure 5-94 The Rocker Angular Velocity Curve
Figure 5-96 The Rocker Angular Acceleration
Curve
140
Figure 5-95 The Rocker with Rod Angular
Velocity Curve
Figure 5-97 The Rocker with Rod Angular
Acceleration Curve
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 5-98 The Rocker Force Curve
Figure 5-99 The Rocker with Rod Force
Curve
At the impact moment the rod maximum angular velocity begin to decrease unlike the rocker
minimum angular velocity which begin to increase until reach to its maximum at the position
which act its role to direct the rod by the jaws for impact again and again.
At the impact moment the rocker angular acceleration equal zero and the rod acceleration decreased until reach to its minimize value else
At the impact moment the rod force is higher than the rocker force
141
Chapter Six:
Machine
Manufacture
And Assembly
VERTICAL FORMING, FILLING AND SEALING MACHINE
6. Machine Manufacture and Assembly
1. Introduction
In this chapter, the manufacture processes used in the machine are described. The main processes used in the manufacture was sheet metal processes. As sheet metal is the abundant part
in the machine. It is used in chassis, sealing mechanism, sealing fixtures, filling casing and
filling parts. Some parts were made using milling and turning in sealing mechanism. 3D printing was used for filling cup. But most of parts in sealing mechanism was purchased for higher
quality and lower cost. All steps done in manufacture or parts selection is discussed in this
chapter.
2. Sheet Metal Processes
2.1.
Sheet Metal Processes for Chassis
2.1.1. Material Final Selection
By comparing the prices of stainless steel 304 and steel A36, it was found that stainless steel
304 price is about 3 times steel A36 price. Since both materials were suitable choice from
analysis and gives nearly equal results for stresses and stiffness. The advantage of stainless
steel 304 over steel A36 is that stainless steel is safer for food. But food is away from chassis
and never touches it in this machine. This makes steel A36 a suitable material for manufacture
2.1.2. Manufacturing Methods
The chassis is totally made from sheet metal. It is manufacture depends on three main processes. The processes are:
1. Sheet metal cutting
2. Sheetmetal bending
3. Sheet metal painting
2.1.3. Sheet Metal Cutting
Sheet metal can be cut using different ways e.g., (laser cut, water jet machining, plasma,
EDM, shearing, manual cutting using saw and drillers…etc.). Since water jet machining,
plasma and EDM are excluded because of high cost and not widespread in local market.
Shearing requires dies and punches for the process which requires mass production, which
makes it excluded as well. Laser cut and manual cutting are both suitable methods for this application. The following table shows a comparison between them
PoC
Laser Cut
Manual Cutting
Quality
Higher quality
Lower quality
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Surface Finish
Gives high surfaces finish
Gives low surface finish
Time
Does not consume much time
Time consuming process
Cost
Approximately the same cost Approximately the same cost
as manual cutting sometimes as laser cut maybe higher
lower
Suitable for all cuts
Yes
No
From the comparison it is concluded that the suitable manufacture method is laser cut.
2.1.4. Laser Cut Process
To cut parts using laser cut, first parts should be flatten as shown in Figure 6-1.
Figure 6-1 Flatten Sheet Metal of Chassis Top and Front
The files should be given to the workshop a .dxf files as shown in Figure 6-2 to be nested using coral draw program.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-2 DXF File of Chassis Flatten Pattern for Top and Front
Then the nest is converted into laser cutting program and cut. Figure 6-3 and Figure 6-4 shows
Laser Cutting Process from Chassis Parts.
Figure 6-3 Chassis Sheet Metal During Laser Cut Process
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-4 Chassis Sheet Metal During Laser Cut Process (Wider View)
2.1.5. Sheet Metal Bending
Sheet metal bending can be done using CNC bending machine or manual bending machine.
Both machines are of the same cost. CNC machine is more suitable for angular bends. While
manual bending machines are more suitable for right angles. CNC gives higher quality than
manual machines. The problem with CNC bending is it is not locally widespread. So, the
bending process was done using manual machines
To bend a part, it is a must to have drawing of the flatten part as a reference for the worker.
The drawing is shown in Figure 6-5 and Figure 6-6.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-5 Working Drawing for Chassis Top and Front Flatten Pattern
Figure 6-6 Working Drawing for Chassis Base Flatten Pattern
Figure 6-7 and Figure 6-8 shows Bending Process During installing part and after bending it.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-7 Chassis Sheet Metal Installing Before Bending
Figure 6-8 Chassis Sheet Metal After Bending
The process of making flatten parts, prepare drawing papers, dxf files and nesting is called
manufacture paper preparation.
