Final year project report on material inspection and sorting conveyor

4. v
TABLE OF
CONTENTS
CHAPTER TITLE PAGE
NO NO.
iii
iv
viii
ix
1
ACKNOWLEDGEMENT
ABSTRACT
LIST OF TABLES
LIST OF FIGURES
INRODUCTION 1
1.1 INTRODUCTION 1
1.2 OBJECTIVE OF THE PROJECT 1
1.3 PROJECT SCOPE 1
1.4 ORGANIZATION OF PROJECT WORK 1
1.5 ORGANIZATION OF CHAPTERS 2
1.6 CONCLUSION 3
2 LITERATURE REVIEW 4
2.1 INTRODUCTION 4
2.2 MATERIAL HANDLING 4
2.3
MAJOR EQUIPMENTS IN MATERIAL
HANDLING 5
2.4 CONVEYOR SYSTEMS 6
2.4.1
Pneumatic systems for material
inspection 10

5. vi
2.5 CONCLUSION 11
3. DESIGN CALCULATIONS 12
3.1. INTRODUCTION 12
3.2. REQUIRED CALCULATIONS 12
3.3. CONCLUSION 22
4. ASSEMBLY AND PART DRAWINGS 23
4.1. INTRODUCTION 23
4.2. 2D DIAGRAM 23
4.3. PART DIAGRAMS 24
4.4. ASSEMBLY DRAWING 29
4.4 CONCLUSION 30
5. SYSTEM DESIGN 31
5.1. INTRODUCTION 31
5.2. MODEL OF THE SETUP 31
5.3. CONCLUSION 34
6. PROCESS SHEET 35
6.1. INTRODUCTION 35
6.2. COMPONENT SPECIFICATIONS 35

6. vii
6.2.1 Project Specification 35
6.2.2 Components of Pneumatic system 36
6.2.3 PLC Specification 38
6.2.4 Programming Logic Controller 39
6.3 PROCESS FLOW CHART 40
6.4 CONCLUSION 41
7 PLC PROGRAMMING 42
7.1 INTRODUCTION 42
7.2 PLC PROGRAMMING 42
7.3 LADDER LOGIC DIAGRAM 43
7.4 CONCLUSION 44
8 COST OF THE PROJECT 45
8.1 INTRODUCTION 45
8.2 COST TABLE 45
8.3 CONCLUSION 46
9 FABRICATION OF THE PROJECT 47
9.1 INTRODUCTION 47
9.2 FABRICATION PHOTOS 47
9.3 CONCLUSION 50
10 CONCLUSION 51
10.1 INTRODUCTION 51

7. 10.2 CONCLUSION 51
REFERENCES 52
APPENDIX 54

8. viii
LIST OF TABLES
TABLE TITLE PAGE
NO. NO.
6.1 Component specification 35
6.2 PLC specification 38
8.1 Cost estimation 45

9. ix
LIST OF FIGURES
FIGURE TITLE PAGE NO.
NO.
1.1 2
3.1 17
3.2 18
3.3 20
4.2.1 23
4.3.1 24
4.3.2 25
4.3.3 26
4.3.4 27
4.3.4 28
4.4.1 29
4.5 30
5.2.1 31
5.2.2 32
6.1 40
7.3 44
9.2.1
Organization of chapters
Bending moment of beam 1
and 2
Bending moment of beams 3
and 4
Bending moment of beams 5
and 6
2D Diagram
Bearing
Pneumatic cylinder
Supporting Column
Roller
Conveyor belt
Assembly view
3D View
Circuit Diagram
Working model of PLC
Process flowchart
Ladder logic diagram
Conveyor model 47

10. 9.2.2 Conveyor model 48
9.2.3 Conveyor model 49
9.2.4 Conveyor model 49

11. ACKNOWLEDGEMENT
At this juncture, we take the opportunity to convey our sincere thanks
and gratitude to the management of the college for providing all the facilities
to us.

12. ABSTRACT
In this project “Material Inspection and Sorting Conveyor", instead of
using manual inspection here we are introducing the automatic system by
using the pneumatic comparators. The sensors are used to measure the
material dimensions and this signal is given to control Unit. The control unit
gives the appropriate signal to the pneumatic cylinder.
In this type of conveyor sensors are used to measure the dimensions of
parts placed over it and a pneumatic cylinder is placed next to the sensor
which will remove the detective parts.By using this system,we completly
eliminate manual work and reduce inspection time and also increase
production rate.

13. 1
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Material Inspection and Sorting Conveyor uses automatic inspection
instead of the manual system by using the pneumatic comparators. The
sensors are used to measure the material dimensions and this signal is given to
control Unit. The control unit gives the appropriate signal to the pneumatic
cylinder.
1.2 OBJECTIVES OF THE PROJECT
To design and fabricate the material inspection and sorting conveyor
which is capable of inspecting components without human intervention with
the help of pneumatic systems.
1.3 PROJECT SCOPE
Basically ,this project is to achieve the objective.
1.Focus on implementing automation in industrial field.
2.Focus on reducing labours.
3.Focus on making low cost machine for material inspection.
1.4 ORGANIZATION OF PROJECT WORK
This project work is compiled in 7 chapters. The organization of the
chapter is explained in the figure 1.1, Chapter 1 introduces the objective, the
organization and the flow of process in which the project work is executed.
Chapter 2 consists of literature review. Chapter 3 consists of assembly
drawing and part diagrams of the component used and working principle.
Chapter 4 explains the process of the component used and working principle.
Chapter 5 explains the commissioning and Chapter 6 explains the cost
estimation followed by the conclusion and reference.

