Contoh Fyp Gmi

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CHAPTER I
INTRODUCTION
1.1 PROJECT BACKGROUND
We have overcome to make a Post-Mix Instant Noodle Machine for our Final year
project in our last semester at German Malaysian Institute. This project is being set off
as one of requirement to finish our diploma program and the most important thing is it
gives us a feel of a real working life by making a machine that we create and apply all
things that we have study during these three years of diploma.
First of all, this idea comes from when one of our members wanted to eat instant
noodle. Later we found out that making an instant noodle ready to eat has some step to
follow. So it was good to make our busy live much easier if we have make a ready to
eat instant noodle machine. As it was like a vending machine that are easy for us to
use.
This machine gives entrepreneur another way to promote their product.

Entrepreneur can put this kind of machine at the market area like inside shopping
complex, nearer house area or office building. This place is where most of people exist.
This kind of vending machine does not been make in our country yet, so it was our
advantages to introduce this machine to industrial by making a variety for vending
machine. It would give people a better choice to eat what they want freely.
We have done some researched about vending machine outside off our country
and study about their way of handling vending machine. It is to make sure that we will
have enough information and knowledge about vending machine.
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1.2 OBJECTIVES
Project Objectives:
The objectives we doing this project are to design and construct Post-Mix
Instant Noodle Machine and acquainting with the process to fully automatic process. As
also to assemble the new machine for SMI (Small Medium Industry) and produce the
cooked instant noodle in 2 minutes.
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CHAPTER II
LITERATURE REVIEW AND FEASIBILITY STUDIES
2.1 FEASIBILITY STUDY
During a brainstorming session between team members, we had been carried

out feasibility study for our project. Each team members will give their own opinion and
solution for every process station in our machine system including designing
mechanical or electrical part. The discussion included:
Discuss between team members
Discuss and refer to supervisor and TTO
Refer to our senior, which is have been done their Final year project to get the
guidance through doing the project.
Get an extra information through book, internet
Give solution through idea, knowledge, skills and experience while studying at
German Malaysian Institute and during Industrial Training.
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2.1.1 Primary Source
Grab a packet of two minute noodles, any brand will do.
Get a kettle and boil around 1L of water(depends on

size of bowl).
Empty packet into bowl.
Add flavoring on top or anything you desire.
Now, wait until the water has boiled.
Once boiled pour water into bowl.
Either put on a cover over them so the moisture stays

in the bowl or grab a fork and start eating
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Figure 2.1: Primary Source
2.1.3 Type of Plastic
Material that we are using for placing flavour is plastic. Plastic used in food
packaging should be of greater purity than plastic used for non-food packaging. Food
grade plastic does not contain dyes or recycled plastic deemed harmful to human. It
has to follow HACCP (Hazard Analysis and Critical Control Point) standard
Figure 2.2: Recycle symbol

Type 5: PP (Polypropene)
High tensile strength, making it ideal for use in caps and lids that have to hold
tightly on the threaded openings
Because of it high melting point, polypropene can be hot filled with products
designed to cool in bottles, including ketchup and syrup.It is also used for
products that need to be incubated such as yogurt.
Different PP grades are available dependent on the application and chosen

processing method.
Physical Properties
Tensile Strength 0.95 - 1.30 N/mm
Notched Impact Strength 3.0 - 30.0 Kj/m
Thermal Coefficient of expansion 100 - 150 x 10-6
Max Cont Use Temp 80 C
Density 0.905 g/cm3
(Source : Plastipedia.co.uk)
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Resistance to Chemical
Dilute Acid ****
Dilute Alkalis ****
Oils and Greases ** variable
Aliphatic Hydrocarbons *
Aromatic Hydrocarbons *
Halogenated Hydrocarbons *
Alcohols ****
KEY * poor ** moderate ***
good ****
very good
(Source : Plastipedia.co.uk)
Figure 2.3: Hazard symbol 1
It is suitable for oven use. Our silicon ware is manufactured from state-of-the-art
material that is light, flexible & withstands temperatures ranging from -25C to 220C,
making it ideal for use in the freezer, refrigerator, microwave & conventional oven.
Figure 2.4: Hazard symbol 2
The fork and glass symbol guarantees the suitability of using Tupperware products for
foodstuffs. It means that the product has been tested and proven to not transfer
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components into food in quantities that can endanger human health, change food
composition in an unacceptable way or deteriorate its taste & odour.
2.1.4 Stainless Steel
Figure 2.5: Stainless Steel Bowl
Stainless steel is used for the water heating tank. We had chosen to use the
stainless steel grade 304 because it is suitable to be used as water heating tank. The
SS304 also have low carbon properties thus making it safe to use to boil water.
2.1.6 Heating element
Figure 2.6: Emersion Heater
A heating element converts electricity into heat through the process of Joule
heating. Electric current through the element encounters resistance, resulting in
heating of the element. Most heating elements use Nichrome 80/20 (80% nickel, 20%
chromium) wire, ribbon, or strip. Nichrome 80/20 is an ideal material, because it has
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relatively high resistance and forms an adherent layer of chromium oxide when it is
heated for the first time. Material beneath the wire will not oxidize, preventing the wire
from breaking or burning out.
2.1.7 Feasibility study report
Experiment 1
Figure 2.7: Suction cup and bowl dispenser
Title
: Suction cup and bowl dispenser
Date
: 30/4/2011
Objective
: To see if suction cup can pull bowl downward from bowl

dispenser
Equipments
: 1) Suction cup
2) Bowl
3) Bowl dispenser
Method
:1) Put supply on suction cup

2) Place the bowl inside the bowl dispenser
Discussion
: When suction cup try to pull the bowl downwards, the bowl did
not follow it. It seems that the suction cup did not give enough
vacuum air to make bowl removes from bowl dispenser or the
bowl dispenser is too tight for the bowl to removes.
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Conclusion
: Failed, the bowl cannot be removed from bowl dispenser
Recommendation
: Use a bigger suction cup so it has enough air to pull the bowl.
Experiment 2
Figure 2.8: Motor pump
Title
: Motor pump water flow
Date
: 30/4/2011
Objective
: To see the flow of water inside the pump
Equipments
: 1) Pump motor
2) Hose
3) Tank
Method
:1) Connect pump motor with tank using hose

