"EEET 5004 – Engineering Research PracticeStudent:ID:P a g e | 1 EEET 5004 – Engineering Research PracticeTable of ContentsList of acronyms ..................................................................................................................... 31 The Problem and its setting ................................................................................................ 31.1 General background and importance of the study ....................................................... 31.2 The statement of the problem and its subproblems ..................................................... 41.3 The limitations............................................................................................................. 51.4 The assumptions .......................................................................................................... 62 The review of the related literature ..................................................................................... 63 The research methodology .................................................................................................. 93.1 The data needed and the means for obtaining the data ............................................... 93.2 Systematic description of solving the problem ........................................................... 93.2.1 How to solve Sub-problem 1: To measure the different capacitive sensortechnologies for its ability to distinguish between dry and wet cardboard. ..................... 103.2.2 How to solve Sub-problem 2:To measure the physical characteristics of thesensor available for its ability to fit and be integrated into an existing line control system.103.2.3 How to solve Sub-problem 3: To measure the sensors ability to provide realtime data at varying sensing distances via I/O link into the PLC processor. ................... 104 An outline of the proposed study ...................................................................................... 115 References ........................................................................................................................ 13P a g e | 2 EEET 5004 – Engineering Research PracticeList of acronymsTWE Treasury Wine EstatesBPC Bilyara Packaging CentreAB Allen BradlyHMI Human Machine InterfacePLC Program Logic ControllerCPU Central Processing UnitI/O Inputs and OutputsSOP Standard Operating ProcedurePS Power SupplySOH Stock on Hold CIR Corrective incident reportBOOTP Bootstrap ProtocolDHCP Dynamic Host Configuration ProtocolEDSElectronic Data SheetRS Rockwell SoftwareACCC Australian Competition and Consumer Commission1 The Problem and its setting1.1 General background and importance of the studyPackaging product that is not fit for sale is a huge issue for wine companies. If it is allowed tomake it to the market place it can have a detrimental effect on sales and the company’sreputation. There are also safety concerns for the customers and employees with broken glassand damaged cartons unable to hold the weight of the bottles. Therefore a system fordetecting wet cardboard, before it is allowed to reach the market place, is of huge benefit. There is currently no reliable detection method for broken or leaking bottles in packagedcardboard cartons. Therefore this study will look into the sensing technology available to beused in the design of a system that can reliable detect moisture present on the base of apackaged wine carton.This is a current problem for my employer, treasury wine estates (TWE), who are veryconcerned at the number of broken bottle making it through their packaging process. I haveP a g e | 3 EEET 5004 – Engineering Research Practicetaken this project on and will begin by using the proposal for both Engineering ResearchPractice and to justify my investigation and the expense to produce a prototype for trial at theBilyara Packaging Centre.With Automation playing a large role in manufacturing, new methods of detecting defectableproduct can be used in the quality assurance of the product. With program logic controller(PLC) control packaging lines, sensors play an important role in the feedback of a controlsystem. Sensor I/O data fed into a PLC central processing unit (CPU) can be evaluated andunder pre-set conditions raise an alarm, this results in a reduction in the amount of damagedproduct getting through the packaging process. An effective sensing technology integratedinto the existing production lines PLC control system will provide a cost effective way ofensuring the product is quality right first time. If successful, this research will produce the necessary data necessary for the design of a wetcarton sensing system.Upon completion of this proposal, the research will lead to a designphase which will see a prototype built for further research and testing. If successful it will beapplied to the four high speed production lines at TWE’s Bilyara packaging centre (BPC).The successful performance of the system will see a reduction in stock on hold (SOH) events,a reduction in related line downtime, a reduction in rework, a reduction in broken glass safetyrisks and overall a reduction in operational costs.1.2 The statement of the problem and its sub problemsThis research proposal details a proposed investigation and experiment that will exploresensing technology available to detect wet cardboard cartons. The technology will beinvestigated to determine fit can be used directly or if it can be altered to achieve the desiredoutcome. The investigation will include how the components can be incorporated in theP a g e | 4 EEET 5004 – Engineering Research Practicedesign of a system and how thissystem could be integrated into an automated industrialcontrol system. The overall system must remain cost effective and reliable to detect andalertof a positive result.This research will look at capacitive sensing technology.The sensors raw output data will bemapped into the CPU of an industrial PLC over Ethernet, this data will be conditioned in thePLC program code to give real timedata that can be evaluated. This real time data can be compared against a threshold value to determine if a cartoncontains a damaged bottle that is not fit for purpose. This is very important as TWE does notwant deflectable product getting to the consumer market. Therefore the research question can be stated as: What is required in the design of a cost-effective system for detecting wet cardboard, causedby damaged glass bottles that are sealed and packaged in cardboard cartons, on a high speedwine packaging line?This problem can be classified intofollowing threesub-problems:1. Compare different capacitive sensor technologies for its ability to distinguish betweendry and wet cardboard. 2. Of the sensor technology chosen compare the physical characteristics of the sensorsavailable for its ability to fit and be integrated into an existing line control system. 3. Of the suitable sensor available compare each sensors ability to provide real time dataat varying sensing distances via inputs and outputsI/O link into the PLC processor. 1.3 The limitationsThe limitations of this research are as follows:P a g e | 5 "