DESIGN AND CALCULATION FOR AUTOMATIC COUNTING STATION FOR CUTLERY
By
Rheza Valdi 11301034
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
Revision after the Thesis Defense on 19 January 2018
STATEMENT BY AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Rheza Valdi
_____________________________________________
Student Date
Approved by:
Benny Widjaja, M.T
_____________________________________________
Thesis Advisor Date
Dr. Irvan Kartawiria, S.T., M .Sc.
_____________________________________________
Dean Date
ABSTRACT
DESIGN AND CALCULATION FOR AUTOMATIC COUNTING STATION FOR CUTLERY
By
Rheza Valdi, Student Benny Widjaja, M.T, Advisor
The main purpose of this thesis is to design a sorting and counting machine for cutlery with a food grade material. The cutlery will come on the top level and spoons will stay on top level while forks stay on middle level and knives stay on bottom level. An eccentric shaft will rotate the moving frame to make the cutlery slide down to the end of the rail and counted by the sensor.
Keywords: Sorting, Counting, Cutlery
© Copyright 2018 By Rheza Valdi All rights reserved
DEDICATION
I dedicate this thesis to all human beings on Earth.
ACKNOWLEDGEMENTS
First of all, I would like to thank God, families and friends for being with me while I am going through hard times.
I would like to thank Benny Widjaja, M.T for the knowledge and patience through all the process happens in this thesis project. I would also like to thank Yohanes Freddy and Albertus Rumawas for all the help in this project.
Special thanks to batch 2013 SGU student that has give me lots of unforgetable memories.
TABLE OF CONTENTS
Page
STATEMENT BY AUTHOR... 2
ABSTRACT ... 3
© Copyright 2018 ... 4
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 13
CHAPTER 1 – INTRODUCTION ... 14
1.1 Background ... 14
1.2 Thesis Objectives ... 14
1.3 Thesis Problems ... 15
1.4 Thesis Scope ... 15
1.5 Thesis Limitation ... 15
1.6 Thesis Outline ... 16
CHAPTER 2 – LITERATURE REVIEW ... 17
2.1 Introduction ... 17
2.2 Eccentricity ... 17
2.3 Mechanics of Material ... 18
2.3.1 Yield Strength ... 18
2.3.2 Tensile Strength ... 19
2.3.3 Shaft sizing ... 19
2.4 Food Grade Materials ... 20
2.4.1 1060 Aluminium Alloy... 20
2.4.2 Grade 316 Stainless Steel ... 21
2.4.3 Polypropylene ... 22
2.5 Bearing ... 22
2.5.1 Ball Bearing ... 23
2.5.2 Linear Bearing ... 24
2.6 Solidworks ... 24
2.7.2 AC Induction Motor ... 26
2.8 Inverter ... 28
2.9 Programmable Logic Controller ... 30
CHAPTER 3 – RESEARCH METHOD ... 31
3.1 Introduction ... 31
3.2 Overall Design Objectives ... 31
3.3 Sorting machine Subsystem ... 31
3.4 Moving Frame Design Justification ... 32
3.4.1 Polypropilene rail ... 32
3.4.1.1 Top Level Rail ... 35
3.4.1.2 Middle Level Rail ... 39
3.4.1.3 Bottom Level Rail ... 40
3.4.2 I-Lite Profile Frame ... 42
3.4.2.1 I-Lite Profile Connection To Linear Bearing ... 44
3.4.2.2 I-Lite Profile Connection to Actuator ... 47
3.5 Actuator Design Justification ... 54
3.5.1 Bending Stress Calculation... 57
3.5.2 Torsional Stress Calculation ... 61
3.5.3 Material Selection ... 64
3.5.4 Motor Power Calculation ... 67
3.6 Fixed Frame ... 69
3.6.1 Structural Strength ... 69
3.6.2 Base Plate Heigth ... 72
3.6.3 Linear Bearing Calculation ... 75
3.7 Electrical Schematic... 77
3.7.1 Motor Circuit ... 77
3.7.2 Sensor Circuit ... 79
CHAPTER 4 – RESULT AND DISCUSSIONS ... 81
4.1 Introduction ... 81
4.2 Mechanical Assembly Result ... 81
4.2.1 Additional Aluminium Strip ... 82
4.2.2 Fork Rail Changes ... 83
4.2.3 Bracket Setscrew ... 84
4.2.4 Coupling Misalignment ... 84
4.2.5 Maximum Height Increase ... 85
4.3 Electrical Wiring Result ... 86
4.3.1 Motor Wiring ... 86
4.3.2 Sensor Wiring And Algorithm ... 88
4.4 Data Taking ... 90
4.4.1 Fail Data Taking ... 90
4.4.2 Spoon Speed Data... 94
4.4.3 Fork Speed Data ... 97
4.4.3 Knife Speed Data ... 98
4.4.3 Counting Data ... 99
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 104
5.1 Conclusions ... 104
5.2 Recommendations ... 104
GLOSSARY ... 105
REFERENCES ... 106
APENDIX ... 107
CURRICULUM VITAE ... 114