2) Put supply on pump motor
Discussion
: When the motor start running, the water flows too fast inside
the tank. It seems that we had to control the water flow as our
tank is small and only need 300ml water in one time.
Conclusion
: Failed, need to slow the flow of water to the tank.
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Recommendation
: Put on water level sensor so that motor pump will stop when
sensor detect.
Experiment 3
Figure 2.9: Before
Figure 2.10: After
Title
: Temperature controller cut-off
Date
: 29/4/2011
Objective
: To see whether the temperature controller will cut-off heater

when it reaches certain boiling point.
Equipments
: 1) Temperature controller
2) Heater
3) Tank
4) Thermocouple
Method
: 1) Put water inside the tank with heater at side of tank and
connect the thermocouple with temperature controller
2) On supply for heater and temperature controller and start
process
3) Wait until temperature controller cut off which mean it reach
curtain degree of heat.
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Discussion
: From our observation, the temperature controller gives a right

value for the temperature as the thermocouple detects the
temperature heat. When it reaches at desired temperature,
temperature controller cut off the heater supply.
Conclusion
: Success, temperature controller cut off the heater when it

reaches certain temperature
Recommendation
: Put a buzzer as another notification about the water

temperature
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Experiment 4
Figure 2.11: Suction cup and bowl dispenser
Title
: Suction cup and bowl dispenser
Date
: 30/4/2011
Objective
: To see if suction cup can suck bowl downward from bowl

dispenser
Equipments
: 1) Suction cup
2) Bowl
3) Bowl dispenser
Method
:1) Put supply on suction cup

2) Place the bowl inside the bowl dispenser
Discussion
: When suction cup try to suck the bowl downward, the bowl did
follow it. It shows that the suction cup have enough vacuum air
to make bowl removes from bowl dispenser.
Conclusion
: Success, suction cup can pull the bowl downward and remove
it from the bowl dispenser.
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Recommendation
: As other option, if does not have a bigger suction cup, use two
small suction cup as it is also can give enough air to pull the
bowl.
Experiment 5
Figure 2.12: Boiler temperature
Title
: Feasibility of heater temperature
Date
: 24/5/2011
Objective
: To know the heater functionality
Equipments
: 1) Heater
: 2) Relay
: 3) Power Supply
: 4) Test pen
: 5) Water
Method
: 1) Connect heater with relay

: 2) Relay connected with power supply and on supply
: 3) Put heater inside water
: 4) Check using test pen if the heater is on or not
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: 5) See if water is boiling or not
Discussion
: After 3 minute on testing, the water does not heating up.
Conclusion
: Failed, the heater does not function correctly
Recommendation
: Use another heater whether recycles or buy a new one.
2.2 PROJECT COSTING
2.2.1 Purchase Planning

At first, we have to determine what the components we need to buy or used
recycle. Once we determine that, we have to list down the entire component and find a
product requirement for it.
When we are really sure to buy the components, find a suitable price for our
budget costing. The price for all purchased item should not be over the limit to avoid
over budget.
2.3 AUDITING METHOD OF COSTING
Auditing methods also has to be considered to avoid over budget. The method
includes:
List the required components of the machine.
List the components that already have from recycled component.
Conduct survey which companies can supply those components.
Get the quotation from the suppliers.
Compare the price, specification and delivery period.
Make the decision. Consider the cheaper price, good quality and fast delivery.
Estimate the total cost of recycled components.
Estimate the total cost of purchased components.
Get the total cost for the machine.
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For the recycled components, it has to be checked thoroughly to make sure the
component are usable and in good condition. If there some damage components or
parts cannot be used anymore, change it if it is still available. Otherwise get the new
one from the supplier.
2.3.1 Petty cash
This second method is meant for items, which is low in terms of amount or
value that cannot be purchased in credit item. Due to that, we have to buy it in cash.
This petty cash will only be provided at the end of the month during the implementation
stage through the number of claims, which varies among the different group.
2.3.2 Purchase order
This method is used for the parts that use a large amount of money or standard
part that have a certain specification and to buy at the place itself.
Firstly, we need to give the part specifications to the right company or supplier
and wait for them to give a review about their current product according to the
specification that has been given. Once we are satisfied with the product given, we will
ask for the quotation on product price. Later, after receiving the quotation, we will do a
purchased request for a product to send to GMI finance for their reference and account
statement. One member in a group represent for RM1000 for a project budget. Once
finance receive purchase request, they will process the purchased order for us to send
to the supplier.
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2.4 RECYCLED PARTS
Recycled part is the part that is being used for the past semester student or part
that are commonly use for all mechatronics course.
Mechanical component
No. Component
Quantity
Price per unit / RM
Price / RM
Screw, bolt & nut
100
0.50
50.00
Aluminium profile (40 X 40)
330.00
660.00
TOTAL
710.00
Table 2.1: List of Mechanical Parts (Recycle Part)
Pneumatic component
No
Component
Quantity
Price per unit / RM
Price / RM
4/2 way valve
250.00
1500.00
5/3 way valve
250.00
500.00
Standard cylinder
250.00
1500.00
Vacuum module
450.00
900.00
Solenoid valve
250.00
250.00
TOTAL
4650.00
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Table 2.2: List of Pneumatic Parts (Recycle Part)
Electrical component
No. Component
Quantity
Price per unit / RM
Price
MCCB
8.00
RM 8.00
ELCB
50.00
RM 50.00
Programmable logic
2000.00
2,000.00
controller
4
Expansion module
1250.00
1,250.00
Tower lamp
120.00
120.00
Terminal block
70.00
70.00
Buzzer
32.00
32.00
Emergency button
20.00
20.00
Pushbutton
2.00
6.00
10
Dc geared motor
500.00
2,000.00
11
Dc geared motor
1000.00
1000.00
12
Ac pump motor
159.00
159.00
13
Reed switch
15
75.00
1,125.00
14
Thermocouple
50.80
50.80
15
Temperature Controller
805.00
805.00
16
Proximity Capacitive sensor
180.00
900.00
TOTAL
Table 2.3: List of Electrical Parts (Recycle Part)
Total recycled component
9595.80
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No. Component
Price / RM
Pneumatic component
4650.00
9595.80
710.00
TOTAL
14,955.80
Table 2.4: Total Cost Recycle Parts
2.5 PURCHASED PART
No. Component
Quantity
Price per unit / RM
Price / RM
330.00
660.00
75.00
300.00
TOTAL
960.00
Table 2.5: List of Mechanical Parts (Purchase Part)
No. Component
Quantity
Price per unit / RM
Price / RM
40.00
40.00
Heater
TOTAL
40.00
Table 2.6: List of Electrical Parts (Purchase part)
Fabrication component
No. Component
Quantity
Price per unit / RM
Price
1000
1000
Boiler Tank
TOTAL
1000
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Table 2.7: List of Fabrication Parts
Miscellaneous component
No. Component
Quantity
Price per unit /
Price / RM
RM
1
Instant noodle
1 packet x 8
13.80
13.80
pieces
2
Curry flavour
1 packet x 500g
6.50
6.50
Chicken flavour
1 packet x 500g
7.00
7.00
Soto flavor
1 packet x 500g
6.00
6.00
Container
1 x 30 container
RM 12.00
12.00
TOTAL
45.30
Table 2.8: List of Miscellaneous Parts
Total Purchased component
No. Component
Total Price / RM
960.00
40.00
Fabrication component
1000
Miscellaneous component
45.30
TOTAL
2045.30
Table 2.9: Total Cost Purchase Parts
Total Costing
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No. Component
Total Price / RM
Recycled component
14,955.80
Purchased component
2045.30
TOTAL
17,001.10
Table 2.10: Total Overall Costing
2.6 SAFETY SIGN
Figure 2.13: Safety Sign

