Diploma "Packaging Foam in Film"

Contents

Contents

Introduction

Study the status of the issue, setting the design task

Film Packaging Techniques

Purpose of the course project and setting of the task

Process System Analysis

Process Illustrator Development

Development of RTC layout option and selection of optimal

Process Part

Process Description

Overview of Foam Polystyrene Packaging Equipment

Linear displacement module

Vacuum pickup module

Pusher

Belt conveyor

Thermonage automatic

Design Part

Calculation of vacuum suction cup

Calculation of design parameters of pneumatic cylinder of vacuum grip module

Calculation of piston diameter of pusher pneumatic cylinder

Belt Conveyor EMC Calculation

Electric motor selection

Calculation of the required gear ratio of the gearbox

Determination of torque, speed and angular speeds of each drive shaft

Gearbox selection based on calculated data

Calculation of reduced moment of inertia and moment of resistance

Performance calculation

Determination of air flow rate

Control System Design

Design of algorithm and construction of cyclogram of operation of automatic line of foam packing in film

Development of cylinder operation control program

Safety of life

Analysis of working conditions during process preparation of foam pack packing into film

Microclimate

Noise and vibration

Lighting

Fire-and-explosion hazard

Electrical safety

Calculation of grounding device

Conclusion

Bibliographic list

Application

Summary

In this graduation qualification work, an automated foam sheet group packing line is considered.

In the general part, the issues of the technology of packing foam sheets into film, system analysis of the technological process, life safety are considered. The work also solves the following issues: selection and calculation of parameters of components and devices of the automated complex; analysis of the structure of automated complexes using modern technological equipment; calculation of parameters of main and auxiliary equipment in order to clarify design diagrams of actuators and construction of a cyclogram.

In the process, theoretical knowledge obtained in the study of all disciplines, as well as GOST, ESKD, reference literature, etc. is used.

The diploma project contains an explanatory note with a volume of 62 pages, a list of literature of 13 titles, annexes, and 6 sheets of the graphic part.

Introduction

Today, the development of the market for the production of insulation materials is at the stage of growth, and the growth rate is quite high.

First of all, this is characterized by an increase in the production of polystyrene foam. The prospects for the development of the consumption and production of foam plastic (polystyrene foam) are associated with the development of the construction industry. The requirements for the thermal protection of buildings have changed and tightened, which has led to the widespread use of a variety of insulation materials in the construction industry: polystyrene foam PSBS, foam plastic, extruded foam polystyrene, mineral plates, mineral wool boards, etc.

Foam polystyrene foam, due to its remarkable properties, provides the necessary thermal characteristics and thermal protection of objects under construction or reconstruction. One of the main properties and advantages of polystyrene foam is the ability to carry a relatively high mechanical load at a minimum density.

This predetermined the possibility of its use in the construction industry.

To date, there are several problems that to some extent limit the ability of polystyrene foam manufacturers to increase the production of polystyrene foam and maintain relatively low prices for the product produced.

The main problem of the Ukrainian market is dependence on imports of raw materials (polystyrene pellets ).

In Ukraine, there are no prospects for creating a raw material base in the near future, so the development of technologies for the production and use of polystyrene foam plates is greatly hindered.

The production of foam (polystyrene foam) in most cases occurs using outdated techniques based on the slurry polymerization method.

Modern techniques for the production of foam products are based on the use of foamed polystyrene obtained by continuous bulk polymerization.

As a result, Ukrainian processors of foam polystyrene, which have modern equipment, are forced to use exclusively imported raw materials.

Today, imports of raw materials occupy 68%, and this percentage will constantly grow.

The scarcity of domestic raw materials and dependence on imports poses significant challenges:

Manufacturers' problems:

- high price of imported foaming polystyrene, and, as a result, higher cost of final products

- possible production downtime (due to the impossibility of competent material support of production and regularity of supply).

