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DESIGN & FABRICATION OF PNEUMATICALLY
OPERATED
PRESS MACHINE USING PLC
VANSH KUMAR (R880212062)
PRABHPREET ARORA (R880212032)
HARDEEP SINGH DHIMAN (R880212017)
College of Engineering
University of Petroleum & Energy Studies
Dehradun
May, 2015
2. 2
MINOR PROJECT REPORT
ON
DESIGN & FABRICATION OF AUTOMATED PRESS MACHINE
A project report submitted in partial fulfilment of the requirements for the
Degree of
Bachelor of Technology
(Mechatronics Engineering)
By
VANSH KUMAR (R880212062)
PRABHPREET ARORA (R880212032)
HARDEEP SINGH DHIMAN (R880212017
Under the guidance of
MR. ROUSHAN KUMAR
Assistant Professor
Department of Electronics & Instrumentation Engineering
Approved
………………………………..
Director
College of Engineering Studies
University of Petroleum & Energy Studies
Dehradun
May, 2015
3. 3
CERTIFICATE
This is to certify that the work contained in this report titled “DESIGN &
FABRICATION OF PNEUMATICALLY OPERATED PRESS MACHINE USING
PLC” has been carried out by VANSH KUMAR, PRABHPREETARORA&
HARDEEP DHIMAN under my/our supervision and has not been submitted
elsewhere for a degree.
……………………….. ………………………..
………………………. ……………………….
………………………. ……………………….
………………………. ……………………….
Date Date
4. 4
Abstract
The proposed work describes the design and fabrication of prototype of Automatic press
machine controlled by PLC and explains about the working principle and the hardware
structure of the system. Pneumatic system is used for the operation as it would be suitable for
the low pressure application of our project. Sensors and PLC system is interfaced with the
conventional punching process for achieving the automation.
The machine is operated by a stepper motor, 4 pneumatic cylinders and a vacuum generating
unit. Each pneumatic cylinder has its own function. The hardware structure of the project
includes the belt-conveyor model, the pick & place unit, the pushing cylinder and the press
machine structure all of which are mounted on the wooden base. A proximity sensor, a
stepper motor with a relay box and a status light along with a 220V relay are also mounted on
the base. Limit switches are also fixed at the required position for setting & resetting the
pneumatic cylinders. The directional control valves and the vacuum generators are mounted
on the bottom of the base.
The pneumatic actuators and vacuum generating unit of pick & place unit are controlled using
Directional Control Valves. The Stepper motor is used for driving the belt conveyor. The
programming & controlling of Stepper motor is done using a PLC. The pneumatic actuators &
vacuum generating unit are also controlled through a PLC. Ladder Logic is used for
programming on PLC.
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Acknowledgement
We are grateful to University of Petroleum & Energy Studies for their kind help in supplying
the required components and giving their laboratory facility to complete this project. First of
all, we would like to express our deepest gratitude to our mentor, Mr. Roushan Kumar for his
unwavering guidance throughout the completion of the project.
We would like to offer our sincere gratitude to Mr. Durga Dutt Uniyal, BOSCH Lab assistant
for providing us the lab equipment and for his co-operation. We would like to thank Amiyan
Sagar Das, M.Tech Robotics (2nd year), for his endeavoring support during the course of the
project.
We are also very grateful to the faculties & lab assistants of the Workshop Technology Lab
for providing us the required equipment.
