ELECTRO-MECHANICAL DRUM FILLING STATION Ryan Trimmer, Matthew Dunbar, Seth Howdershelt, Brandon Rau

EAGLE MANUFACTURING Eagle Manufacturing was established in 1894 in Wellsburg,WV as a glass factory. The company began to manufacture safety cans which in turn led to developments in other safety products. Eagle currently has over 750 industrial safety and hazardous material handling products. Family owned business. All products made in the USA. Plant is over a million square feet.

PROBLEM Design an industrial automation system that will accurately fill manufactured drums with a specific weight to be tested for quality control and for UN/DOT certifications.

CERTIFICATION UN/DOT certification Drums must pass 3 tests to pass. a)Side Drop b)Center of Gravity Drop c)Stack Test Two drop heights (4 & 6 feet) Must be stored in freezer for 48 hours before each test (0° F)

JUSTIFICATION FOR DESIGN Drums previously filled and emptied by hand (2-3 hours) Takes 2-3 maintenance workers to fill by hand. Each drum (3 of each type per test) must be tested each year for certification. Over 50 types of drums.

REQUIREMENTS Design a device to fill drums to specific weights(based on user input) while still maintaining full volume of the drum. Must fill the drums automatically. Design dimensions must be compatible with room specifications. Machine must be safe and easy to operate/repair.

COMPONENTS HMI Screen Allen Bradley PLC (micrologix 1100) Scale (1000lb) Hopper Vacuum System Remote Proportioning Valve RS Logix 500 and 5000

HMI SCREEN

PLC MicroLogix 1100 Programmable Logic Controller

TEST 14 GAL, 143 LB dispensing targets lbs sand31.2lb22% resin35.8lb25% sand67.0lb47% resin71.5lb50% sand102.7lb72% resin107.3lb75% sand138.5lb97% resin143.0lb100%

BASIC LADDER LOGIC DIAGRAM

SCALE Industrial Drum Scales with a Ramp and Stainless Steel Sensors 1000lb Capacity RS232 Communication

HOPPER

REMOTE PROPORTIONING VALVE

GATE VALVE AND SOLONOID

PROPRIETARY DESIGN

Basic Block Diagram of Design

ACCOMPLISHMENTS All components selected and priced. Design finalized with the selected components. HMI menu system created. PLC Program algorithm created. Density of materials calculated. Submit final design proposal to Eagle Manufacturing President.

BUSINESS POTENTIAL Sell our specific fill station design to other companies that require similar filling of drums. Create several variations of our design to meet other company’s various filling applications.

FUTURE DEVELOPMENTS Add future products to the menu. Add additional dispensers to fill multiple drums at once. Add to program algorithm in order to fill multiple drums. Dynamic filling options for any drums.

QUESTIONS?