Problems of builders:

- high price of polystyrene foam insulation, and, as a result, higher cost of construction;

-use of materials of the worst quality.

Of course, modern production of foaming polystyrene will also appear in Ukraine. But by this time, most likely, the Ukrainian market will be almost 100% dependent on import supplies.

With regard to the prospects of providing Ukrainian producers of foamed polystyrene with high-quality and modern raw materials, it should be noted that today several Ukrainian enterprises are organizing new productions of foamed polystyrene that meet modern requirements for the manufactured raw materials, but new companies producing foamed polystyrene will be able to offer modern and high-quality raw materials to Ukrainian producers of foamed polystyrene only by 2014.

Until that time, producers of polystyrene foam, seeking to produce high-quality products, will depend on the import of raw materials.

So if back in 2007 Ukrainian manufacturers covered 50% of the demand for polystyrene foam, then according to forecasts, by 2014 the situation will really become critical - our manufacturers will be able to satisfy only a third of the demand for polystyrene foam.

For producers of polystyrene foam to survive this time, it is necessary to take certain steps now. And the first action in this direction is to remove the customs duty on the import of raw materials.

Foaming polystyrene is used to produce the following products:

- production of polystyrene foam blocks and slabs of different shapes and configurations for heat and sound insulation of buildings of any purpose (facades, walls, roof, foundation, floors, warehouses, pavilions, residential buildings, garages, basements, loggias );

- production of complex packaging for various equipment and devices requiring protection against impact during transportation or storage;

- production of floating means, decorative interior products;

- to manufacture finishing materials for facades and ceilings - tiles, plinths, sockets, decorative elements.

Quite new applications of foaming polystyrene are the production of non-detachable formwork from penopolitansirol for monolithic house building and shells for heat protection of pipelines.

Study the status of the issue, setting the design task

Film packaging techniques.

The film packaging process was widely used in all developed countries, including Ukraine. Film polymer materials, developed in the last third of the 20th century, were modified many times, improved, supplemented by new ones. Currently, several dozen types of polymer film from various manufacturers are represented on the market. Packaging in film has become a symbol of a successful company. Packaging in film is especially widely used by transport companies and small food industries, where packaging in the film of the finished product allows to preserve the taste, quality, freshness and commercial appearance of the finished product.

At this stage, the film packaging is divided between two competing technologies.

Packing in a streaksheet. This kind of film packaging is based on the stunning properties of streachpolymers to tend to their former form. As the number of layers of such polymer increases, the film coating becomes increasingly rigid, preventing deformation of the main product. Packaging in this type of film is distributed mainly at large industrial and transport units. Automatic stacking packers ensure good quality and strength of the packaging coating, prevent the fall of loads from pallets. Streichplenka, despite a number of positive qualities, also has its own shortcomings. Packing pallets in such a film causes excessive consumption of packaging material, which adversely affects the costs of the company, especially if large amounts of use are expected. The arrowhead becomes opaque as the number of layers increases. In addition, products wrapped in a streakable film lose their presentable appearance. Currently, packaging in such a film is applicable to large batches of goods shipped with pallets over long distances. Small goods that do not pose serious appearance requirements are also packaged in a film cluster.

Thermal packaging. Packaging in a film that can vary in size under the influence of temperature has found application both in large industrial complexes and in private production. First of all, packaging in a film with shrink properties allows saving material, since only one layer of film is sufficient for packaging. Most often, this layer is put on top of the pallet in the form of a sleeve, and then heated in a special flow chamber. If heat shrinkage of the film is required in inaccessible places, a special portable pistol with hot air is used. The use of thermal film is becoming increasingly popular. If we consider the package in the film of hands and thermal packaging, we can distinguish the main advantages of the latter:

Packaging in a film with a variable structure saves material.

The package looks more aesthetic, due to the strength of the thermal film.

Packaging does not hide the appearance of the object, as a result of which the product advertises itself.

