NAME : NG AIK HOE

STUDENT ID : 041150186

COURSE CODE : TME309/10

COURSE NAME : ME PROJECT

CLASS CODE : 4P-MEP1-Z

TUTOR : LOH HEAN SEONG

ASSIGNMENT : TMA 2

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 THIS FORM MUST BE COMPLETED AND ATTACHED TO EACH ASSIGNMENT THAT
YOU SUBMIT TO THE OAS FOR MARKING

PLAGIARISM DECLARATION
I declare that the attached work is entirely my own (or when submitted to meet the
requirements of an approved group assignment is the work of the group), except where
materials cited, quoted or paraphrased are acknowledged in the text. I also declare that this
work / assignment has not been submitted for assessment in any other course or university
without due acknowledgement.

I understand that plagiarism, collusion, and copying are grave and serious offences.

I understand that disciplinary action (which may include deduction of marks in the TMA) will be
taken against me if I am found to be an offender of TMA plagiarism.

Full name and IC No: NG AIK HOE/ 941206-07-5521

Date:2/9/2017

Tutor Marked Assignment (TMA)

Semester/Year June/2017

Student’s Name NG AIK HOE

Student’s ID No: 041150186

Course Code TME309/10

Course Title ME PROJECT

Class Code 4P-MEP1-Z

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TMA No: TMA2

No. of pages of this 18

TMA (including this page)
Tutor MR. LOH HEAN SEONG

Course Coordinator DR. TEOH PING CHOW

T-DF TMA Declaration Form (version #002/2017)

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Project objective:
 To study catalogues and standard parts in order to choose and design the most
suitable part for machines
 To use SolidWorks design software to design 3D fabrication parts for the Machines
and convert into nice 2D drawing in other to let others can fabricate more easily.
 To design cost effective fabrication part by well knowing the process of machining
such as drilling, cutting, milling, surface finishing and many more.
 To measure and test for the fabricated parts can be assembled up into a machine
 To make sure designed machine can function properly, easy maintenance and user-
friendly.

Overall objective:
This project is important and worthwhile because nowadays automation
inspection machines are widely used in the automation company. A good quality
automation inspection machines will improve the process of the company and
decrease the cost needed. I can acquire the knowledge about the vision inspections
system and the knowledge of mechanical design and process control that will help
me in the future.

Proposed objective:
 In order to choose most suitable and cost effective parts, survey can be done to
collect data needed.
 Experiment will be conduct to test for each of the parts to test either the part is in
good condition or not
 After complete assembly, the machine will be tested and data will be collected.
 The collected data will be analyzed, to make improvement to the machine.
 Improved machine will be continue tested to get a good and stable machine.

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 Duration
Task Start Date End Date
(days)
3 Hardware 118 3/9/2017 30/12/2017
3.1 Design and sourcing 30 3/9/2017 3/10/2017
3.2 Buy and fabricate parts 21 3/10/2017 15/11/2017
3.3 Test for parts 22 24/10/2017 30/12/2017
3.4 Assembly machines and rework
45 15/11/2017 30/12/2017
for fail parts

3/10/2017. Besides, I have changed the

(3.2 buy and fabricate parts) end date to 15/11/2017 due to the detailing drawing delay
and fabrication part delay. Therefore, the (3.3 test for parts) end date changed to
30/12/2017 due to test part should be done with (3.4 assembly machines and rework for
fail parts). Lastly, now the machine is completely setup and in testing machine steps.

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 (1. Dr. Helmut Hamfeld, Freudenberg, 2016)

(1. Dr. Helmut

Hamfeld, Freudenberg, 2016).
According from the statement I have read from the article. T

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 Duration
Task Start Date End Date
(days)
4.1 Prepare Interim report 117 3/9/2017 29/12/2017
4.2 Submit Interim report 1 29/12/2017 30/12/2017
5 Testing 56 31/12/2017 25/2/2018
5.1 Test machines 31 31/12/2017 31/1/2018
5.2 Troubleshoot and let customer
25 31/1/2018 25/2/2018
check machine
6 Additional 41 26/2/2018 8/4/2018
6.1 Add feature 20 26/2/2018 18/3/2018
6.2 Troubleshoot 21 18/3/2018 8/4/2018
7 Final report (TMA3) 112 31/12/2017 22/4/2018
7.1 Prepare final report 111 31/12/2017 21/4/2018
7.2 Submit final report 1 21/4/2018 22/4/2018

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 This project is a personal project. This project is how I am involve in the design
and assembly for Vision Inspection Machine. The reason I choose this project is to
improve the knowledge about mechanical design, machining process, material
knowledge and many more Hence, I decide to take the challenge to involve in this kind
of project.

