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Designing of Bottle Washing Machine in Virtual Environment Using the Enhanced Mechatronics System Design Methodology

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2015 ASEE Annual Conference & Exposition


Seattle, Washington

Publication Date

June 14, 2015

Start Date

June 14, 2015

End Date

June 17, 2015





Conference Session

Instrumentation Division Technical Session 1

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Page Count


Page Numbers

26.480.1 - 26.480.19



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Paper Authors


Rizwanul Neyon Purdue University Calumet (College of Technology)

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Rizwanul Neyon, M.Sc, has completed his masters from Purdue University Calumet majoring in Mechatronics Engineering Technology. In his MS Directed project he worked in a Pick & Place machine where he has integrated a Programmable Logic Controller (PLC) & Human Machine Interface (HMI). He was awarded a graduate assistantship from Purdue University Calumet in 2012. As a graduate assistant in engineering Technology department of Purdue University Calumet, from August 2012 to May 2014, he assisted professors in several researches & conduction of labs & classes. In the summer of 2013 and 2014 he also worked as an intern in A Packaging Systems, La Porte, IN, where he was introduced with the primary packaging technologies such as bottle filling & bottle capping machines. As a research assistant he was also involved in designing a scaled down closed loop geothermal heat pump & simulate that model in LabVIEW software. He achieved his bachelor degree in Electrical & electronic Engineering from Chittagong University of Engineering & Technology. Previously he designed & assembled a 3 Wooden Blades Horizontal Axis Wind Turbine.

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Nirjhar Das Sharma Purdue University Calumet

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My name is Nirjhar Das Sharma. I was born on November 20, 1990 in Chittagong, Bangladesh. I pursued my passion for engineering from my early childhood while I was going through High school education. I completed a four year B.Sc. course in Electrical and Electronic Engineering (2008-2013) from Chittagong University of Engineering & Technology, Bangladesh. The last two years of the Bachelor study introduced me to some real-life learning along with a lot of important experiences. I personally believe that the Industrial training at TICI (Training Institute for Chemical Industries), Narshingdi was the most valuable tour where I experienced about the Industrial Production Technology, sensing and control systems, manufacturing, packaging and Programmable logic controllers(PLC). This training made my decision easier to become a Graduate student of Mechatronics Engineering Technology at Purdue University Calumet, USA (from August, 2013 till present). Now I am learning Electrical controls, PLC (allen bradley), HMI programming and Robot (Motoman) programming as the integral part of my research. Besides, I have been working as an Instructor for an undergraduate level course 'Electricity and Electronics fundamentals' from January, 2014 at Purdue University Calumet. Throughout the journey that I made so far as a Graduate student, I have also experienced to work as a Teaching Assistant, designing PLC trainers and working with several mechatronics projects. At present, I am also working as an Engineering Intern at A Packaging System, La porte, IN (from May, 2014) experiencing different technologies like liquid filling machine, Bottle capping machine in a primary packaging environment. I strongly believe that my experience and education would create excellent opportunities for me and would flourish my knowledge in the future.

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Priom Chakraborty Purdue university Calumet

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Priom Chakraborty, B.S, currently working as a Teaching assistant of Purdue University calumet .He is now doing his Masters focusing in Mechatronics Engineering Technology. He also worked as lab assistant in AWAKE (Assisting Workforce by Advancing Knowledge for Employment) program in Purdue University Calumet. His recent work is designing of Bottle Washing Machine in Virtual Environment Using the New Mechatronics System Design Technology. He has done his B.S. In American international University of Bangladesh(AIUB) his interests are in the area of programmable logic controlled devices, FPGA system design by Verilog programming, Application of process control in industrial works, Robot programming.
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Akram Hossain Purdue University Calumet (College of Technology)