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TABLE OF CONTENTS
CONTENTS
ABSTRACT 4
1 INTRODUCTION 7
1.1 Concept of the project ……………………………………………… 7
1.2 Overview of the work to be done…………………………………….. 8
1.3 Statement of purpose ………………………………………………… 8
2. LITERATURE REVIEW 9
3. METHODOLOGY 10
3.1 System overview ………………………………………………………… 10
3.2 Details of the working platform ……………………………………….. 11
3.2.1 PLC’s ……………………………………….. 11
3.2.2 Types of PLC’s …………………………………… 11
3.3 Block diagram of PLC …………………………………………………... 13
3.4 Sequence of operations………………………………………… 14
3.5 CAD design of initial model…………………………………………. 16
3.6 Force/Load Calculations ……………………………………….. 17
3.7 Pneumatic Circuit Diagram…………………………………………. 18
3.8 Ladder Logic Program……………………………………………… 19
3.9 Relay Circuit Diagram……… ………………………………… 23
4. CONCLUSION AND RECOMMENDATION 24
4.1 Conclusion ……………………………………………………. 24
4.2 Recommendation …………………………………………. 24
7. 7
Chapter 1
INTRODUCTION
1.1) CONCEPT OF THE PROJECT
The basic concept of our project is PLC based Press Machine. The press machine is used for
the deformation process & it finds application in the separation of scrap in the industries. A
toy car is taken as the work piece for our project. Pneumatic system is used for exertion of the
required force. The concept of automation is achieved by the control of the conventional
pneumatic systems using PLCs. We have used BOSCH REXROTH Indra Control L20 PLC in
our project and we have used Indra Logic L20 software for ladder logic programming of the
PLC.
The machine is operated by a stepper motor, 4 pneumatic cylinders and a vacuum generating
unit. Each pneumatic cylinder has its own function. The hardware structure of the project
includes the belt-conveyor model, the pick & place unit, the pushing cylinder and the press
machine structure all of which are mounted on the wooden base. A proximity sensor, a
stepper motor with a relay box and a status light along with a 220V relay are also mounted on
the base. Limit switches are also fixed at the required position for setting & resetting the
pneumatic cylinders. The directional control valves and the vacuum generators are mounted
on the bottom of the base.
The pneumatic actuators and vacuum generating unit of pick & place unit are controlled using
Directional Control Valves. The Stepper motor is used for driving the belt conveyor. The
programming & controlling of Stepper motor is done using a PLC. The pneumatic actuators &
vacuum generating unit are also controlled through a PLC.
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1.2) OVERVIEW OF THE WORK TO BE DONE
The objectives of this project are:
To identify the input and output components like pneumatic actuators,
sensors, switches, solenoid valves and stepper motor.
To learn more about the types of pneumatic parts & components.
CAD model & structural model of the mechanical hardware.
Sequence identification of the process.
Project development using ladder logic for sequential programming.
To build a new press machine model that has more safety.
To create the press machine that needs only one worker to handle the
entire process.
1.3) STATEMENT OF PURPOSE/MOTIVATION FOR THE PROJECT
A similar type of press machine was observed in MINDA STONERIDGE INSTRUMENTS
LTD., PUNE which was used for the speedometer pointer assembly. It was used for pressing
the pointer onto the speedometer up to the required depth. Since the process required less
pressure, pneumatic system was used. The inspiration for our project was driven by this
project.
ADVANTAGES OF PLC:
PLC has been used as the flexibility aspect with one single controller can easily run
many machines.
PLC also allows controlling any change in circuit design or sequencing simple as
retyping the logic. Correcting errors in PLC is extremely short and cost effective.
PLC can be programmed and evaluated in a laboratory & thus is user-friendly.
A user can use large numbers of contacts, coils, timers, sequencers, counters as the
PLCs can have very large memory sizes which helps in reducing complexity of the
program.
A PLC can be used in high ambient temperature & pressure conditions and hence can
be used in industrial conditions.
On the account of following advantages, we decided to use PLC for our project.
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Chapter-2
LITERATURE REVIEW
The Automated Press Machine is a project that is designing a new way to improve the
previous press machines in industries which has a few weaknesses in safety while operating
processes. This will create a lot of problem to the operators which have the higher risk to have
an accident. The new press machine is a project to improve previous press machine which
have weakness in safety while operating it. This matter creates a lot of problem and at the
same time the operators and technician have the higher risk to have an accident in industries.
The solution for this problem is a development of a new program of machine which running
same operation but the machine is more safety and easy to use due to the help of internal
timers & counters present in the PLC.