Safety sign are use to give a user extra safety while running this machine, other
than put a safety feature, sign should be put together so that people are aware of
danger and it was one of the way of safety by vision.
We are using 4 types of safety sign. One is Beware of Moving Parts. This sign
is use to make people aware of moving part in our machine. In our machine, there is
conveyor and actuated cylinder that moving without warning as it were following the
sequence.
Second is Hot Surface sign. This sign is use to avoid people from touching our
boiler. The boiler is use a stainless steel as it was hot on the surface and it may cause
a burn on our skin if we touch it.
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Third is Keep Hands Away sign. This sign is use to make people aware of pick
and place area where our hands may be stuck in between while the process are
running.
Lastly, we are using Electrical Hazard signs. This sign is use to make people
beware of 240v voltage flow in project. And it is dangerous for people to touch it without
a safety as it may hurt our body if we touch it while the current are still flow.
CHAPTER III
PROJECT METHODOLOGY
3.1 PROJECT SPECIFICATION
Machine Description
The design of this product is new in the market. The Automatic instant noodle
machine is constructed based on DIN standard as below:
Machine name
Product
Number of station
Power supply
Post-Mix Instant Noodle Machine

Instant noodle
4 stations
220~240 Vdc, 50Hz
Power supply unit
24 Vdc
Pneumatic source
6 bar
Controller
Sensor
Indicator
Transfer system
Drive system
Programmable logic controller (PLC) Siemens s7-200

Capacitive sensor and Photo sensor
Tower lamp
Conveyor and cylinder
Dc motor
Cycle time
2 minute for 1 instant noodle
Dimension
1m x 1m x 1.8m
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Operation mode
Automatic Mode and Manual Mode

Table 3.1: Machine Description
Material specification
Material
Quantity
Noodle
77 gram
Water
300 gram
Flavour
8 gram
Container
1 gram
Cover container
1 gram
Estimation of end product (outflow): approximately = 387gram

Table 3.2: Material Specification
Part description
No.
Part
1.
Pneumatic
Used to pull the bowl into
Cylinder
desired place
Dc geared motor
Used to move the propeller
2.
Picture
Description
to blow out flavour from

canister to bowl
3.
Dc geared motor
Used to move the conveyor
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4.
Ac pump motor
Used to pump water into the

silo at station 3
5.
Proximity
Used to detect presence of
Capacitive Sensor
noodle bowl into the area

and to give a signal into
other devices
6.
Heating Element
Used to heating up water
Table 3.3: Part description
3.2 PROJECT FEATURES
This Post-Mix Instant Noodle Machine consists of 4 station which is feeding, flavour
filling, water filling and capping station. Operation in station are being controlled by
PLC Siemens S7-200 and actuated by Pneumatic Valve Cylinder.
Station 1: Feeding station
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Figure 3.1: Station 1
Firstly, user will choose the instant noodle flavour that they want. We are
including three most wanted flavour which is curry, chicken and asam laksa. After
choosing and press the button, cylinder 1 will pull out bowl and put on the rail. Then,
cylinder 2 will feed instant noodle into the bowl. Later, cylinder 3 which is in extended
position will start to retract until bowl reach on the conveyor.
Station 2: Flavour filling station
After cylinder 3 extend, motor 1 will start running and conveyor start moving.
Bowl that on the conveyor will follow conveyor moving until sensor detect. Conveyor
will stop when sensor are detect for filling a flavour. Conveyor will stop according to the
flavour we are choosing. For sensor 1 is curry flavour, sensor 2 is chicken flavour and
sensor 3 is asam laksa flavour. If we are choosing curry flavour, conveyor will stop
when sensor 1 detects and it will pass for sensor 2 and sensor 3. When sensor 1
has detect and motor 1 stop, motor 2 will start running and fill out the flavour into the
bowl. Motor 2 are run for using a timer and stop when timer stops counting. Then
conveyor will continue move until next station. It happen the same for sensor 2 with
motor 3 and sensor 3 with motor 4.
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Station 3: Water filling station
Conveyor will continue to move until sensor 4 detect. Once sensor 4 detect
solenoid valve will start drain water into the bowl. Solenoid valve will stop drain out
when timer off. Then conveyor will continue moving until sensor 5 detects the bowl.
When sensor 5 detect presence of bowl motor 1 will stop the conveyor. Then,
cylinder 4 will extend and push bowl into the rail. Cylinder 4 will only extend half for a
first move, because station 4 is in the middle of the rail.
Station 4: Capping station
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After cylinder 4 is extend and stop at the middle, cylinder 5 extend and pick up
bowl cover and retract back. Then, cylinder 6 will extend and move the cylinder 5 on
the top of the bowl and cylinder 5 will extend to cap the cover into the bowl. Later, both
cylinders will go back to their initial position. After finish capping station, cylinder 4
continues extend until it reach at the end of the rail and lastly serve to custo
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3.3 SYSTEM LAYOUT
3.3.1 Machine Layout Diagram
Figure 3.5: Actual Machine View
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Figure 3.6: Isometric Drawing
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Figure 3.7: Front View
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Figure 3.8: Top View
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3.3.2 Electrical Wiring Diagram