Packing in a thermoplastic film increases the safety of transportation, since opening the package can mean damage to the cargo. In the case of wrapping in a film of arrows, the pallet can be rewound. The thermal film can only be packed with special equipment.

Thermal film packaging has significant advantages, however, when quick packing of multi-ton weights is required, the film is used because of its multilayer structure, which allows substantially better resistance to the internal pressure of the load, has greater strength and resistance to punctures and cuts.

Packaging in film, of course, is becoming a priority type of packaging today. The decline in the market share of traditional packaging materials such as paper and cardboard is largely due to the popularity of thermal film. Film packaging has many advantages over standard hard packaging:

Traditional packaging is fast. The structure of the paperboard fibers cannot be fully restored after the material has been wet. That is why cardboard boxes are stored exclusively in dry rooms. Keeping such boxes in the refrigerator leads to an increased release of cardboard fibers. At the same time, the boxes very quickly lose their original shape. Unlike cardboard, packaging in film protects the product from any external chemical effects. When using film packaging, fresh vegetables retain their freshness longer than in cardboard packaging conditions. In addition, the film packaging allows moisture to be retained within the package, which prevents the drying process. If the film was packed in a vacuum or gas. That product can retain its beneficial properties 3-4 times longer than with conventional paper packaging.

Most residents of large cities are confident that packaging in film causes irreparable harm to the environment. Traditional paper and cardboard packages are easily decomposed and therefore well processed. The polymer bases may not break down for 500 t years. Such shocking numbers mislead people. Few people know that the production of polymer packaging is 3 times safer for air and 10 times safer for water than the production of cardboard or paper. Film packaging involves the use of synthetic materials while paper and paperboard are made of wood. Polyethylene films during the entire decomposition period practically do not release harmful and toxic substances into the atmosphere and soil. In addition, existing polyethylene processing programs allow you to use it several times.

Traditional packaging materials, as practice shows, are gradually becoming a thing of the past. The film packing process is safe, simple and cheap. This makes it very popular around the world, especially in Western Europe, where special programs for the recycling and processing of polymer films save not only money, but also the priceless natural resources of the planet.

Modern production cannot do without packaging materials. Foodstuff film (food film) and polyethylene film, shrink film, thin film, polypropylene and polyethylene bags - do not count the methods and packaging options, and the packaging process itself can be met in almost all areas of human activity. Some products (in particular foodstuffs) require mandatory sealing and protection in case of transportation, and this is difficult and expensive to achieve without proper packaging.

With the invention of polyethylene, polypropylene, polyvinyl chloride and other materials, the problem of product packaging has been eliminated. These packaging materials made it possible to make and use such indispensable today: food polyethylene film, PVC film, polypropylene tape, stretch film, construction film and much more.

Polyethylene film production is carried out in accordance with the specifications of the Technical Specification of the 002035882394 and has a certificate of conformity and a sanitary epidimological conclusion for contact with food products.

Film is produced by extrusion of polyethylene melt with further blowing and water cooling of produced hose. The insignificant thickness is provided by a rotating tower. The film can be produced in the form of a web, half-sleeve and sleeve with a maximum width of 980 mm. The film thickness is in the range of 30,200 microns. If desired by the Customer, the film may be activated by corona discharge for more efficient printing. The film may be colored, and it is technically possible to paint the outer and inner layers in different colors. As a result, the film can be used for both barrier and advertising purposes.

Today we are faced with such products everywhere. In everyday life, for example, you can not do without thin food film and stretch films for packaging products, garbage bags for waste, double-sided scotch for finishing work, tape for repair.

Over the past 3-5 years, the range of polymer (polyethylene) films has expanded significantly, but, nevertheless, the main market share is polyethylene film. According to expert data, the production of polyethylene films consumes about 635 thousand tons of polyethylene (PE). Low density polyethylene (LDPE) consumption continues to lead, although the proportion of linear low density polyethylene (LLDPE) consumption increased by 2025 per cent by 2006 compared with 2001, for example.