2.1.6. Sheet Metal Painting
The objective of painting is to form a coating film on the surface of the chassis in order to protect the chassis and give a fine appearance. Painting may also have other special functions.
There are various types of painting methods.
The most common coating types are spray coating and powder coating. Spray painting, including electrostatic spray painting, is a process by which liquid paint is applied under pressure to
an object. Spray painting may be carried out by hand or automatically. There are several
methods used to atomize the paint for spraying:
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VERTICAL FORMING, FILLING AND SEALING MACHINE
•
using a conventional air compressor – air is driven across the mouth of a small outlet
under pressure to draw liquid paint out of the container and produce an air-paint mist
from the nozzle of the spray-gun
• airless spray painting – the paint container is pressurized pushing the paint to the nozzle where it is atomized by the spray gun
• electrostatic spray painting – an electric pump drives the electrostatically charged liquid paint out of the nozzle which is then applied to the object which is earthed.
Powder coating is a process by which electrostatically charged powder is applied onto an
earthed object. Spray painting and powder coating are carried out in a variety of industries.
Both processes are equal in cost and time. so, select any one of them would not make a huge
different. Powder coating was selected. Figure 6-9 shows some of machine parts during painting process.
Figure 6-9 Machine Parts During Painting process
2.1.7. Final Result
The Following figures shown the Chassis after Cutting, Bending and Painting. Some welds
were added at the corners before painting to improve stiffness and reduce Chassis Vibrations.
The Last Step of Chassis Manufacture is Assembly. Assembly is done later after finishing
manufacture of all parts as will be discussed later.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-10 chassis Front and Top After Cutting, Bending and painting
Figure 6-11 Sealing C-Section After Cutting, Bending and painting
Figure 6-12 Chassis Base After Cutting, Bending, and painting
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-13 Chassis After Manufacture (Assembled with Sealing Mechanism And Transverse
Sealing Jaws)
2.2.
Sheet Metal Bending for Filling System
The Cost of Manufacturing the whole filling sealing from stainless steel 304 was very high.
Stainless Steel 304 costs three times the cost of steel A36. But some of parts of filling system
are in direct contact with food. These parts should be made of stainless steel 304. While other
parts that does not touch food e.g., casing was made from A36. The second iteration was used
because it does not require weldments and the parts of different materials are bolted. The same
steps done in chassis will be done in Filling System parts. The following Figures shows casing’s, filling grid’s and filling pot’s models and flatten working drawing as examples.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-14 Casing Model before Flatten
Figure 6-15 Casing Working Drawing After Flatten
Figure 6-16 Filling Grid Model before Flatten
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-17 Filling Grid Working Drawing After Flatten
Figure 6-18 Filling Pot Model before Flatten
Figure 6-19 Filling Pot Working Drawing After Flatten
For the parts made from stainless steel 304, the parts pass through the same steps same as steel
A36 but the 3rd process was welding. No painting done on Stainless steel 304 as it does not
rust or react with air. The welding process for Stainless Steel 304 was not easy or cheap.
Stainless steel welding is more complicated than carbon steel welding. Stainless steel effectively retains heat causing it to warp when exposed to the high temperatures that welding creates. Stainless steel can also warp or crack during the cooling process after it has been heated
by a welder. Even when a piece of stainless steel doesn’t crack or warp after a bad welding
session, it will nearly always show scratches and blemishes.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Each kind of stainless steel presents a distinct challenge to welders. Austenitic steel may crack
if given a high heat input or if you make a concave or flat weld. Martensitic steel can crack if
not properly preheated. And with its low maximum inter pass temperature of 300, ferritic steel
will lose strength unless it’s heated with a low heat input.
The key to successfully welding stainless steel lies in getting the right filler material. The filler
material grade needs to match the base material’s grade to get a good weld.
TYPES OF WELDING USED FOR STAINLESS STEEL
Choosing the right method for welding stainless steel really depends on the required quality. If
the requirements are more affordable weld, spot welding might be the best option. But if the
material has small thickness, then TIG or gas tungsten arc welding might be the better
choice[28].
• TIG welding or gas tungsten arc welding
• Resistance or spot welding
• MIG welding or gas metal arc welding
TIG was selected because it offers high quality, versatility, and longevity. TIG is the most
common stainless steel welding process. This welding process creates a low heat input, which
makes it perfect for thin material. The argon gas is often mixed with other gases, depending on
the needs of the specific project, including helium, hydrogen and nitrogen. To prevent oxidation and increase resistance to corrosion, a single-sided welding process can be used creating
inert backing gas protection between the interior and exterior welds.[29]
3. 3D Printing Processes in Filling System
3D printing was used for manufacture filling cup. Because it is the most suitable method to
manufacture this part with the lowest material wastage and with accurate dimensions. But its
surface finish was rough, and it has low quality.
