System Workflow
The system operates as an integrated Industry 4.0 cell, synchronizing PLC-driven hardware with IoT-based order management and computer vision. By leveraging a multi-station conveyor layout, the process transforms raw materials into a finished, inspected product through the precise coordination of pneumatic actuators, vacuum systems, and a Raspberry Pi-driven inspection module. The workflow is managed via a Node-RED dashboard, allowing for real-time remote monitoring and customizable production orders, effectively bridging the gap between traditional automation and modern digital manufacturing.
Order Initiation & Material Loading
The process begins at the digital interface. Using a cloud-based dashboard or local touch panel, an order is placed to select specific capsule combinations. An empty bottle and cap are then placed onto the pallet, which serves as the carrier throughout the automated line, introducing students to the fundamentals of smart material handling.
Multi-Hopper Smart Dispensing
Based on the specific order requirements, one of three dispensing hoppers is activated. The system utilizes pneumatic cylinders to release the correct sequence of colored capsules into the bottle. This step teaches students how logic programming translates digital orders into physical sorting and filling actions.
Vision-Based Quality Inspection
Before a product is cleared for dispatch, it passes through an inspection zone. A high-resolution camera module performs a real-time scan to verify fill levels and cap placement. This stage introduces Machine Vision, allowing students to program logic that automatically classifies units as "Good" or "Bad."
Automated Conveying
The conveyor system transports the pallet toward the first work cell. High-accuracy industrial sensors detect the bottle’s arrival, signaling the controller to engage a pneumatic stopper. This stage demonstrates the critical synchronization between sensor feedback and mechanical actuation required to halt high-speed production lines.
Vacuum-Assisted Capping
The pallet advances to the assembly station, where a specialized vacuum suction mechanism picks up the bottle cap. A coordinated pneumatic blow mechanism then secures the cap onto the bottle. This module provides hands-on experience with pneumatic pick-and-place technology and fluid power applications.
IoT Monitoring & System Feedback
In the final stage, all process data is synchronized with a real-time dashboard. A signal tower provides immediate visual feedback on the system status, while the digital interface tracks production metrics. This concludes the cycle by demonstrating Industry 4.0 connectivity, remote monitoring, and data-driven manufacturing.