Demand for high density polyethylene (HDPE) film grades has increased significantly in the CIS in recent years, successfully displacing LDPE in the production of polyethylene bags (Kiev). Existing capacity for the production of high density polyethylene is not enough, so imports grow from year to year. So, in 2006, almost one third of the consumption was the import of high-density polyethylene.

Due to the lack of production of LLDPE film stamps, imports of the latter by 2006 amounted to more than 60 thousand tons/g. In addition to stretch films, where 80% of imported LLDPE is consumed, this material is consumed in multilayer films as a modifier of layers from LDPE.

The purpose of the diploma project and setting the task.

The draft addresses the following issues:

selection or calculation of parameters of units and devices of the automated system;

analysis of the structure and composition of RTK and automated complexes with justification of the layout option of modern technological equipment;

calculation of parameters of main and auxiliary equipment in order to clarify design diagrams of actuators and construction of a cyclogram.

In the process of implementing the DP, theoretical knowledge obtained during the study of all disciplines is used, as well as GOST, ESKD, reference literature, etc.

Process System Analysis

Description of the packing process. Work in the BPwin program.

The process of packing foam sheets into film is reduced to 3 main steps:

- Foam preparation

-Packaging

- Transportation to storage location.

In turn, each stage is divided into some more technological actions.

Foam Preparation:

1 step of moving the foam sheets in oriented form along the inlet conveyor to the vacuum gripping site.

2 step: capturing the foam sheet with a vacuum grip, transferring it to a position where the foam is folded into a stack of 10 sheets.

Step 3: The foam sheet package is moved by the pneumatic cylinder to the packaging film.

Packaging

1 step of pushing the foam stack into the packaging film, whereby the film envelops the entire stack.

2, after pushing, the thermonet presses the film against the base, thereby bonding to the bottom of the film. The film is then trimmed and welded. Special devices tighten the film, thereby bringing it to its initial state.

Transportation to Storage Location

1 stage: after the foam is packed, the pneumatic cylinder moves it to the outlet conveyor.

Stage 2: packaged foam is transported along the outlet conveyor to the unloading station, from where it comes either to the warehouse or immediately goes to the customer.

Development of a process illustrator.

It is executed on one sheet of format A1 and includes the sequence of all operations of this process plan.

Process Illustrator - ITP is a block diagram with sketches of the devices used and their main parameters.

To build an ITR, the process plan must be divided into separate stages.

Development of RTC layout option and selection of optimal one.

At this stage of the diploma project, the analysis of possible RTC layouts (two, three options) is carried out and the optimal one is selected. RTC layout is a general view drawing made in A1 format with indication of overall and reference dimensions, technical characteristics of the complex.

To complete the drawing, I selected the main and auxiliary equipment and found their appearance with the main dimensions.

We depict all the equipment on the same scale.

The layout indicates how to attach the equipment to the base, as which a concrete floor is usually used (usually for stamping, painting, etc.). Common base is required for alignment of PR coordinate systems and process and auxiliary equipment.

Process Part

2.1. Process Description

The machine and hardware diagram of the packaging line of the foam sheet package is shown in the graphic part of the project.

Finished sheets of foam with a size of 1000 * 1000 * 50 mm are fed along the inlet conveyor to the gripping position by the vacuum gripping module, where the optical sensor stands, as a result of which the conveyor stops. A stop is provided to prevent the sheets from being displaced from the positioning point .

Then the vacuum gripping module lowers the suction cup to the lower position, after the suction cup contacts the foam sheet, the pneumatic cylinder stops (the sensor stands), after which the suction cup sets the sheet and the module rises up.

The next step is to move the pnemocillinder to the foam storage site in the stack. The vacuum pickup module is then lowered and the suction cup is turned off. Then the module rises and moves to the sheet gripping position (initial position). All the above mentioned operations are repeated 10 times (in 1 package of polystyrene foam - 10 sheets).