3D printing is done through the following steps:
The first step of 3D printing typically starts with the CAD model. Figure 6-20 shows filling
cup cad model using solidworks.
Figure 6-20 CAD Model for Filling Cup Using Solidworks
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Second step is exporting STL file. The STL file stores the information about conceptual 3D
object.
Third step is choosing the suitable material for the required design, deciding the placement
and size of the print, creating the G-code and printing. Figure 6-21 shows the Placement selection using software.
Figure 6-21 Cup Placement Using Machine Program
3D printing has different infills. Infills differs according to the type of the print. From 0% to
15% used for model prints and figurine. From 15% to 50% used for standard prints. From 50%
to 100% used for functional prints. Flexible prints can be made using infills from 1% to 100%.
Figure 6-22 shows different refill present. Filling Cup is considered a functional print, 85%
infill was selected.
Figure 6-22 Different 3D Printing Infills
Figure 6-23 shows the result of 3d printing process of the cup. Figure 6-24 shows the wasted
material from the process used in supports.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-23 3D Printed Filling Cup
Figure 6-24 The Support or The Wasted Material to Reach the Required Design
4. Collar
It is the bag former for vertical packing machine. It is an accessory added to the machine to
form bags. It is size determine bag dimensions and shape. Since it is in direct contact with
food, it should be made from nontoxic material. Because it passes through forming, machining
and welding processes, the material should be with high formability, machinability and weldability. The selected material is aluminum.
Collar manufacture has many complicated sheet metal processes to give the highest accuracy.
It requires precious machines and skilled labor. Purchasing collar was better option for the
following reasons:
•
•
Poor quality finishing for collars in the most of local workshops
Requires heat treatment and high-quality machines
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VERTICAL FORMING, FILLING AND SEALING MACHINE
•
The lack of manufacturing machines in one workshop, which requires transportation,
and higher costs
• Purchased collar has higher quality and lower cost than manufacturing
Figure 6-25 shows the purchased collar. For minimizing chassis size, the collar length was
shortened. And for minimizing filling system size, the upper part of the collar was cut.
Figure 6-25 Purchased Collar
5. Sealing System Manufacture
5.1.
Sealing Jaws
Sealing jaws are made using aluminum alloy. It can be made using CNC or casting and wire
cutting. CNC was eliminated because:
•
•
•
•
High material wastage
It consists of many details which requires much time
Higher machining time means higher cost
It is not common method and locally less available for sealing jaws compared to casting and wire cutting
First step of manufacture is casting. Then wire cutting is used for making precious details.
Using drilling pross to make streams for heaters & temperature sensors).
5.2.
Knife
it’s critical to use high-quality VFFS knives. Just like any other type of machinery, VFFS machines require high-quality parts and components to ensure it provides long-lasting performance that meets the required production and quality needs.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.2.1. Knife Manufacturer Selection Criteria
It’s important to consider a few crucial factors when choosing a VFFS knives Manufacturer.
•
•
•
The quality of the VFFS Knives – The most important factor in choosing VFFS
knives is using a high-quality, durable knife that can maintain sharpness and durability
for hundreds of thousands of packaging cycles. While choosing an inexpensive knife
may save you money in the short-term, low-quality knives require changing more often, and can even cause manufacturing delays and defects.
The turn-around time and in-stock capabilities of your VFFS machine knife – It’s
essential to always have a good stock of VFFS knives available, both at working place
and from your VFFS machine knife partner. Choose a partner who can quickly manufacture custom knives with a low turn-around time and keep a large stock of knives
prepared for ordering.
Expected ongoing support – To be truly satisfied with your VFFS knives, it is a need
to be able to get support after installation – and get quick and knowledgeable responses
about questions or issues related to your vertical form fill seal knives. This ensures
avoiding downtime.[30]
Figure 6-26 Different Knives Shapes and Types[30]
5.3.