Vision Inspection machine is the methodology of using vision as providing

imaging-based automatic inspection and process control. Vision machine is to integrate
existing technologies in new ways and apply them to solve real world problems.
According to the 4.Automated Imaging Association (AIA), machine vision
encompasses all industrial and non-industrial applications in which a combination of
hardware and software provide operational guidance to devices in the execution of their
functions based on the capture and processing of images. Though industrial computer
vision uses many of the same algorithms and approaches as academic/educational and
governmental/military applications of computer vision, constraints are different.

Vision Inspection machine having methods and technology used to extract

information from an image. The information get from the image can be a used as a
simple check of good part or bad part. It can be more complex set of data such as
position, orientation, identity of object in an image, this also be define as automatic
inspection and process guidance robot in industry. Vision part is normally computer
integrated. For additional, machine vision systems rely on digital sensors protected
inside industrial cameras with specialized optics to acquire images, so that computer
hardware and software can process, analyze, and measure various characteristics for
decision making. (5.Cognex)

Process guidance robot in industry is most of the operations will be done by

autonomous robots that need visual feedback to move around the working space
avoiding obstacles, to work collaboratively with humans, to identify and locate the
working parts, to complete the information provided by other sensors to improve their
positioning accuracy, etc. Different vision techniques, such as photogrammetry, stereo
vision, structured light, time of flight and laser triangulation, among others, are widely

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used for inspection and quality control processes in the industry and now for robot
guidance. Choosing which type of vision system to use is highly dependent on the parts
that need to be located or measured. Thus, in this paper a comparative review of
different machine vision techniques for robot guidance is presented. (6. Gonzalo
Pajares Martinsanz, Academic Editor)

In now big data era, many existing manual inspection process has to be
Converted into automatic inspection process. This is because automatic inspection
require big data storage is no longer an issues anymore. Inspection data can be
converted and stored into system easily and no need to clear frequently.

With the improvement in camera technology, now the camera can be used to
capture clear image and getting faster and this help the vision inspection process can
provide more fast inspection and more accurate result compare to manual inspection.
With the aid of lens, now vision can capture more precise image. The price for an
inspection camera is getting cheaper and not expensive as last time. For example,
Industrial vision systems demand greater robustness, reliability, and stability compared
with an academic/educational vision system and typically cost much less than those
used in governmental/military applications. Therefore, industrial machine vision implies
low cost, acceptable accuracy, high robustness, high reliability, and high mechanical,
and temperature stability. (5.Cognex)

The design of the vision inspection machine in my company project focuses

more on production inspection. What production parts should be inspect depend on
customer. So there will have many kinds of machine processes based on customer
requirement. I will decide the types of camera, lens and light sources that are more
suitable for the vision inspection machine. Machine design will also depend on the size
of parts to be inspected.

PLC will be used to control the main process of the machine, and computer
will be used to control the vision set of the machine only. This is because PLC based
program can be modified more easily compare with computer based. And computer
based OS program for machine will change every 3 to 5 years. For example, if window
7 is used to control a machine, when need to upgrade to window 10, need to rewrite new
program in window 10. So with this disadvantage, PLC will be used as main part of
machine process control.

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 Aluminum profiles are used as structure base of the vision inspection machine
because lighter and more durable compare to other materials. Black anodized coating
are used inside machine structure, because dark environment with correct light
brightness and angles support will help to get more clear images.

Pneumatic cylinder will be used to move light weight objects and motor will be
used to move heavy objects in the machine. There will need a pneumatic valve pack
integrate with PLC to control the pneumatic cylinder. A motor driver is needed to
integrate with PLC to control the motor speed.

Filters, regulators and lubricators are added in the input airline, because
unregulated or improper pressure settings can result in increased compressed air
demand, which will results in increased energy consumption. Excessive pressure will
also increase equipment wear rate, resulting in higher maintenance costs and shorter
tool life in machine. A readily available and simple to use clean compressed air are very
expensive and rarely implement in company facility, so a filters is used to filter air dirt,
regulators is used to control air pressure and lubricators is used to lubricate air to
provide lubrication in airline.

As MS 1722:2011 & OHSAS 18001:2007 - Occupational Health and Safety

Management Systems, security interlock, emergency button, tower light and buzzer are
required for all industrial machine, because safety is an important issues need to be take
care when design machines. Tower light red will show the machine having error, yellow
is machine under initializing, green is showing machine is in good and able to run
condition. A start, stop and reset button will added to machine in order to let the
operator to operate the machine easily.