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Akram Hossain, Purdue University Calumet
Akram Hossain is a professor in the department of Engineering Technology and Director of the Center for Packaging Machinery Industry at Purdue University Calumet, Hammond, IN. He worked eight years in industry at various capacities. He is working with Purdue University Calumet for the past 27 years. He consults for industry on process control, packaging machinery system design, control and related disciplines. He is a senior member of IEEE and he served in IEEE/Industry Application Society for 15 years at various capacities. He served as chair of Manufacturing Systems Development Applications Department (MSDAD) of IEEE/IAS. Currently, he is serving a two-year term as the chair of the Instrumentation of ASEE (American Society of Engineering Education). He authored over 29 refereed journal and conference publications. In 2009 he as PI received NSF-CCLI grant entitled A Mechatronics Curriculum and Packaging Automation Laboratory Facility. In 2010 he as Co-PI received NSF-ATE grant entitled Meeting Workforce Needs for Mechatronics Technicians. From 2003 through 2006, he was involved with Argonne National Laboratory, Argonne, IL in developing direct computer control for hydrogen powered automotives. He is also involved in several direct computer control and wireless process control related research projects. His current interests are in the area of packaging machinery system design & control, industrial transducers, industrial process control systems, modeling and simulation of Mechatronics devices and systems in virtual environment, programmable logic controllers, programmable logic devices, renewable energy related projects, wireless controls, statistical process control, computer aided design and fabrication of printed circuit board.

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Designing of Bottle Washing Machine in Virtual Environment Using the New Mechatronics System Design TechnologyAbstract: Primary packaging signifies the evaluation of the fundamental package which isdirectly related to the manufacturing products. On the other hand, secondary packaging is theprocess of combining the primary packages into one container which is used to transport theproducts from one place to another. In a manufacturing circumstance, a secondary package is notavailable for the end users. Rather it is the primary packaged product that will be available forthe ultimate consumers. Filled bottles with drinkable liquid & solutions that requires sanitizedbottles are one of these kinds of products.In most of the primary packaging industries, bottle washing machines are one of the mostcomprehensively used technologies which is used for efficient washing, sanitizing & dying ofbottles before these are ready to be filled with manufacturing liquid & solutions. Currently, thereare some automatic bottle washing machines available in industry. Generally these machines aremanufactured through practical experiences of conventional machine design which maysometimes result in economic injury and time consumption. These problems can be prevented, ifthe machine design is based on the simultaneous mechatronics system design technology.Mechatronics is the synergistic integration of Mechanical & electrical engineering, computerscience & information technology that comprises control system in addition to mathematicalanalysis used to design products incorporates with intelligence. The modern mechatronics systemdesign is based on concurrent approach to design products with more synergy whereas theconventional system is represented with the sequential approach of design. In new mechatronicssystem design technology the first step of designing a machine starts at emulation of a machine.The term emulation of a system refers to the fact that the system will act as similar as a realsystem without using the hardware. It will enable us to test a system without the hardware. Theproducts that are built through this emulation process before building it in real world aregenerally more reliable, more robust, higher quality & customer satisfactory.This new mechatronics design process can easily be beneficial to a company by increasing theefficiency of the machine. Products become more consistent due to smart and self-connectingsensors. These networkable sensors & control system in a composite environment can reduce theinvestment cost and improve the utilization of the machine.System Description: Figure1: Animation of bottle washing frameEmulation of bottle washing machine project will be emulated by the PLC (Programmable LogicController) software such as RSLogix™ 5000, FactoryTalk® View ME (Machine Edition). PLCwill be emulated by RSLogix™ 5000 Emulator. The whole emulation will run in Allen BradleyFactoryTalk® View Machine Edition. Through this research paper we will establish a process bywhich we will be able to design a bottle washing machine in a virtual intuitive environment. Wewill use PLC (Programmable Lo gic Controller) software tools and Human Machine Interface(HMI) animation tool to achieve the desired outcome of the research.To emulate this bottle washing machine, ladder control logic should be developed in RSLogix™5000 to operate the entire process selecting the PLC type as RSLogix™ 5000 Emulator. Thecommunication between this Emulator and FactoryTalk® View Machine Edition is required torun the virtual animation of the desired machine. The configuration of FactoryTalk® view isalso an important step for the communication with the programmable ladder logic. AllenBradley software DMAT (Drive & Motion Accelerator Toolkit) will be used for the electricalcontrol, Schematic design, panel layout design and HMI design. The process of IntegratedArchitecture solution that includes Allen-Bradley servo drives and PowerFlex® AC drives for thereal-time hardware design.This research involves the emulation of a machine that helps us to build the actual machine withaccuracy, higher quality and reliability.

Neyon, R., & Das Sharma, N., & Chakraborty, P., & Hossain, A. (2015, June), Designing of Bottle Washing Machine in Virtual Environment Using the Enhanced Mechatronics System Design Methodology Paper presented at 2015 ASEE Annual Conference & Exposition, Seattle, Washington. 10.18260/p.23818

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