Mechanism links Manufacture
Mechanism links can be made using rectangular cross section parts with holes at the ends
joined together using bolts. But this method requires milling and drilling processes. Or using
sheet metal with large thickness and cut it using laser. But both methods will not give parts
with changeable length. The second option is using tie rods. Tie rods are used because length
can be changed in small range. This accessibility avoids errors after manufacture as all mechanism lengths can be changed. Tie rods consists of two parts, rod ends and the rod itself.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.3.1. Rods Selection
Table 6-1 Rods Standard tables[31]
According to the modelling results and from the table above the selected rod is
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.3.2. Rod Ends Selection
Table 6-2 Standard Dimensions of Tie Rod Ends[32]
according to the modelling and analysis results and the standard dimensions in Table 6-2, the
selected tie rod end is SI15T/K pos
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VERTICAL FORMING, FILLING AND SEALING MACHINE
5.4.Transmission Shaft
For transmitting power from motor connected with transverse sealing mechanism to the longitude sealing mechanism a Transmission shaft.
5.4.1. Material Used for Shafts
The material used for shafts should have the following properties:
1. high strength
2. good machinability
3. low notch sensitivity factor (low stress concentration i.e. ductile material is used).
The material selected is hard chrome plated shafts, as it is satisfying the above conditions and
locally available in the stock.
Shaft Layout
•
•
•
Axial layout of components
Supporting axial loads (bearings)
Provides transmission torque (discs)
160
VERTICAL FORMING, FILLING AND SEALING MACHINE
5.5.Guide Ways
Table 6-3 Guide Ways Standard Dimensions Table[33]
The selected guideway is SCS12UU(T8)
5.6.
Sealing Mechanism Assembly
Figure 6-27 shows the transverse sealing mechanism after assembly. it shows a sheet metal
part welded to the transmission shaft to facilities manufacture process instead of using tie rods.
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VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-27 Transverse Sealing Mechanism Assembly
6. Machine Assembly
The last step of manufacture is assembly. Chassis bottom is bolted with chassis front side. The
sealing mechanism is installed using the C-section into chassis. The electrical plate is installed
as well. Both plates are bolted with the chassis front plate. Then chassis back plate is bolted
into the two plates. And then bolted with chassis top and base. Filling parts are bolted together
and then bolted into the casing base. Chassis has movable acrylic sides for monitoring and
easy maintenance accessibility. Filling system casing has acrylic back for monitoring. It has
movable casing top to facilitate accessibility for maintenance. The following figures shows the
machine after assembly
Figure 6-28 Machine After Assembling Sealing with Chassis without Sides (side View)
162
VERTICAL FORMING, FILLING AND SEALING MACHINE
Figure 6-29 Chassis After Assembly without Electric Parts
Figure 6-30 The Machine After Manufacture and Assembly
163
Chapter Seven:
Conclusions and
Future
Recommendations
VERTICAL FORMING, FILLING AND SEALING MACHINE
7. Future Recommendations and Conclusions
1. Introduction
This machine was the first model. It faced many errors and faults was made during design,
manufacture, and calculations. It requires many modifications and recommendations. In this
chapter recommendations for each system will be discussed. This would help to produce a
modified model in the future by the same team or other team. These modifications are recommended according to trials was made during this project and errors the project faced. Taking
these recommendations in the future will reduce the errors and improves machine performance, cost, product quality…etc.
2. Filling System Conclusions and Recommendations
1- 3D printing surface finish was very rough. That affected grains smooth sliding. sheet
metal cup would be more suitable as a material. But its design for manufacture and design for assembly was very hard. Also, 3D printing parts modifications after manufacture is the hardest and affects quality.
2- According to references as mentioned before the suitable inclination angle for all parts
is 45 degrees but in actual application it was needed to have inclination angle reaches
to 60 degrees.
3- The system required more space to be easily assembled and not to affect system vibration.
3. Sealing System Conclusions and Recommendations
1- Heat distribution on sealing jaws was not equal. Bad distribution happened heat source
was inserted from one side and it was not centered. It is preferable to have one heat
source in the middle or two heat sources in the ends to have accurate heat transfer
across the sealing jaws.
2- Machine mechanism is suitable only for small machines. While machines with large
size or require filling in higher rate or larger masses it is preferred to use pneumatic
system. Pneumatic system pressure can be controlled. Pressure control gives a wider
range of plastic films used. As each material requires specific pressure.
4. Chassis Conclusions and Recommendations
1- Electric wiring should be taken in consideration to be organized. As electric wire
paths required modifications
2- Painting tolerance should be taking in consideration. Painting adds a layer about
0.5 mm which affected holes diameters.
164
VERTICAL FORMING, FILLING AND SEALING MACHINE
3- Any modifications after manufacture should be done before electrostatic painting
as it increases material hardness. Which makes processes (as drilling, cutting…etc.)
harder as material penetration requires tools with higher hardness.
4- It is preferred to add small welds in the corners as it increases chassis stiffness and
reduce small vibrations happens at the top of the chassis.