MAIN SWITCH
ELCB
L
N
PE
MCB
3A
MCB
6A
MCB
3A
POWER
SUPPLY 12
VDC , 3A
MCB
10A
MCB
13A
MCB
6A
POWER
SUPPLY 24
VDC , 3A
TEMPERATURE
CONTROLLER
POWER
SUPPLY
24VDC
TOUCH
SCREEN
PLC S7-200
CPU 226 @ 224
K2
K1
K4
K3
K5
K6
EXPANSION
MODULE 1
HEATER
MOTOR 2
MOTOR 3
MOTOR 4
MOTOR
1
DC
MOTOR
DC
MOTOR
DC
MOTOR
DC
MOTOR
MOTOR 5
3 PIN PLUG
AC PUMP
MOTOR
Figure 3.9: Electrical Wiring Diagram

From figure above, it shows the connection for the electrical wiring diagram according to actual. The red line indicate life wire, the blue line
indicate neutral wire and the green wire indicate ground or also called earth wire.
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3.3.3 Pneumatic Wiring Diagram
Y1
3 Y2
Y3
3Y4
3 Y6
Y7
3Y8
3 Y10
Y11
Y2
Y13
4
3 Y12
Figure 3.10: Pneumatic Wiring Diagram

From figure above, it shows the flow and pressure of air inside pneumatic cylinder for this machine
45%
3 Y14
Y15
R 19
45%
R 18
R 17
100%
R 16
100%
R 15
70%
70%
Y9
R 14
70%
R 11 R 12 R 13
70%
R 9 R 10
R 8
30%
100%
Y5
R 7
100%
R 6
30%
R 5
100%
R 4
100%
R 3
30%
50%
R 1 R 2
Y16
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3.3.4 PLC Wiring Diagram

24V
START STOP
I0.0
I0.1
SN1
I0.2
I0.3
I0.4
I0.5
SN2
I0.6
SN3
I0.7
SN4
I1.0
SN5
SN6
I1.1
RS1
I1.2
RS2
I1.3
RS3
I1.4
RS4
I1.5
RS5
I1.6
I1.7
CPU 226@224
PLC SIEMENS S7-200

Q0.0
Q0.1
Q0.2
Q0.3
Q0.4
Q0.5
Q0.6
Q0.7
Q1.0
Q1.1
Q1.2
Q1.3
Q1.4
Q1.5
Q1.6
Q1.7
Y1
Y2
Y3
Y4
Y5
Y6
Y7
Y8
Y9
Y10
Y11
Y12
Y13
Y14
Y13
Y14
0V
Figure 3.11: PLC Wiring Diagram 1

From figure above, it shows the wire connection for input and output component that are being connected to the PLC Module.
P a g e | 34
24V
RS6
RS7
I2.0
RS8
I2.1
RS9
I2.2
RS10
I2.3
RS11
I2.4
RS12
I2.5
RS13
I2.6
RS14
I2.7
RS15
I3.0
SN7
I3.1
RS17
I3.2
RS18
I3.3
thermo
I3.4
I3.5
I3.6
I3.7
CPU 226@224
EXPANSION MODULE 1
Q2.0
K1
Q2.1
K2
Q2.2
K3
Q2.3
K4
Q2.4
Q2.5
Q2.6
Q2.7
Q3.0
Q3.1
Q3.2
K5
K6
L1
L2
L3
SL1
BZ
Q3.3
Q3.4
Q3.5
Q3.6
Q3.7
0V
Figure 3.12: PLC Wiring Diagram 2

