Students: Mathijs, Julius, Gamal
DERO-GROEP B.V. INTRODUCES AUTOMATED SAUSAGE CUTTER TO REDUCE MANUAL LABOR AND IMPROVE EFFICIENCY
Introduction
Dero Groep is a company operating in the technology sector, offering solutions for automation challenges. In this project, Dero Groep is seeking a solution to cut the clips on sausages and divide the sausages into two parts. The goal of this project is to automate the production line to achieve optimal and consistent results. Here, we assist Dero Groep in creating a proof of concept in the form of a prototype, which can be further developed in the future.
Problem
Currently, they cut the sausages manually before they are processed on the packaging machine. This manual process carries the risk of inconsistency and takes more time. The automatic cutting clippers and splitting of sausages is expected to make the production line more efficient, with fewer workers involved.
Our Solution
We have designed a prototype machine that automates the process of cutting sausage clippers, significantly improving efficiency compared to traditional manual methods. We also developed a vision-based concept capable of identifying the best splitting spot for sausages. Together, these innovations showcase a blend of automation and intelligent detection, paving the way for more precise and efficient food processing solutions. Further development is necessary for the final machine.
How the product work
The machine starts with the sausage being placed on the metal plate, and a hook in the chain picks up the sausage to guide it along the path until it reaches the cutting station. This chain mechanism is integrated into the overall conveyor system, providing additional support beneath the sausage for smooth and synchronized movement. The combination of the chain and conveyor system ensures that both the top and bottom of the sausage move together in harmony. A motor powers the chain’s movement, while a PLC controls both the motor and the conveyor.
The control of this system is managed through a PLC program, providing flexibility and ease of use for operators. The program allows for adjustments in the speed of both the chain and the conveyor, ensuring the sausage moves at the appropriate pace for the cutting process. The HMI interface also includes an emergency button that can be activated in case of an emergency or any unexpected situation. This added feature ensures that operators have control over the system in all circumstances, ensuring safety and reliability throughout the operation.
In order to determine the cutting point for the sausage, a Python program utilizing OpenCV was developed to detect the contour of the sausage. The program analyzes the shape of the sausage and calculates where it intersects the contour in half, identifying the point for cutting. This image processing technique allows the system to make accurate decisions about where to cut each sausage, ensuring consistency and precision in the final product. This technology improves the cutting process, making it more efficient and reliable.
Major Decision
We designed the clipper cutting machine to enable continuous operation. With this design, the customer simply needs to place the sausage in the machine, ensuring ease of use. We also incorporate vision technology to determine the correct spot for splitting the sausage in half, as the shape of the sausage can vary from one side to the other and may appear mirrored after the clippers cut it. To ensure the cut is made in the right location, we use the surface area to identify the larger and smaller sides after the splitting process.