5- Collar fixture should be more flexible to allow using different collars with different
sizes. Collar size difference gives different bag sizes.
5. Film Transport System Conclusions and Recommendations
1- Adding two shafts to the system under film fixation by a distance from 10 to 20 mm
will improve film control and reduce film bends.
2- If the used shafts will be painted it should be manufactured in dimensions less by the
design by 1mm as painting will add this one mm to the diameter as mentioned in the
chassis.
165
VERTICAL FORMING, FILLING AND SEALING MACHINE
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[3]
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[6]
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[Online]. Available: www.ijstr.org
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R. H. Schmidt, D. J. Erickson, H. Wainness, and S. Paul, “Sanitary Design and Construction of Food Equipment 1.” [Online]. Available: http://edis.ifas.ufl.edu.
[9]
F. Moerman and E. Partington, “MATERIALS OF CONSTRUCTION FOR FOOD
PROCESSING EQUIPMENT AND SERVICES: REQUIREMENTS, STRENGTHS
AND WEAKNESSES.”
[10]
R. H. Schmidt, D. J. Erickson, S. Sims, and P. Wolff, “Characteristics of Food Contact
surface materials: stainless steel,” 2012.
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N. R. Nwakuba, O. C. Chukwuezie, F. C. Uzoigwe, and P. Chukwu, “Friction Coefficients of Local Food Grains on Different Structural Surfaces,” Journal of Engineering
Research and Reports, pp. 1–9, Aug. 2019, doi: 10.9734/jerr/2019/v6i316951.
[12]
H. M. Beakawi Al-Hashemi and O. S. Baghabra Al-Amoudi, “A review on the angle of
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417, May 01, 2018. doi: 10.1016/j.powtec.2018.02.003.
[13]
M. Merabtene, “EVALUATION AND OPTIMIZATION OF A VERTICAL FORMFILL-SEAL PRODUCTION MACHINE FOR FLEXIBLE PACKAGING PAPERS
Evaluation and optimization of a vertical form, fill and seal production machine for
flexible packaging papers,” 2020.
166
VERTICAL FORMING, FILLING AND SEALING MACHINE
[14]
“A000047,” Arduino Mega 2560, Accessed: Jul. 21, 2022. [Online]. Available:
https://store.fut-electronics.com/products/arduino-mega-2560-r3-latest-revision-clone
[15]
“LCD Display Screen.” Accessed: Jul. 21, 2022. [Online]. Available: https://store.futelectronics.com/products/character-lcd-module-16-char-x2lines?_pos=2&_sid=d142efa9c&_ss=r
[16]
“Membrane Keypad 16 Key (Matrix 4x4) – Future Electronics Egypt.” https://store.futelectronics.com/products/membrane-keypad-16-key-matrix4x4?_pos=2&_sid=a1b8752af&_ss=r (accessed Jul. 14, 2022).
[17]
“Getting Started with Load Cells - learn.sparkfun.com.”
https://learn.sparkfun.com/tutorials/getting-started-with-load-cells/all (accessed Jul. 14,
2022).
[18]
“Load Cell Amplifier - HX711 – Future Electronics Egypt.” https://store.futelectronics.com/products/weight-scales-analog-to-digital-converter-adc-24bit?_pos=1&_sid=e661a2a09&_ss=r (accessed Jul. 15, 2022).
[19]
“Load Cell Amplifier HX711 Breakout Hookup Guide - learn.sparkfun.com.”
https://learn.sparkfun.com/tutorials/load-cell-amplifier-hx711-breakout-hookupguide?_ga=2.148109940.271950127.1569183578-60568204.1563144486 (accessed Jul.
14, 2022).
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“L298 Dual H-Bridge Motor Driver.” Accessed: Jul. 21, 2022. [Online]. Available:
https://store.fut-electronics.com/products/l298-dual-motor-driver-module2a?_pos=1&_sid=030ec42f8&_ss=r
[21]
“Servo Motors Control & Arduino.” Accessed: Jul. 21, 2022. [Online]. Available:
https://store.fut-electronics.com/products/standard-servo-motor-3-2-kgcm?_pos=1&_sid=88085c612&_ss=r
[22]
“Servo Motor Standard (180) 3.2 kg.cm Plastic Gears (FS5103B) - RAM Electronics.”
https://ram-e-shop.com/product/servo-fs5103b/ (accessed Jul. 14, 2022).
[2
3]
“KY-040 Arduino Rotary Encoder User Manual Keyes KY-040 Rotary Encoder.” Accessed: Jul. 21, 2022. [Online]. Available: https://ram-e-shop.com/product/kit-ky040rotary-encoder/
[24]
“DC Motor Driver VNH2SP30 (30A Peak-15A Continuous)”, Accessed: Jul. 16, 2022.