Figure above are the expansion of PLC Module as we are used more input and output component for this project.
P a g e | 35
Input Table
Symbol
Address
Start
stoper
S1
S2
S3
SN1
SN2
SN3
SN4
SN5
SN6
RS1
RS2
RS3
RS4
RS5
RS6
RS7
RS8
RS9
RS10
RS11
RS12
RS13
RS14
RS15
floating_sensor
RS17
RS18
reset
TERMO
I0.0
I0.1
I0.2
I0.3
I0.4
I0.5
I0.6
I0.7
I1.0
I1.1
I1.2
I1.3
I1.4
I1.5
I1.6
I1.7
I2.0
I2.1
I2.2
I2.3
I2.4
I2.5
I2.6
I2.7
I3.0
I3.1
I3.2
I3.3
I3.4
I3.5
I3.7
Description
Start all program
Stop
curry
chicken
soto
sensor 1 or limit switch
cy1
cy1
cy1
cy2
cy2
cy3
cy3
cy4
cy4
cy4
cy5
cy5
cy5
cy6
cy6
floating sensor
stoper
suction cup (station 1)
reset to initial condition
Termocouple
Table 3.4: Input table PLC
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Output Table
Symbol
Y1
Y2
Y3
Y4
Y5
Y6
Y7
Y8
Y9
Y10
Y11
Y12
Y13
Y14
Y15
Y16
K1
K2
K3
K4
K5
K6
L1
L2
L3
SL1
BZ
Address
Q0.0
Q0.1
Q0.2
Q0.3
Q0.4
Q0.5
Q0.6
Q0.7
Q1.0
Q1.1
Q1.2
Q1.3
Q1.4
Q1.5
Q1.6
Q1.7
Q2.0
Q2.1
Q2.2
Q2.3
Q2.4
Q2.5
Q2.6
Q2.7
Q3.0
Q3.1
Q3.2
Description
cy1
cy1
cy2
cy2
cy3
cy3
cy4
cy4
cy5
cy5
cy6
cy6
cy7
cy7
suction cup 1
suction cup 2
conveyor motor
dc motor 1
dc motor 2
dc motor 3
pump motor
heater
lamp (red)
lamp (orange)
lamp (green)
solenoid valve (boiler)
buzzer
Table 3.5: Output table PLC
P a g e | 37
3.4 STEP SEQUENCE
START
INITIAL
CONDITION
RS1
STEP 1
Q4.0
Y1, CYLINDER 1 (EXT)
STEP 2
Q4.1
Y2, CYLINDER 1 (RET)
M10.1
NS
Q4.0
NS
Q4.1
STEP 4
Q4.1
M10.3
Q4.2
STEP 5
Q4.3
M10.4
NS
Q4.2
Q4.5
M10.0
RS3
RS2
STEP 3
S
T
O
P
E
N
D
M10.2
RS4
RS5
RS7
STEP 6
M10.5
Figure 3.13: Step Sequence 1
P a g e | 38
SN1
RS6
STEP 7
Q4.4
M10.6
NS Q4.5
SN2
Q6.0
K1,MOTOR 1 (RUN)
STEP 8
NS Q6.0
K1, MOTOR 1 (STOP)
M10.7
Q5.4
SL1, SOLENOID 1 (RUN)
STEP 9
NS Q5.4
SL1, SOLENOID 1 (STOP)
M20.0
RS7
S
T
O
P
E
N
D
SN3
K1, MOTOR 1 (RUN)
SN4
STEP 10
M20.1
Q6.0
SN5
STEP 10
M1, MOTOR 1
NS Q6.0
(STOP)
S Q6.1
M2, MOTOR 2
(RUN)
M20.1
STEP 10
M1, MOTOR 1
NS Q6.0
(STOP)
S Q6.2
M3, MOTOR 3
(RUN)
Y5,
NS Q4.4 CYLINDER 3
(EXT)
3
M20.1
NS Q6.0
M1, MOTOR 1
(STOP)
S Q6.3
M4, MOTOR 4
(RUN)
P a g e | 39
3
RS12
RS10
STEP 11
NS
Q4.6
M20.2
Q5.0
NS
Q6.0
M1, MOTOR 1 (RUN)
STEP 12
NS
Q5.0
M20.3
Q5.2
Q5.0
STEP 14
Q5.1
M20.5
Q5.3
STEP 15
Q4.6
M20.6
NS
Q5.0
NS
Q5.3
STEP 16
Q4.7
M20.7
NS
Q4.6
RS13
RS14
RS12
STEP 13
M20.4
S
T
O
P
E
N
D
RS15
RS13
RS9
RS11
P a g e | 40
1
STEP 11
Q6.0
M1, MOTOR 1 (RUN)
M20.2
NS
Q6.1
M2, MOTOR 2 (RUN)
NS
Q6.2
M3, MOTOR 3 (RUN)
NS
Q6.3
M4, MOTOR 4 (RUN)
STEP 12
NS
Q6.0
M1, MOTOR 1 (RUN)
M20.3
Q4.6
STEP 13
NS
Q4.6
M20.4
Q5.0
NS
Q6.0
M1, MOTOR 1 (RUN)
STEP 14
NS
Q5.0
M20.5
Q5.2
Q5.0
STEP 16
Q5.1
M20.7
Q5.3
STEP 17
Q4.6
M30.0
NS
Q5.0
NS
Q5.3
STEP 18
Q4.7
M30.1
NS
Q4.6
RS8
SN6
RS11
RS9
RS12
RS13
E
N
D
S
T
O
P
RS11
STEP 15
M20.6
RS14
RS12
RS8
RS10
P a g e | 41
3.5 INSTRUMENT AND EQUIPMENT SPECIFICATION
3.5.1 CALCULATION FOR CYLINDER SIZING
Cylinder 1 & 2 sizing
Mass = 0.1 kg Gravity = 9.81 m/s

F = mg
= (0.1kg) (9.81m/s)
= 0.981 N
Safety factor
P = 6bar
P a g e | 42
Cylinder 3
Mass = 0.71 kg
Gravity = 9.81 m/s
F = mg
= 0.25(0.71kg) (9.81m/s)
= 17.413 N
Safety factor
= 0.25
P = 6bar
P a g e | 43
Cylinder 4
Mass = 7.2 kg Gravity = 9.81 m/s

F = mg
= 0.25(7.2kg) (9.81m/s)
= 17.658 N
Safety factor
= 0.25
P = 6bar
P a g e | 44
Cylinder 5 & 6
Mass = 0.3kg Gravity = 9.81 m/s
= 0.25
P = 6bar
F = mg
= 0.25(0.3kg) (9.81m/s)
= 0.735
Safety factor
Conclusion
We are used a recycled cylinder that have the nearer bore size as the calculation.
P a g e | 45
3.5.2 CALCULATION FOR MOTOR SIZING
Motor 1
+ fy = 0
N-w = 0
N=w
= 16.65(9.81)
= 163.35 N
If = N
= 0.8(163.35)
= 130.68
+ fx = 0
F-f = 0
F = 130.68
TL = F D/2
= 130.68 (0.03)
= 3.92
4Nm
P a g e | 46
Motor 2
+ fy = 0
N-w = 0
N=w
= 10.00(9.81)
= 98.1 N
If = N
= 0.8(98.1)
= 78.48
+ fx = 0
F-f = 0
F = 78.48
TL = F D/2
= 78.48 (0.03)
= 2.36
3Nm
Conclusion
We are use a recycled motor that are using the same purpose which is motor 1 are
used on conveyor and motor 2 are used on the canister.
P a g e | 47
3.6 SAFETY FEATURES
Safety features are important in order to minimize and to eliminate hazardous

that can cause injury or damages to the object. In order to ensure the safety of the
personnel operating the machine, there are few safety features that are needed to be
considering for the machine. Below are some of the additional safety requirements that
have been included with this machine:
Emergency Stop Button
Figure 3.17: Emergency Stop Button

