AUTOMATIC MASKING

MACHINE
Guide:
Prof. Vijay V. Bhosale
Group members:
1615025 Pratik Kunder
1615026 Saurav Limbachiya
1615030 Durgesh Mohanty
This presentation will cover the following points:
1. Introduction & Concept of Project
2. How we Started
3. Reasons behind making this Project
4. Current Production Development stage
5. Prototypes
6. Working
7. Challenges Faced and Solution to it
8. Pros and Cons of current setup
9. Future Scope
10. Conclusion
1. Introduction & Concept of Project:
• In this project we will be designing and fabricating a machine whose main
purpose is to reduce the human effort while applying mask on the answer
sheets after examination for an unbiased correction of the answers.
• In order to work in this project, we need to have basic knowledge about
designing various mechanical elements like lead screw, conveyer belt
selection, etc.; programming knowledge on various microcontrollers and
linking of various sensors with the microcontroller. The expected outcome
of this project is successfully performing the targeted task of masking the
answer sheets.
• The main concept of this project is to replace the manual work of pasting
mask over the answer with a automated machine that will paste the mask on
the answer sheet on the designated spot. This machine will just need a
person to put the bundle of answer sheets in the feeder and masking sticker
to the punch.
2. How we Started
• In this particular semester this project was in planning phase i.e. we
were studying about existing or similar machines used in factories or
some other place for reference purpose.
• After studying we decided on algorithm that our machine will follow
and discussed on various design aspects that can be considered for our
project based on the algorithm we planned out and made a 3D CAD
model of prototype using Solidworks software to check whether our
design is feasible or not.
• After finalizing a design of one of the prototype we discussed on
various sensors and controllers that can be used to fulfill our aim of
project and shortlisted the ones which are feasible and cost effective.
3. Reasons behind making this Project
• After collection of answer sheets from students, one of the tedious job
that we counter is to mask the black sticker( Masking sticker) on the
answer sheet such that the answer sheet remains anonymous during the
correction process thus giving unbiased paper checking.
• This masking process is manually done, so even though the task is to
paste the sticker over the answer sheet it becomes hectic as this is been
done for tons of answer sheets.
4. Current Production Development stage
This section consist of the task completed by our team. The entire
section is a verbal explanation of the current project stage. For better
understanding images of the project model during VIII semester is
presented.
 Piston