Wheels are added to machine in order to make machine able to be relocated

more easily without using external tools.

To make an automation machine, machine design is the most important

elements. We need to consider many design aspects and combine all the good features to
improve the machine. As you know vision inspection machine is getting more widely
used in inspection process, vision inspection machine will replace all manual inspection
process in the future.

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 Start

Research and design according to

customer specification

Detail design of machine Standard parts sourcing

/sub modules and selection

3D Solid Modelling by using

SOLIDWORKS 2015

Prepare and detailing 2D engineering Standard part order and

drawing and send for fabrication purchase

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 A

Fabricate new
Assembly, part or purchase
troubleshooting and new standard
machine testing part

Update drawing.

Need
modification? Redesign

Analysis Machine

END

The machine is design by divide into 5 main modules, which is structure,

vision set, input station, index station, and output station. Every main module will be
divide into few sub modules to have easy change when modification is needed. The
input and output track dimension need follow customer unit dimension strictly with
tolerances of 0.5mm.

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exploded views

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 After fabrication parts and standard parts are in place, the mechanical parts can
be assembled together and the electrical parts can be wired to make machine to
functions. After trouble shooting, the fail fabrication part will be sent for rework, fail
design module will need major modification to solve it.

After the designer satisfies with the machine, it will be sent out for customer to
test and analysis according the design specification list and 1000 unit test run ready by
customer. If specification not meet, modification is needed. If customer required future
improvement, modification is also needed. The machine is done when customer approve
the machine.

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TABLE OF CONTENT FOR

Page
TITLE i
ABSTRACT ii
APPROVAL iv
DECLARATION v
TABLE OF CONTENT iv
LIST OF TABLES ix
LIST OF FIGURES x
LIST OF ABBREVIATIONS xi

CHAPTER 1: INTRODUCTION 1

1.1 Background of study ( 500 words) 1

1.2 Problem statement ( 500 words) 3

1.3 Objective ( 150 words) 6
1.4 Scope of the study (500 words) 7

CHAPTER 2: AIMS 10
2.1 Literature Review (500 words) 10
2.2 Literature Study 12
2.2.1 Auto Inspection Machine (500 words) 12
2.2.2 Vision Inspection (500 words) 15
2.2.3 Structure (500 words) 19

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 2.2.4 Standard Part (500 words) 21
2.3 Design Specification (200 words) 25
2.4 METHODOLOGY Flow Chart 26
2.5 METHODOLOGY Explanation (500 words) 28

CHAPTER 3: MAIN TEXT AND DISCUSSION 31

3.1 Development of design solution 31
3.1.1 Auto Inspection system (500 words) 31
3.2 Mechanical Hardware Design 35
3.2.1 Module 1 Input Station (500 words) 35
3.2.2 Module 2 Index Station (500 words) 38
3.2.3 Module 3 Output Station (500 words) 41
3.2.4 Module 4 Vision Set (500 words) 44
3.2.5 Module 5 Structure (500 words) 47
3.2.6 Standard Part (500 words) 50

CHAPTER 4: CONCLUSIONS AND RECOMMENDATION 54

4.1 Conclusion (1500 words) 54
4.2 Recommendation (500 words) 62

ACKNOWLEDGEMENTS 65
REFERENCES 66
APPENDICES 67

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Reference

1. http://www.machinedesign.com/manufacturing-equipment/6-factors-consid
er-moving-automated-inspection
6 Factors to Consider Before Moving to Automated Inspection. Dr. Helmut
Hamfeld, Freudenberg , Jul 05, 2016 (Article)

2. https://www.controldesign.com/articles/2014/fast-accurate-automated-visio
n-inspection/?show=all
Fast, accurate, automated vision inspection. Brian Altman, Altman
Manufacturing, Feb 14, 2014 (Article)

3. https://www.valtronic.com/top-5-reasons-to-use-automated-optical-inspecti
on/
Top 5 Reasons to Use Automated Optical Inspection, Valtronic, April 13,
2016

4. https://www.visiononline.org/
Automated Imaging Association

5. http://www.cognex.com/what-is/machine-vision/what-is-machine-vision/
What is Machine Vision, Cognex

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6. https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4813910/
Robot Guidance Using Machine Vision Techniques in Industrial
Environments: A Comparative Review. Gonzalo Pajares Martinsanz,
Academic Editor

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