Emergency stop button is needed to ensure the safety of the whole system incase of any unwanted accident. When any fault occurs, the emergency stop button is
the best way to cut-off all the power supply to the machine to avoid further problems.
Circuit Breaker
Figure 3.18: MCB

Circuit breakers are used to protect the whole system (main power supply)
when there are any short circuit or currents leakages. It will act as a safety switch to cut
off the power supply to the circuit.
P a g e | 48
Relays and Contactor
Figure 3.19: Contactor

Relays or contactor are normally used for frequent making and breaking of the
circuit. The purpose is to isolate the main power supply from the control unit and to
provide a better assurance towards the system.
Indicator
Figure 3.20: Indicator

Indicators are used to indicate the current status or the machine status of the
operating machine. In addition, the operator will always be aware on the current
operation status of the machine.
Alarm / Buzzer
Figure 3.21: Buzzer

The buzzer is used to give warning signal when anything goes wrong during the
machine operating. It will attract peoples attention to make sure people will be aware if
there is danger.
P a g e | 49
CHAPTER IV
PROJECT IMPLEMENTATION
4.1 PROCESS PLAN
4.1.1 Block Diagram
Station 1:
Station 4:
Feeding station
Capping station
Station 2:
Station 3:
Flavour filling
station
Water filling
station
Figure 4.1: Block Diagram
P a g e | 50
4.1.2 Flowchart
4.1.2.1 Main Flowchart
Start
Supply
No
Yes
Initial Position
Press flavor button

No
Yes
Feeding Process
Filling Flavor
Process
Filling Water
Process
Capping Process
End
Figure 4.2: Overall Flowchart
P a g e | 51
4.1.2.2 Flowchart Station by Station
Station 1
Start
Initial Position
Cylinder 1 Extend
No
RS3 detect
Yes
Vacuum On
Cylinder 1 Retract
Vacuum pull bowl

downward from
magazine
No
RS2 detect
Yes
Vacuum Off
Cylinder 2 Extend
Push noodle from

magazine to bowl
No
RS5 detect
Yes
Cylinder 2 Retract
No
RS4 detect
Yes
Cylinder 3 Retract
End
Figure 4.3: Flowchart station
P a g e | 52
Station 2
Start
Cylinder 3 Extend
No
RS7 detect
Yes
Motor 1 Run
No
Sn1 detect
Yes
No
Motor 1 Stop
Sn2 detect
Yes
No
Motor 2 Run
Motor 1 Stop
Sn3 detect
Yes
Curry flavor fall into

bowl
Motor 3 Run
Motor 1 Stop
Motor 2 Stop
Chicken flavor fall

into bowl
Motor 4 Run
Motor 3 Stop
Soto flavor fall into

bowl
Motor 4 Stop
Motor 1 Run
End
Figure 4.4: Flowchart station 2
P a g e | 53
Station 3
Start
Motor 1 Run
No
Sn4 detect
Yes
Motor 1 Stop
Solenoid valve on
Hot water flow into

bowl
Solenoid valve off
Motor 1 Run
End
P a g e | 54
Station 4
Start
Cylinder 4 Extend
No
RS 9 detect
Yes
Cylinder 4 Retract
Cylinder 5 Extend
No
RS 10 detect
Yes
Cylinder 5 Retract
No
RS 12 detect
Yes
Cylinder 6 Extend
No
RS 15 detect
Yes
Cylinder 5 Extend
No
RS 11 detect
Yes
Cylinder 5 Retract
No
RS 12 detect
Yes
Cylinder 6 Retract
End
P a g e | 55
4.2 QUALITY PLAN
4.2.1 Electrical Component
No
Component
Quality Checking
Power Supply
Connect the power supply to the socket and test

using a multimeter. If the multimeter shows output, it
means power supply is in good condition.
Capacitive Sensor
Gives a supply to sensor and put the sensor near

object. If the sensor gives an output, it means the
sensor is in good condition.
Relay
Test using a multimeter, if multimeter show some

output, it means relay are in good condition.
PLC Siemens S7-200
Gives a supply to PLC and see if PLC is on or not.

To check the input and output port, construct a
simple program in computer and download to PLC.
Connect a switch in input port and lamp in output
port. If the lamp is giving a response when press a
switch, it means the port are in good condition.
Dc Geared Motor (Canister)
Connect the motor to the power supply. If motor run,

it means motor is in good condition.
Dc Geared Motor (Conveyor)

Ac pump Motor

MCB
Connect one side of multimeter to MCB and another

side to the ground. If multimeter show a response, it
means the MCB are in good condition.
Contactor
Connect the contactor to the power supply and put it

in normally open condition. If the contactor gives a
response, it means the contactor is in good
condition.
10
Heater
Connect the heater to the supply, put heater inside
P a g e | 56
bowl of water. If water does boil, it means heater is in
good condition.
Table 4.1: Electrical Component Quality Plan
4.2.2 Mechanical Component
No.
Component
Quality Checking
Pneumatic cylinder
Gives an air supply to the cylinder and see if the

cylinder can move smoothly or not.
Canister
Clean the canister and removes all dirty inside

canister as it was use to insert the flavour.
Roller
Check if the roller can move without any disturb.
Conveyor
Assemble the conveyor and tighten the belting for a

smoothing movement.
Aluminium profile
Measure the Aluminium profile according to the

desired length and cut using a grinding machine.
Remove the burr using a file.
PVC plate
Measure the PVC plate according to the desired

length and cut using a jig saw. Remove the burr
using a file.
Acrylic
Measure the acrylic according to the desired length

and cut using a plastic cutter. Remove the burr using
a file.
Table 4.2: Mechanical Component Quality Plan
P a g e | 57
4.3 PROJECT SCHEDULE
Every project has its own dateline. To complete this project, we have 4 main
stages that must be follower
4.3.1 Project Proposal

