The ultimate aim of the project is to minimize the human effort by implementing automation system. Using the PLC, this process can be controlled automatically as well.

1. AUTOMATIC REAM HANDLING
SYSTEM (AUTOMATIC STORAGE
& RETRIEVAL SYSTEM) BY USING PLC
V.S.B ENGINEERING COLLEGE,KARUR
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
THIRD REVIEW
(03.04.2018)
INTERNAL GUIDE EXTERNAL GUIDE
Mrs.Dr.K.UMAMAHESWARI Mr.A.MAHESH BE(EEE)
ASSOCIATE PROFESSOR,EEE ASSISTANT MANAGER
V.S.B ENGINEERING COLLEGE,KARUR TNPL,KARUR
PROJECT MEMBERS
S.MALATHI(922514105025)
M.TARUNI(922514105049)
R.YUVAPRIYA(922514105054)
M. CHAARUMATHI(922514105701)

2. CONTENTS
• Industrial project-TNPL
• Abstract
• Need of the project
• Literature survey
• Existing system
• Proposed system
• Block diagram and layout
• Components used
• Programming methods of PLC
• Simulation
• Software requirement
• Work plan
• References

3. INDUSTRIAL PROJECT
•TNPL, which its operated in the year
1984, has completed 33 years of
operation.
•TNPL installed a new state of the art
paper machine .
•The annual production capacity of
the machine is 155,000 MT.
•It has the advantage of low
specific energy consumption .
•Tamil Nadu newsprint and paper
limited (TNPL) produces sheet
bundle which is called ream can be
stored in AS/RS (Automatic
storage and retrieval system) of
7000 tons capacity.

4. ABSTRACT
• An Automated Storage and Retrieval System (ASRS) automatically
stores and retrieves raw materials as well as finished goods.
• The PLC controls and coordinates the movement and performance
of ASRS.
• The ultimate aim of the project is to minimize the human effort by
implementing automation system.
• Using the PLC, this process can be controlled automatically as
well.
• By adding intermediate path between packing and storage section,it
will reduce the paper damage and give full efficient work

5. NEED OF THE PROJECT
● To eliminate the manual power for ream handling.
● To increase the production according to the increasing
demand.
● To pick and place the ream from various places to storage
area is automatically done by three arm axis which is
controlled by PLC.
● To minimize the damage of equipment due to manpower.

6. LITERATURE SURVEY
AUTHOR TITLE JOURNAL REMARKS
RAVINA SHARMA
SAPANA NAVTAKE
PROF.H.P.CHAUDHARI
AUTOMATIC
MATERIAL
STORAGE AND
RETRIEVAL
SYSTEM USING
PLC AND SCADA
IJCIR,2017
PROXIMITY SENSOR
DETECTS AN NEARBY
OBJECT WITHOUT ANY
PHYSICAL CONTACT.
ROLF DORNBERGER
THOMAS HAME
REMO RYTER
MICHAEL STAUFFER
OPTIMIZATION
OF THE PICKING
SEQUENCE OF
AN AUTOMATED
STORAGE AND
RETRIEVAL
SYSTEM(ASRS)
IEEE,2014
FIFO(FIRST IN FIRST
OUT) CONCEPT IS USED
FOR PICKING THE
REAM.

7. EXISTING SYSTEM
• The ream are handled by human effort.
• Time consumption is more.
• Production is less.
• Accuracy of detection is less.
• Operation speed is slow.
• Palletizing is done manually.

8. PROPOSED SYSTEM
• Simulation is done by using WPLSOFT 2.41
• The system eliminates manual handling and it is controlled by
PLC with automation and manual control.
• If one PLC fails, the another PLC connected in the same
network will retake the process without causing any
interruption or malfunction.
OVERCOMES
• Reduces the human effort.
• Production time can be improved.
• Improves the accuracy of the system.

9. BLOCK DIAGRAM

10. LAYOUT

11. COMPONENTS USED
• PLC(Programmable Logic Controller)
• Conveyors
• Hydraulic pusher
• Proximity sensor
• Stack crane
• Storage and Retrieval

12. PLC
•Programmable Logic
Controller
•It is a digital
computer used for
automation control in
industries.

13. CONVEYORS
•It is used to move the
materials or to locate in
some places.
•Here we use Roller
conveyors.
•Gear motors with
contactor control for one
direction of conveyor
movement.
•Conveyor movement
speed:0.30 m.
• Roller conveyors

14. HYDRAULIC PUSHER
• It is used to push the materials.
• After it get signal from the proximity
sensor, it pushes the bundle to the
conveyor.

15. PROXIMITY SENSOR
•It is used to sense the nearby
objects without any physical
contact.
•It has high reliability and
long functional life because
of the lack of physical
contact.

16. STACK CRANE
● It is used to store and retrieve the
materials from the location.
● It is a tri functional axis that moves in
X Y and Z axis to move the material
from the input conveyor to the desired
location.
● Stack crane speed:1500 rpm.

17. DELTA PLC
● Delta plc is used for simulation in our
project.
● It offers high speed,stable and highly
reliable applications.
● It gives fast logic operation.

18. DELTA WPLSOFT 2.41
● This software is used to design the
Ladder logic for PLC.
● Ladder logic program is loaded into
the PLC using RS-232 cable.
● This software is a program editor of
delta DVP series PLC for windows
computers.

19. PROGRAMMING METHODS OF PLC
● Ladder logic
● Functional block diagrams.
● Structure text.
● Instruction list.
● Sequential functional chart.

20. SIMULATION

21. SIMULATION

22. SIMULATION

23. SIMULATION

24. SOFTWARE REQUIREMENT
• Programming language - Ladder logic program
• Simulation - WPL SOFT 2.41

25. WORK PLAN
WITHIN DATE WORK ASSIGN
09.01.2018 Literature survey
09.02.2018 Layout
07.03.2018 Simulation output
28.03.2018 Demonstration
11.04.2018 Correction

26. REFERENCES
1) F. T. Chan and H. Chan, “Improving the productivity of order
picking of a manual-pick and multi-level rack distribution warehouse
through the implementation of class-based storage,” Expert Systems
with Applications, vol. 38, no. 3, pp. 2686–2700, Mar. 2011.
2) R. Dornberger, T. Hanne, and L. Frey, “The way to an open-source
software for automated optimization and learningOpenOpal,” In 2010
IEEE Congress on Evolutionary Computation (CEC), (pp. 1-8). IEEE,
2010
3) B.Padmanabhan, "Advanced Technology of Automated Storage and
Retrieval System Using PLC Integration", International Journal of
Engineering Trends and Technology (IJETT) – Volume 9 Number 9
Mar 2014.
4) H . karnataka, "PLC controlled low cost automatic packing",
International Journal of advanced mechanical engineering, vol . 4, no .7,
PP.803-811,2014.