[Online]. Available: www.fut-electronics.com
[25]
“Linear Magnetic Hall Switch Sensor Module - RAM Electronics”, Accessed: Jul. 21,
2022. [Online]. Available: https://ram-e-shop.com/product/kit-ky024-hall-switch/
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[26]
“Waterproof Temperature Sensor (Digital) – Future Electronics Egypt”.
[27]
“Relay Module (1 Channels - 5V) – Future Electronics Egypt.” https://store.futelectronics.com/products/relay-module-1-channels5v?_pos=3&_sid=62c76382e&_ss=r (accessed Jul. 14, 2022).
[28]
“A Short Guide to Welding Stainless Steel - Kloeckner Metals Corporation.”
https://www.kloecknermetals.com/blog/a-short-guide-to-welding-stainless-steel/ (accessed Jul. 13, 2022).
[29]
“3 Common methods for welding stainless steel.” https://www.atwf-inc.com/blog/3common-methods-for-welding-stainless-steel (accessed Jul. 13, 2022).
[30]
“A Quick Guide To VFFS (Vertical Form Fill Seal) Knives - TGW International.”
https://www.tgwint.com/2020/05/11/quick-guide-vffs-vertical-form-fill-seal-knives/
(accessed Jul. 13, 2022).
[31]
“Tie Rods and Tiebacks – Williams Form Engineering Corp.”
https://www.williamsform.com/marine/tie-rods-and-tiebacks/ (accessed Jul. 13, 2022).
[32]
“M5/6/12 Female Rose Joint Right Thread Bronze Liner Performance Rod End.”
https://www.teknistore.com/en/machinery-parts/47664-m5-6-12-female-rose-jointright-thread-bronze-liner-performance-rod-end.html?mobile_theme_ok (accessed Jul.
13, 2022).
[33]
“SCS..UU-Pillow-Block-Linear-Bearings”.
168
VERTICAL FORMING, FILLING AND SEALING MACHINE
Appendix A
(The Kinematic Analysis of Sealing Mechanism Tables)
Table 0-1 Input Data for Sealing Mechanism Kinematic Analysis
Sealing Mechanism
Object Name
State
Scope
Joint
Definition
DOF
Type
Magnitude
Suppressed
Impact time
Table 0-2 Jaws Relative Velocity Values
Fully Defined
Revolute - Part2 To Part1
Rotation Z
Rotational Velocity
40. RPM (step applied)
No
3s
Table 0-3 Back Plate Relative Velocity Values
Time [s]
Jaws velocity
[mm/s]
Time [s]
Back plate velocity
[mm/s]]
0.00
63.579
0.00
-64.425
0.50
-45.54
0.50
49.834
1.00
-23.383
1.00
17.929
2.000
60.784
2.000
-62.399
2.50
-45.934
2.50
50.188
3.00
63.579
3.00
-64.425
Table 0-4 Jaws Relative Acceleration Values
Table 0-5 Back Plates Relative Acceleration Values
Time
[s]
Jaws Acceleration
[mm/s2]
Time
[s]
Back plate Acceleration
0.00
-200.82
0.00
142.19
0.50
-219.49
0.50
198.32
1.00
579.38
1.00
-447.51
2.000
-219.43
2.000
197.4
2.50
549.69
2.50
-427.89
3.00
-200.82
3
142.19
169
[mm/s2]
VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 0-7 Back Plate Forces values
Table 0-6 Jaws Forces values
Time [s]
jaws (Total Force) [N]
Time [s]
Back Plate (Total Force) [N]
0.00
1.3032e-003
0.00
1.3603e-003
0.5
2.0328e-003
0.5
4.9525e-004
1.00
1.3044e-003
1.00
6.1604e-003
2.00
2.0204e-003
2.00
4.55e-004
2.50
1.4448e-003
2.50
5.2847e-003
3.00
1.3032e-003
3.00
1.3603e-003
Table 0-8 Output Data For Jaws And Back Plates Kinematic Analysis Summary
Object
Name
State
Jaws
Back plate
Type
Boundary Translational
Condition – rod to jaw
Orientation
Method
Orientation
Translational
– rod to back
plate
jaws
Back plate
jaws
Back plate
Solved
Definition
Joint Probe
Translational Translational Translational
Translational
rod to back
rod to back
- rod to jaw
- rod to jaw
