Project-Based Learning Exercise:
In a water packet manufacturing unit, the process of counting packets and placing them into boxes is
currently manual, leading to inefficiencies and errors. There is a need for an automated system that can
count the packets on a conveyor belt, place them in boxes, and automatically replace the filled box with
an empty one after it holds 50 packets. This project aims to develop a mechatronics system to automate
the process.
Team Includes: Team consists of 5 members (one each from Mechanical, Electrical, Electronics,
IT, CSE departments)
Objective:
The goal is to design and develop an automated system that:
1. Uses sensors to accurately count the water packets on the conveyor belt.
2. Automatically places packets into boxes.
3. Replaces the filled box with an empty one once it holds 50 packets.
4. Integrates all components into a fully functional, real-time system
Expected Outcomes:
1. Packet Counting System: A working sensor-based system that tracks and counts packets on the
conveyor belt.
2. Box Filling and Replacement Mechanism: An automated mechanism that detects when the
box is filled and swaps it with an empty box.
3. Arduino-based Control: The system will be controlled using an Arduino microcontroller,
handling sensor data and controlling actuators.
4. CAD Design: A 3D CAD model of the overall system, including the conveyor belt, packet
counter, and box replacement mechanism.
5. Sensor Integration: Students will integrate various sensors (e.g., IR or proximity sensors) with
Arduino to count packets and detect the status of the boxes.
6. App/Web Dashboard: Development of a simple app or web interface for monitoring the
system, including real-time data on packet counts and box status.
7. Functional Prototype: A working prototype demonstrating the automation of the water packet
counting and box replacement system.
Learning Opportunities:
1. Arduino Programming:
Students will work with Arduino to:
o Read sensor data (e.g., IR, proximity sensors) to count packets.
o Control actuators such as motors for box replacement.
o Implement logic for handling packet counting and box replacement.
2. CAD Modelling:
o Students will create 3D models of the entire system, including the conveyor belt, packet
placement mechanism, and box replacement unit.
o They will use CAD software such as SolidWorks, AutoCAD, or Fusion 360 to visualize
and design the mechanical components.
3. Sensor Integration:
o Students will learn how to integrate and calibrate sensors for real-time data collection.
o They will focus on integrating proximity or IR sensors for counting packets and limit
switches or load sensors to detect box fill levels.
4. App/Web Development:
o Students will develop a simple app or web-based dashboard to monitor the system.
o The dashboard will display real-time data such as the number of packets, current box
status, and system health.
o They can use technologies like HTML/CSS/JavaScript for web development or Android
Studio/Flutter for mobile apps, interfacing with the Arduino system via Wi-Fi or
Bluetooth.
Project idea floated by - Dr. A. P. Pail