This is the first phase where we begin to make a project. We are meeting with
our supervisor to ask what kind of process of our project we should use as a reference
for us to make an idea for the project proposal. Form project proposal, we will have a
brainstorming between team members to give a different kind of idea for our final year
project machine. After we finish discussing what project we want to come out, we will
ask our supervisor if it was suitable to make that machine as our final year project.
Once finish on bring out the idea, we begin to do a feasibility study about the
project and designing the project layout. During feasibility study, we will do a research if
there is other machine that are already made and see how they done the process did.
The research for other machine is only for our reference in making design.
When we start to designing our machine, this is where we are applying what we
had learnt through 2 and half year at German-Malaysian Institute. We will start to
design the mechanical part of the machine by using SolidWork and construct the circuit
wiring by referring to the electrical wiring that we had learn from last semester.
P a g e | 58
4.3.2 Project Implementation
After our proposal has been approving, we will start to do a project in a real
time. At this stage, where we will have to really determine the right component that are
going to be use and the mechanical design should be done in a right way as to ensure
the project are in applicable way.
4.3.3 Project Documentation
At this stage is where will prove that we are the one that made this machine. All
the progress while do the project are being recorded in data to show it as a copyright
are made by us. It is to ensure that no other people will make a copy of our machine
process through all the features also. All the works that have been done since proposal
until final presentation are represent in this documentation.
4.3.4 Project Presentation
At this stage is where we will prove that this machine are finish and can do a
process according to the sequence without having any problem. It is to give a person
know that the machine process and what type of process are being use in visual look.
P a g e | 59
4.3.5 Task Content

Task content for the project will be divided as project design, which is designing
on project process through mechanical and electrical. After finalize the design, and
then we will order and purchased a product or part according to our design. Start to
constructing mechanical and electrical wiring according to what we have design from
the beginning. Later, doing a programming controller for the machine and do
documentation by according to the first process that we have done for the project until
project function. Lastly, we present it to people to show proves of our project
completion with success.
4.3.6 Delegation of Task
Task has been delegate into 6 main tasks, which is:
1. Project Design
Designing task is the first stage to start a project. This is where the
project are being design according to standard and propose it to lecturer to see
whether the design that we made are correct or need an improvement or totally
doing in a wrong way. Any mistake that we make at this stage will not make a
project function properly or not function at all.
2. Product Enquiry
First, we make a list of the equipment and then find the vendor or
supplier to get the quotation, before submitting the purchase requisition form.
The specification and delivery date must be confirm from the vendor or supplier.
All of this process is important because some careless mistake will affect the
implementation of project.
P a g e | 60
3. Mechanical construction
This task can be done only after receiving mechanical part, either
fabricated or recycled part. While waiting for purchased fabricated part, we can
start build other station that are using a recycled part and do a self fabricate
part also. It can help to finish a project in a required time.
4. Electrical wiring
This task is being done by person in-charge to finish the wiring part. It is
containing to connect the power supply with plc controller and together with
input and output device. Input device such a s switch, relay and sensor and for
output device like pneumatic cylinder, motor or cylinder. All this input and output
device are connected with plc controller as their link.
5. Programming and controller
Person in-charge should do a sequence of the program to control all

component and device. The movement of the process from input area until
output is should be done correctly to avoid crash between components or it may
destroy the component or process.
6. Documentation and presentation
Person in-charge will collect all data from the first day starting to do the
project until project finish. The data should contain all information about project
including design, project progress.
P a g e | 61
4.3.6.1 Group Member Task Distribution

We have many jobs that we must do. Because of this, we divide each task to each of
our group member.
ELYAS
He has been given responsible as a group leader for this group. Do for designing and
approving on mechanical drawing and layout also for machine wiring including
pneumatic, electrical and PLC. Lastly, he is also responsible to design and
troubleshoot PLC programming.
RAMZUL
Do for designing mechanical drawing and assembly machine layout also purchasing
and costing for fabrication part and recycled part.
HAJAR
Do for designing mechanical drawing and layout and troubleshooting for PLC
programming. Besides, she is also responsible for organizing the schedule, costing of
part, documentation report and presentation.
EMERSON
Do for designing mechanical drawing and assembly machine layout also for
documentation report and presentation.
P a g e | 62
4.3.6.2 Gantt Chart
To do this project we must have a proper planning toward the success of Final
Year Project. Therefore, a clear Gantt chart which list down the necessary tasks and
the duration to complete each tasks is drafted. This Gantt chart will list the task to be
performed by our group, the time scale allowed for each individual tasks and task bar
for better visualization of the individual project phases.
During the project stages, it is possible to keep track on the development of the
project according to the chart. It is also possible to measure the projects phase time
allocation and perform any corrective actions needed in order to complete the project
on time.
In order to complete the machine, we must follow the Gantt chart. Scheduling is
also important in the ways that:
To make sure the jobs / tasks follow the sequence and procedures.
To arrange the times according to the schedule given.
To avoid any clashes with classes or colleges activities.
To prevent from any consequences that might be interrupt the progress such as
delay time of the part delivery or short of money.
P a g e | 63
4.4 CONTINGENCY PLAN
Since any project to implement any project or unpredictable problem, a