plate
plate
Joint Reference System
Reference Coordinate System
Suppressed
No
Options
Result Type
Relative Velocity
Result Selection
Display
Time
Relative Acceleration
X Axis
Total Force
Total
End Time
X Axis 63.579 mm/s -64.425 mm/s
Results
-200.82
mm/s²
142.19 mm/s²
Total
1.3032e-003
N
1.3603e-003
N
2.7781e-003
N
7.5937e-003
N
4.2631e-005
N
5.1795e-006
N
Maximum Value Over Time
X Axis 85.179 mm/s
74.709 mm/s 626.55 mm/s² 244.88 mm/s²
Total
Minimum Value Over Time
-219.62
-478.71
X Axis -85.187 mm/s -74.727 mm/s
mm/s²
mm/s²
Total
Information
170
VERTICAL FORMING, FILLING AND SEALING MACHINE
Time
3. s
Table 0-9 Crank Relative Velocity
Values
Time
[s]
Table 0-10 Crank Relative Acceleration
Values
Crank velocity
[rpm]
Time [s]
Crank angular acceleration
0.00
9.195e-015
0.5
1.9451e-014
1.00
-1.7745e-014
2.00
-1.0669e-014
2.50
3.0128e-015
3.00
4.5266e-014
[rad/s2]
0.00
0.50
1.00
40
2.000
2.50
3.00
Table 0-11 Crank Forces Values
Time [s]
Crank force [N]
0.00
2.8537e-002
0.5
3.9217e-002
1.00
0.15771
2.00
3.9027e-002
2.50
0.14634
3.00
2.8537e-002
Table 0-12 Crank Analysis Results Summary
Object Name
State
crank
crank
Solved
crank
Definition
Type
Joint Probe
Revolute – crank
Boundary Condition
Orientation Method
Orientation
Suppressed
Joint Reference System
Reference Coordinate System
No
Options
Result Type Relative Angular Velocity
Result Selection
Relative Angular Acceleration
Z Axis
171
Total Force
Total
VERTICAL FORMING, FILLING AND SEALING MACHINE
Display Time
End Time
Results
Z Axis
40. RPM
4.5266e-014 rad/s²
Total
2.8537e-002 N
Maximum Value Over Time
40. RPM
6.6198e-014 rad/s²
Z Axis
Total
0.17501 N
Minimum Value Over Time
40. RPM
-1.1083e-013 rad/s²
Z Axis
Total
5.1036e-003 N
Table 0-13 The Angular Velocity of the Coupler
Values
Time [s]
Coupler angular velocity [rpm]
0.00
23.65
0.5
-9.9181
1.00
-21.712
2.00
-10.053
2.50
-24.56
3.00
23.65
Table 0-14 The angular velocity of Coupler with rod
Values
Table 0-15 The Angular Acceleration of Coupler
Values
Time
[s]
Coupler with rod angular velocity [rpm]
0.00
-3.137
0.5
-6.237
1.00
12.644
2.00
-6.2077
2.50
13.02
3.00
-3.137
Table 0-16 The Angular Acceleration of Coupler
With Rod Values
Time
[s]
Coupler angular acceleration
Time
[s]
Coupler with rod angular acceleration
[rad/s2]
0.00
-2.8902
0.00
-1.7357
0.5
-7.8634
0.5
1.6976
1.00
26.561
1.00
-3.8687
2.00
-7.8582
2.00
1.7252
2.50
23.474
2.50
-2.7293
3.00
-2.8902
3.00
-1.7357
Table 0-17 Total Force of The Coupler Values
Time [s]
Couple force [N]
0.00
1.0721e-002
0.5
9.4672e-003
1.00
9.6142e-002
2.00
9.4389e-003
[rad/s2]
Table 0-18 The Total Force of Coupler With Rod
Values
172
Time [s]
Couple with rod force [N]
0.00
1.6246e-002
0.5
2.2287e-002
1.00
5.2014e-002
VERTICAL FORMING, FILLING AND SEALING MACHINE
2.50
8.6325e-002
2.00
2.218e-002
3.00
1.0721e-002
2.50
4.9363e-002
3.00
1.6246e-002
Table 0-19 Output Data OF Coupler Analysis Summary
Object Name coupler
coupler
coupler
coupler
with coupler with coupler with
rod
rod
rod
Solved
State
Definition
Type
Joint Probe
RevoRevoRevoRevoRevoRevolute lute lute lute lute lute Boundary Condition shaft
shaft
shaft
coupler
coupler
coupler
To
To
To
To rod
To rod
To rod
coupler
coupler
coupler
Orientation Method
Joint Reference System
Orientation Reference Coordinate System
Suppressed
No
Options