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3.2) DETAILS OF THE WORKING PLATFORM:
Programmable Logic Control (PLC) :-
PLC can be used in all industrial, with application right from small machine to large plants.
PLC plays an important role in automation .All monitoring as well as the control actions are
taken by PLC. PLC senses the input through I/P module processes the logic through CPU &
memory & gives output through O/P module.
CPU is the brain of the system .This consists of Arithmetic Logical Unit, program memory,
process image memory, internal timers & counters, flags. It receives the information from I/P
devices and takes decision depending upon the information & logic written & sends the
information to O/P device. Power required for PLC is 110-230VAC or 24VDC.
The role of I/O modules is to receive data from I/P devices (Switches & Senors) & send it to
O/P device (Relays & Solenoid Valves). Communication modules are used either for
communication external hardware or software .The hardware can be PLC, controller I/O
module smart transmitter .The software can be SCADA software .There are fixed & modular
PLC’s .In fixed PLC will have inbuilt power supply I/O’s in one unit, in modular PLC will
have separate slots for com0ponents like power supply I/O module
TYPES OF PLCs:
FIXED PLC: They have CPU and analog/digital inputs and outputs on the same module.
Mostly they are non-expandable. The drawback with this type is that they have limited no. of
inputs/outputs. They are used for small applications.
MODULAR PLC: Modular PLCs have a chassis (also called a rack) into which are placed
modules with different functions. The processor and selection of I/O modules is customized
for the particular application. Several racks can be administered by a single processor, and
may have thousands of inputs and outputs. A special high speed serial I/O link is used so that
racks can be distributed away from the processor, reducing the wiring costs for large plan.
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We have used BOSCH-Rexroth PLC with model name as IndraControl L20.
The software used for programming this PLC is IndraLogic L20.
The IndraControl L20 is a modular and scalable control.
It combines the benefits of a compact small control with a standardized I/O system
on the basis of terminal technology.
Supply Voltage -24V DC.
It provides onboard interfaces, e. g. high-speed inputs and outputs (8 each) and
communication interfaces, such as Ethernet, PROFIBUS and RS232.
The locally available I/O units can be extended by the Rexroth Inline I/O system,
just by simply mounting the components side by side.
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3.3)BLOCK DIAGRAM OF PLC
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Power Supply (+24v)
PLC
CONTROLLER
(Indra Control
L20)
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PROGRAMMING DEVICE
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1. The work piece (a toy car) is kept on the conveyor belt.
2. A stepper motor is run by the PLC which drives the conveyor belt.
3. The work piece on conveyor starts moving & reaches at a point where it is detected by
a proximity sensor.
4. As the proximity sensor energizes, the conveyor stops.
5. The pick & place unit picks up the work piece from the conveyor and drops it to a
place on the base away from the conveyor.
6. At this place, a pneumatic cylinder pushes the work piece to a place under the punch
of the press machine.
7. As soon as the work piece comes under the punch & the pushing cylinder retracts
back, the press machine performs the required operation.
8. The above steps are repeated for every work piece kept on the conveyor belt.
Note: The 2-dimensional CAD design depicting the overview of the entire process was
designed in SOLIDWORKS 2010.
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3.5) CAD DESIGN OF THE INITIAL MODEL
The 3D model of the conveyor belt, the coupler and the motor and their assembly was design
in CREO PARAMETRIC.
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3.6) FORCE /LOAD CALCULATIONS:
The force that is generated by the punching cylinder can be calculated by using the formula:
Force, F = Pressure * Area N
Therefore,
F = P*(π(d^2))/4
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Chapter-4
Conclusion and Recommendation
4.1)Conclusion
All the operations were being performed sequentially and the project was completed
successfully as per the requirements.
4.2)Recommendations
DC motor can be used instead of Stepper motor.
A Proximity sensor can be used for setting up a warning signal which will halt the
entire process if anything or any person is detected in the vicinity of the press
machine.
Good quality conveyor can be used for better stability of conveyor system.
Main base of the project can be made of Aluminum metal for better strength and
stability.