Piston Holder
Suction Cup

Table
Roller
• This section describes about the
assembly for each processed part of
previous step.
• You can say that the table is the
foundation for housing all
structures in this project.
• Like firstly the piston and holder
assembly was installed on the table.
• Then the bearing pillow block was
mounted using a wooden block to
give desired height to mount the
roller.
• After that the conveyor belt we
made was mounted on the roller.
• The image in the slide shows the
machine after setting up the belt on
it.
5. Prototypes
• In this phase we considered two prototypes based on its method of
dispensing paper.
• After understanding pros and cons of each setup we decided on one
prototype model that will be feasible for our task.
• The name of prototypes are Prototype I and Prototype II respectively.
 Prototype I
• The model in this slide was our piston
first prototype.
bucket
• In this prototype we used gravity conveyor
for feeding answer sheets onto
the conveyer system and later
mask will be stamped on the
sheet by piston with vacuum cup
holding the mask.
• The bundle of answer sheets in
bucket acts like stack system Vacuum cup
using FIFO (First In First Out).
The first sheets entering the
bucket (sheet at the bottommost
of the bundle) will be feeded first
in the conveyer.
• The flaw of this setup was that it was difficult to control the number of
answer sheet passed by conveyer in each pass.
• Initially considering a bundle of 35 answer sheets in the bucket, during
the feeding process the answer sheet at the bottom of bundle is
compressed due to weight of the sheets above it so at once there is
chance of more tan one sheet is loaded on the conveyer which is
undesirable.
 Prototype II
• In this prototype we shifted the bucket
to the end of the conveyor and set the conveyor lead screw
whole system over a table for easier
mounting of model. linear guides
• Here the stack of answer sheets are
lifted using a platform by lead screw platform
mechanism and linear guides as support
to the platform.
• This mechanism basically uses LIFO
(Last In First Out) as the last sheet
(sheet on top of the stack) is feeded to piston
the conveyor.
• When the sheet reaches at level of Suction cup
conveyer it will be pushed using a ramp
on the wall of the bucket towards the
conveyer and thus getting feeded to the
conveyor.
Final Design
• The previous CAD models were
the illustrations for us. The actual
model has few changes.
• The working is same but the
parts are now made as per
standard available and few other
changes to ease up the mounting
the parts in reality.
Ideal Prototype -
• This is the ideal prototype
designed for loading of mask as
well as the answer booklet using
two conveyors.
• But there is a need or a attendee
who will remove the base strip of
the mask paper and place it on
the conveyor for the process.
6. Working
(i) Flow of process
• First turn ON the supply.
• Place the stack of the answer sheets on the platform.
• Press ‘START’ Button connected to PLC.
• The machine will lift the platform till the first sheet reach near the conveyor (for his process the stepper motor
mounted on the lead screw will rotate till proximity sensor is trigger at top of cabinet).
• The ramp along the casing will gradually push the sheets towards the conveyor as the platform moves up.
• The conveyor has already started moving when ‘START’ button was pressed. So as the first sheet reaches the
conveyor it will be carried towards the piston holding the mask.
• As the LDR below the piston detects the answer sheet the conveyor will stop.
• The piston will apply the mask.
• The conveyor starts again as the piston returns to original position.
• The masked answer sheet is delivered to other end of the where all the masked sheets will be collected.
• The cycle will repeat till last answer sheet is feeded to the mask
(ii) Ladder Program
7. Challenges Faced and Solution to it
Challenges Faced
• As per our calculations most of over parts
were selected as per standards available. But
the conveyor belt that we need was not
available.
• After setting up the belt we observed that the
rollers are being pulled towards each other
and thus dismounting after few rotation.
• After above problem was solved we found
that the belt shifts towards a side with time as
the machine is working.
• After uploading over code on the
microcontroller (Arduino) we found there are
chances of code being corrupted with time.
So, we have to reupload it frequently.
Solution
• We decided to take a large sheet of rubber
sheet (1200 X 1000 X 2.5 mm3) and cut it to
pieces to form 300mm X 300mm square
sheets and glue it to form our desired belt.
• To counter this dismounting problem we
changed the bolt used as shaft with as stainless
steel rods which made the working of machine
more smooth.
• We set up flange on both sides of the belt on
the roller which solved this problem.
• So, we decided to use PLC for controlling our
machine as it is robust and preferably used in
industries.
8. Pros and Cons of current setup
PROS
• Number of manual workers for the
masking task are considerably
reduced.
• Time required to mask the bundle of
answer booklets is also reduced.
• Easy to operate as the attendant has to
start/stop the machine just by button.
• This project is quite flexible as it can
be enhanced by extra parts just like the
answer booklet carrying cabinet.
CONS
• At the current stage machine cant
carry both mask and answer booklet so
the attendant has to put masking paper
for every answer booklet in the suction
cup.
• The attendant has to remove the base
strip of the mask before loading it on
the suction cup since the current
machine can’t separate it.
9. Future Scope
• As the machine is pretty flexible we can experiment on it and test out
new ideas for its enhancement.
• Few ideas that can be implemented are-
1. We can add a setup to remove the base strip from mask while
feeding it to the suction cup.
2. Increasing the speed of process by adding accessory or changing the
process flow such that without stopping conveyor we can perform
the task of masking.
10. Conclusion
• The procedure stream referenced in this section is essentially the normal working
that we focus on it is yet to be tried, in actuality. A model can mark an
insignificant number of sheets every hour supplanting their current method of
masking by hand. The project despite everything needs some minor changes like
instance a lot more than an answer sheet should be on transport at once and to
guarantee no unwanted movement happens, for example knocking or slipping on
belt and surrounding areas.
• Time management was a problem during the course of the project which delayed
parts that needn’t to be delayed such as the programming part and the mere
finishing touches.
• The Masking machine is a present for educational institute since no such machines
are yet accessiblele. The cost of the project was less than estimated initially in the
project proposal, both in terms of components and in terms of work invested in the
project.
• The robotized prototype is currently on track but not fully completed. The tasks
left for the future are listed in the future plans section.
Thank You
Any Questions?