Relative Angular Relative AnguResult Type
Velocity
lar Acceleration
Result Selection
Display Time
Results
23.65
Z Axis
RPM
Z Axis
Total Force
Total
End Time
-3.137 -2.8902 -1.7357
RPM
rad/s² rad/s²
1.0721 1.6246
e-002 e-002
N
N
Total
Maximum Value Over Time
25.609 13.371 32.461
Z Axis
RPM
RPM
rad/s²
6.702
rad/s²
0.112
N
Total
5.6316
e-002
N
Minimum Value Over Time
-34.75 -7.2481 -8.354 -6.9017
Z Axis
RPM
RPM
rad/s² rad/s²
4.7996 7.0467
e-003 e-003
N
N
Total
Information
Time
173
3. s
VERTICAL FORMING, FILLING AND SEALING MACHINE
Table 0-20 The Rocker Angular Velocity Values
Table 0-21 The Rocker with Rod Angular Velocity Values
Time [s]
Rocker angular velocity [rpm]
0.00
-20.597
Time [s]
Rocker with rod velocity [rpm]
0.5
16.59
0.00
20.291
1.00
8.2167
0.5
-15.009
2.00
16.691
1.00
-11.107
2.50
10.467
2.00
-15.125
3.00
-20.597
2.50
-14.118
3.00
20.291
Table 0-22 The Rocker Angular Acceleration Values
Table 0-23 The Rocker with Rod Angular
Acceleration Values
Time
[s]
Rocker angular acceleration [rad/s2]
Time
[s]
Rocker with rod angular
acceleration [rad/s2]
0.00
4.0172
0.00
-6.2419
0.5
5.9234
0.5
-6.7911
1.00
-20.62
1.00
27.691
2.00
5.8819
2.00
-6.7814
2.50
-18.908
2.50
25.205
3.00
4.0172
3.00
-6.242
Table 0-24 The Rocker Force Values
Time [s]
Rocker force [N]
0.00
1.4286e-002
0.5
1.7136e-002
1.00
0.11104
2.00
1.7061e-002
2.50
0.10068
3.00
1.4286e-002
Table 0-25 The Rocker with Rod Force
Values
Time [s]
Rocker with rod force [N]
0.00
7.266e-003
0.5
8.3652e-003
1.00
8.3524e-003
2.00
8.3524e-003
2.50
2.0012e-002
3.00
7.266e-003
Table 0-26 Rocker and Rocker with Rod Analysis Output Summary
Object Name
Rocker
Rocker with
rod
Rocker
174
Rocker with
rod
Rocker
Rocker with
rod
VERTICAL FORMING, FILLING AND SEALING MACHINE
State
Type
Boundary
Condition
Orientation
Method
Orientation
Suppressed
Result Type
Result Selection
Display Time
Revolute fixed To
Rocker
Revolute Rocker to
rod
Solved
Definition
Joint Probe
Revolute Revolute fixed To
Rocker to
Rocker
rod
Revolute fixed To
Rocker
Revolute Rocker to
rod
Joint Reference System
Reference Coordinate System
No
Options
Relative Angular AcceleraRelative Angular Velocity
tion
Total Force
Z Axis
Total
End Time
Results
Z Axis -20.597 RPM 20.291 RPM 4.0172 rad/s² -6.242 rad/s²
Total
1.4286e-002
N
7.266e-003
N
0.1278 N
2.3048e-002
N
Maximum Value Over Time
31.763
Z Axis 24.203 RPM 29.551 RPM 9.3169 rad/s²
rad/s²
Total
Minimum Value Over Time
-23.429
-7.5792
Z Axis -24.199 RPM -29.55 RPM
rad/s²
rad/s²
4.7113e-003 2.4007e-003
N
N
Total
Time
Information
3. s
175
VERTICAL FORMING, FILLING AND SEALING MACHINE
Appendix B
(MATLAB Figure Design for Comparison Between the Results)
The Relation Between the Jaws Rod And The Back Plate Rod
`
176
VERTICAL FORMING, FILLING AND SEALING MACHINE
The Crank Analysis
8. The Coupler Analysis
The angular Velocity
The Angular Acceleration
The forces
The relation Between Angular Velocity and Acceleration
177
VERTICAL FORMING, FILLING AND SEALING MACHINE
The forces
The relation Between Angular Velocity and Acceleration
The Rocker And Rocker With Rod Analysis
The Angular Acceleration
The Angular Velocity
The Angular Velocity Ang Angular Acceleration
The forces
178
VERTICAL FORMING, FILLING AND SEALING MACHINE
The forces
The Angular Velocity Ang Angular Acceleration
179