Shalika Dulaj Amarathunga

This project aims to insert book packs from the polythene sealing machine into corrugated boxes and move them to the gantry robot for palletizing. (Completed only design)

Designed and fabricated a unit to collect books from the delivery conveyor of the Saddle Binder machine. And stacks books with a two-axis robot with a rotating arm, and transfer them for packaging. Testing Videos

The object of this project is to introduce a new maintenance strategy for the pen assembly and book manufacturing plants to convert the existing Calender Based Maintenance process into Condition Based Maintenance system.

The same work can be done as version 1. But with increased speed, because servo motors have been used instead of induction motors and pneumatic cylinders. Machine Production Rate - 22000 EX books per Hour.

The objective of this project is to develop a digital twin for the back-plug mounting station in a ballpoint pen assembly machine in order to predict unexpected breakdowns caused by the misalignment in rotary holders using vibration analysis

Developed a system with Haiwell PLC to get the weight of the corrugated box and it gets rejected from the line if it is not in range. And if it is in range, the system prints the weight on the box by Domino inkjet printer. PLC sends the printing data to the printer through serial communication. The purpose of the project is to error-proof the book count inside a corrugated box. Solidworks Design of Weighing Conveyor Solidworks Design of Rejection Conveyor

The objective of this project is to develop a machine that can feed books automatically into the Prefect Binding machine. Automated Process Manual Process

Convolutional Neural Networks have been used to detect damages in books after the trimming process. Image processing was used to count the number of books in each stack

Developed a book auto feeding unit for manual sewing machines. It eliminates the process of one-by-one manual insertion into the machine. Now the operator can feed 20 books at once. Then the unit feeds books into the machine one by one.

Developing a SLAM-based robust and accurate self-localization algorithm for varying environmental conditions to navigate an AGV in a production floor using a camera and a lidar sensor.  Objectives are  •Develop a robust and accurate self-localization method under varying environmental and floor conditions  •Eliminating the dependency of light conditions on the accuracy of the SLAM algorithm •Do the self-localization within a short calculation cycle  •Improving transportation efficiency by finding the best path on the production floor and recognizing objects & obstacles  

Designed and developed two gantry robots for palletizing corrugated boxes in the book manufacturing plant and pen assembling plant. Two methods have been used, one with mechanical gripping and the other one with vacuum gripping. Both robots consist of 3 linear axes and one rotational arm.

In the flexo printing section, three separate processes(ruling, folding, and cutting) are combined into one process. The folding machine was connected at the end of the conventional ruling machine, and then the cutting unit was fixed which was developed internally

Designed and implemented a book stacking unit for the Bielomatik machine (Book Manufacturing Machine). It can mix and stack books according to the required quantity. It is installed between the Bielomatic machine and the polythene sealing machine.  The main actuators were the induction motors and pneumatic cylinders. Machine Production Rate - 10000 CR books per Hour.

 Developed an AR mobile application for 5S audits review with Unity and Vuforia.

Background of Problem At the assembly department of Atlas Axillia Co. (Pvt) Ltd, there are many automated machines. But there are a few manual processes. Pen box packing is one of a manual process. The manual process is slow and needs to allocate permanent labor for this operation for each main assembly machine. And they would like to increase the speed of the packing process and decrease the cost of packing as much as possible. Its current operating cost primarily consists of the salaries of laborers. Because the current packaging process is fully manual. Aims and Objectives Solidworks Design

Developed a glue-filling machine for 350ml glue bottles. The main functions were feeding bottles, filling glue, inserting caps, and tightening caps. SolidWorks Design Manual Process  

A pen barrel separating machine was designed and fabricated for atlas Chooty T pens. The runners that come out from the injection molding machine go through two conveyors. One conveyor runs continuously and the other conveyor runs periodically, generating a jerk to separate pen barrels from runners Manual Process First Design  Second Design  

An Android application was developed that can communicate between the machine operator and the SCADA (Supervisory Control and Data Acquisition). It was developed with MIT app inventor online android application development Software MIT App Inventor for Android is an open-source web application originally provided by Google and now maintained by MIT (Massachusetts Institute of Technology).