contingency plan should be provide as a back up for the countermeasure in order to
avoid any unsettled problem during implementation stage. This contingency plan
comes in handy when possible problems occur to our plan, therefore we have figured
out some possibilities that might occur due to unexpected factors.
Filling station
If using a sensor does not helping in telling how many gram of flavour and water
are filling inside the bowl, we will choose to use a timer.
Transfer system
If transfer by pushing cylinder at station 4 cannot make it stop at the right angle
at pick and place station, we decided to make a stopper at the middle of the conveyor
to make the bowl are state at the right place to put a cover on top of it.
P a g e | 64
CHAPTER VI
FINDINGS AND ANALYSIS
5.1 PROBLEMS ENCOUNTERED & COUNTERMEASURE
No.
Problems Encountered
Countermeasure
For a food and beverage product like For the mechanical parts that do not
our machine, using stainless steel touch the food we replace it by using
surely a must as it was the most a PVC plate only
suitable material to be using for food
product.
Temperature
controller
does
function
3
not Change to the new temperature

controller.
Bowl does not stop accurately at Use stopper in between

station 4
Cylinder 2 extend earlier
Reprogram the PLC program
Cylinder 2 stuck when retract
Align back the cylinder position
Table 5.1: Problem Encountered and Countermeasure
P a g e | 65
5.2 RESULTS & DISCUSSIONS
No
Process
Result
Machine Sequence
All sequence of machine is running according to

required plan
Product Output
Automatic and Manual All automatic and manual process are running as we
Process
Product output are as desired
desired
Table 5.2: Result and Discussion
P a g e | 66
CHAPTER 6
CONCLUSION
6.1 CONCLUSION
This machine is can run in manual mode and semi-auto mode as it may not fully
function in auto mode yet. After all the process can be done in 2 minutes and the
water are boil correctly according to standard water heating.
Sequence of process is running according to what we had planned. The
process in each station also according to what we have desired.
Finally, we are able to make the machine function manually and semi-auto and
make an instant noodle are cooked well.
P a g e | 67
6.2 RECOMMENDATIONS
First recommendation that we would like to suggest is regarding our transfer

system. Instead of using a rollers and cylinders, it is better if we only use a conveyor for
the whole transfer system as it will be much more efficient and systematic. Instead
making the bowl move from one station to another, it will be better to move the station
to the bowl, so that the process may run more smoothly.
Secondly, in order to make it like a real vending machine, we suggest that a coin
slot should be installed and therefore this machine can really be used as a service
machine.
Third recommendation is making a bigger space for noodle dispenser so it can
store more noodles and also making the noodle dispenser to be airtight so that the
noodles stored inside can be kept much longer.
Fourth recommendation is to put a sensor on all dispenser and boiler also to detect
the weight of the flavour and water being put onto the bowl.
Last but not least, we would like to use the real HACCP requirement for a food
safety through biological, chemical, product and economical as follows:
Use a galvanize steel pipe for a water transfer

Use a High Density Polyethylene (HDPE) for food storage.
P a g e | 68
REFERENCE
Cals Arizona. (n.d). HACCP Food Safety. Retrieved from
http://cals.arizona.edu/pubs/health/foodsafety/az1082.html
Tupperware Brands (n.d.). Quality Assurance & Warranty, Decoding the codes.
Retrieved from http://tupperware.com.my/safety_assurance_decoding.php
Plastipedia (n.d.). Polymer thermoplastic, Polypropylene PP. Retrieved from

http://www.bpf.co.uk/Plastipedia/Polymers/PP.aspx
EarthOdysse, LLC (n.d.). Recycling symbols(us) Retrieved from

http://www.earthodyssey.com/symbols.html
Youtube (n.d.). Japan Vending Machine. Retrieved from

http://www.youtube.com/watch?v=qdnU2DUS-g8

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Page |1

1.1 PROJECT BACKGROUND

This machine gives entrepreneur another way to promote their product.

LITERATURE REVIEW AND FEASIBILITY STUDIES

2.1 FEASIBILITY STUDY

During a brainstorming session between team members, we had been carried

Discuss between team members

Discuss and refer to supervisor and TTO

Get an extra information through book, internet

2.1.1 Primary Source

Grab a packet of two minute noodles, any brand will do.

Get a kettle and boil around 1L of water(depends on

Empty packet into bowl.

Add flavoring on top or anything you desire.

Now, wait until the water has boiled.

Once boiled pour water into bowl.

Either put on a cover over them so the moisture stays

2.1.3 Type of Plastic

Figure 2.2: Recycle symbol

Different PP grades are available dependent on the application and chosen

Tensile Strength 0.95 - 1.30 N/mm

Notched Impact Strength 3.0 - 30.0 Kj/m

Thermal Coefficient of expansion 100 - 150 x 10-6

Max Cont Use Temp 80 C

Density 0.905 g/cm3

Dilute Acid ****

Dilute Alkalis ****

Oils and Greases ** variable

KEY * poor ** moderate ***

Figure 2.3: Hazard symbol 1

Figure 2.4: Hazard symbol 2

2.1.4 Stainless Steel

Figure 2.5: Stainless Steel Bowl

2.1.6 Heating element

Figure 2.6: Emersion Heater

2.1.7 Feasibility study report

Figure 2.7: Suction cup and bowl dispenser

: Suction cup and bowl dispenser

: To see if suction cup can pull bowl downward from bowl

:1) Put supply on suction cup

: Failed, the bowl cannot be removed from bowl dispenser

Figure 2.8: Motor pump

: Motor pump water flow

: To see the flow of water inside the pump

:1) Connect pump motor with tank using hose

: Failed, need to slow the flow of water to the tank.

Figure 2.9: Before

Figure 2.10: After

: Temperature controller cut-off

: To see whether the temperature controller will cut-off heater

: From our observation, the temperature controller gives a right

: Success, temperature controller cut off the heater when it

: Put a buzzer as another notification about the water

Figure 2.11: Suction cup and bowl dispenser

: Suction cup and bowl dispenser

: To see if suction cup can suck bowl downward from bowl

:1) Put supply on suction cup

Figure 2.12: Boiler temperature

: Feasibility of heater temperature

KEY * poor moderate *