The pusher then pushes the stack into the film, whereby the film envelops the sheet stack. Then, the thermoset presses the film, trims and welds. To control the unwinding of the film, there is a film roll displacement limiter and an automatic film winding device.

With the concluding step, the pusher moves the stack to the outlet conveyor, which in turn moves the finished product to the storage place.

2.2. Overview of foam polystyrene packaging equipment.

2.2.1. Linear displacement module.

Camozzi's spineless cylinder is selected. Series 50.

Two-way, magnetic

diameter 16, 25, 32, 40, 50, 63 and 80.

Series 50 spineless cylinders come with 7 different diameters in order to provide the largest number of possible applications. A permanent magnet is installed on the piston of the cylinder, which provides actuation of magnetic sensors fixed in special grooves on the side surface of the cylinder.

The cylinders of this series are equipped with damping devices at the end of the stroke with adjustment of braking intensity using throttles located in the covers.

Series 50 cylinders are recommended so as not to exceed maximum loads and moments.

2.2.2. Vacuum pickup module.

Vacuum suckers.

Camozzi's VTCF Series flat vacuum suction cups are quite strong and wear resistant, and consist of a nipple and a rubber part. In suction cups with a diameter of up to 50 mm, the nipple is mounted directly into the rubber part. In suction cups with a diameter of more than 60 mm, the nipple is mounted in a fastening plate, which is sealed into a rubber part. Suction cups and nipples are delivered separately. VTCF series suction cups are commonly used for gripping objects with both smooth and uneven surfaces, for example, sheets of various materials, stamped profiles, cardboard boxes, plastic materials, wooden plates, etc.

Application:

- Gripping flat articles with smooth or uneven surface;

- The silicone model allows you to capture products that have a high temperature.

Pneumatic circuit

Double acting magnetic and non-magnetic cylinders with and without damping (DIN/ISO 6431)

The sleeve made of extruded aluminum profile has two longitudinal T-shaped slots (on three sides) to accommodate reed sensors. This allows the same cylinder mounting dimensions to be maintained.

Studs are located inside the sleeve.

Position of piston is determined by magnetic position sensors installed directly in slots of cylinder housing.

Cylinders are equipped with damping devices at the end of stroke with braking intensity adjustment.

Besides, piston has plastic washers providing silent stop in extreme positions.

Travel length - up to 600 mm.

Guides.

Series 45. for cylinders DIN/ISO 6431 0 32, 40, 50, 63, 80, 100.

The 45 Series guides were designed to prevent rotation of the pneumatic cylinder rod and to avoid radial loads on the pneumatic cylinder rod.

The 45 Series guides are available in three different modifications depending on the load applied. Models such as UT and HT use self-lubricating sliding bearings, while NHB guides are equipped with a ball bearing.

Series 45 guides can be used with all cylinders DIN/ISO 6432,020 and 025 and DIN/ISO 6431,032,+,100.

The shorter the stroke, the greater the load the guide can carry.

2.2.3. Pusher.

Cylinders. Series 40

bottom and two-sided, magnetic.

Diameter 32, 40, 50, 63, 80, 100, 125, 160, 200, 250.

Optional with speed controller for cylinders up to 100 mm in diameter.

Position of piston is determined by magnetic position sensors fixed on cylinder.

Cylinders of this series are equipped with damping devices at the end of the stroke with braking intensity adjustment.

Besides, piston has plastic washers providing silent stop in extreme positions.

In the front cover of the pneumatic cylinder there is a guide bronze bushing, along which the rod slides. The stroke length of standard cylinders of the 40 series is up to 1500 mm.

2.2.4. Belt conveyor.

In various enterprises, these conveyors have been widely used, since they allow you to transport almost any type of cargo (except liquid) in horizontal and inclined directions, to implement various transport operation schemes. The widespread use of belt conveyors is due to the fact that they are simple in design and in operation, reliable in operation, economical, and have a wide range of productivity.

Any belt conveyor consists of a closed traction element (belt), which is both a working element, which moves along stationary roller supports and envelops guide devices. The upper branch of the belt, on which the load is located (usually called the working branch), moves along stationary grooved roller supports. The lower part of the belt (usually called idle) moves, relying on straight roller supports. Belt is driven by drive drum coupled via transmission mechanism with electric motor.

The belt is moved by the friction force between the drive drum and the belt, which occurs when sufficient pre-tension of the traction member is provided. In the conveyor shown in the figure, a horizontal load tensioner is used, consisting of a tensioning drum connected by a steel cable to a set of weights. Roller supports, drive and tension devices are attached to the bed made of steel profile (angle, channel). Cargo is delivered to the belt through the device and can be unloaded from the conveyor at any point using a unloading trolley. Such a belt conveyor arrangement is quite characteristic of this type of continuous transport machine.

Main Belt Conveyor Assemblies

Belt conveyors consist of the following main units: a traction element (belt) that combines the functions of a bearing (working) element; support devices in the form of stationary roller supports or rigid flooring; a drive device consisting of an electric motor, a transmission mechanism and a drive drum; tensioner (screw or cargo); loading and unloading devices; frame on which all conveyor units are fixed. Consider some of the belt conveyor schemes used in grain processing plants.

Drive station is located in place of bulk cargo unloading. The traction element tension is a vertical cargo device with its location near the drive station. The diagrams of stationary belt conveyors discussed provide an idea of ​ ​ the variety of structures, but far exhaust the possible options.

Most often, the conveyor is unloaded through a drive (head) drum. In some cases, intermediate unloading of the conveyor in its middle part is necessary, then a drum unloading trolley or a plow discharger is used.

Conveyor belt is driven by friction drive. Conveyor drive consists of drive drum and drive mechanism connected to each other by slow-moving coupling. Drive mechanism consists of motor, reduction gear and couplings connecting them, which are installed on their frame. The conveyor belt is located on roller supports: the upper branch of the belt on the upper (grooved or straight), the lower branch on the lower straight.

Provision of friction connection of drive drum with belt is performed by tensioning of belt with tensioner. Tensioning devices can be screw, trolley and vertical. In addition, the belt conveyor has automation means for its operation: centering roller supports, devices against the descent and cut of the belt, etc.

Drive drum and tensioner are installed on their supports, and roller supports on sections, which themselves are installed on posts of middle part. In some cases, it is advisable to support the lower leg of the belt with straight upper roller supports, which are installed on posts with a bracket.

Fixed general purpose conveyor belts shall be designed for each specific application condition. When designing the conveyor, the layout of its route, initial data (capacity, belt speed, characteristic of the transported load) and other operating conditions of this conveyor are determined. According to the initial data, traction calculation is carried out (by an approximate or updated method), on the basis of the results of which the questionnaire is filled in; development and supply of supporting steel structures is possible under a separate agreement of the customer with the plant.

2.2.5. Thermonage is automatic.

Designed for welding and cutting of thermal shrinkage film in the process of preliminary packaging of products. It has pneumatic drive of thermonoom and package shaper, film roll displacement limiter, film automatic winding device.

Conclusion

In the course of my diploma project, I provided one of the options for an automatic line to pack a package of foam sheets into film. I considered an analytical section in which I analyzed possible options for the layout of the line and chose the most optimal one. The following is a technology section in which I provided a description of the main packaging equipment of my line. The basic equipment parameters and line performance were also calculated. He designed the control system of the entire RTK and wrote the program. He developed the electrical control circuit of the EMC belt conveyor. Then I provided a business case, calculated the cost of production and the payback period of the line. In the section on labor and environmental protection, I showed the most dangerous factors affecting labor protection, calculated protective grounding. In conclusion, I proposed measures to protect workers and employees of the workshop in the event of an NPP explosion not far from the plant.