14. 2
1.5 ORGANISATION OF CHAPTERS
!
Fig 1.1 Organisation of chapters

15. 3
1.6 CONCLUSION
The objective of this project work and the problem statement have
been framed for the “Design and fabrication of automated material inspection
and sorting conveyor” has been organized. Thus, the work from scratch to the
completion of the project is explained in the further chapters.

16. 4
CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Before starting this project, it is important to research existing
machines and the technologies used in them. This will help us understand any
existing problems and try to find solutions for these problems in such a way
that it can be implemented in our project. Going through the literature also
helps us understand the practical outcomes of the project and how to attain the
required outcomes.
2.2 MATERIAL HANDLING
In the process or manufacturing industry, raw materials need to be
transported from one manufacturing stage to another. Material handling
equipment are designed such that they facilitate easy, cheap, fast and safe
loading and unloading with least human interference. For instance, belt
conveyor system can be employed for easy handling of materials beyond
human capacity in terms of weight and height.
Different methods such as fork lifting, use of bucket elevators,
conveyors systems, crane, etc. has been identified for lifting or transporting
bulk materials or products from one place to anothern the manufacturing
industries depending on the speed of handling, height of transportation,
nature, quantity, size and weight of materials to be transported.It is easier,
safer, faster, more efficient and cheaper to transport materials from one
processing stage to another with the aid of material handling equipment
devoid of manual handling.
Handling of materials which is an important factor in manufacturing
is an integral part of facilities design and the efficiency of material handling
equipment add to the performance level of a firm. Conveyor systems are
durable and reliable in materials transportation and warehousing. Based on

17. 5
different principles of operation, there are different conveyor systems namely
gravity, belt, screw, bucket, vibrating, pneumatic/hydraulic, chain, spiral,
grain conveyor systems, etc. The choice however depends on the volume to be
transported, speed of transportation, size and weight of materials to be
transported, height or distance of transportation, nature of material, method of
production employed. Material handling equipment ranges from those that are
operated manually to semi- automatic systems. [1]
Material handling involves movement of material in a
manufacturing section. It includes loading, moving and unloading of materials
from one stage of manufacturing process to another. A belt conveyor consists
of an endless and flexible belt of high strength with two end pulleys (driver
and driven) at fixed positions supported by rollers.Pulleys are used for
providing the drive to the belt through a drive unit gear box powered by an
electric motor. It also helps in maintaining the proper tension to the belt. The
drive imparts power to one or more pulleys to move the belt and its loads.
Materials are transported over the required distance as a result of
friction generated between the roller surface and the moving belt set in motion
by a rotating pulley (drive pulley). The other pulley (driven or idler pulley)
acts as a wheel around which the material rotates and returns in a continuous
process. Continuous processes are characterized by non-stop motion of bulk
or unit loads along a path without halt for loading and unloading.
2.3 MAJOR EQUIPMENTS IN MATERIAL HANDLING
Transport Equipment is an equipment used to move material from
one location to another (e.g., between workplaces, between a loading dock
and a storage area, etc.). The major subcategories of transport equipment are
conveyors, cranes, and industrial trucks. Material can also be transported
manually using no equipment.
Positioning Equipment is used to handle material at a single

18. 6
location (e.g., to feed and/or manipulate materials so that are in the correct
position for subsequent handling, machining, transport, or storage). Unlike
transport equipment, positioning equipment is usually used for handling at a
single workplace. Material can also be positioned manually using no
equipment.
Unit Load Formation Equipment is used to restrict materials so that
they maintain their integrity when handled a single load during transport and
for storage. If materials are self-restraining (e.g., a single part or interlocking
parts), then they can be formed into a unit load with no equipment.[2]
Storage Equipment is used for holding or buffering materials over
a period of time. Some storage equipment may include the transport of
materials (e.g., the S/R machines of an AS/RS, or storage carousels). If
materials are block stacked directly on the floor, then no storage equipment is
required.
2.4 CONVEYOR SYSTEMS
Conveyor systems have been used for decades to transport bulk and
unit loads.They have proved their worth everywhere because belt conveyor
installations can be adapted to meet nearly all local conditions.They are work
safe and essential.
The demand for ever increasing capacities and ever longer
conveying lengthshas accelerated the development of the belt conveyor
technique, new materials are being developed, new conveying systems are
being planned and tested especially those having regard to the environment.
A conveyor system is a common piece of mechanical handling
equipment that moves materials from one location to another. Conveyors are
especially useful in applications involving the transportation of heavy or
bulky materials. Conveyor systems allow quick and efficient transportation
for a wide variety of materials, which make them very popular in the material
handling and packaging industries.
They also have popular consumer applications, as they are often

19. 7
found in supermarkets and airports, constituting the final leg of item/ bag
delivery to customers. Many kinds of conveying systems are available and are
used according to the various needs of different industries. There are chain
conveyors (floor and overhead) as well. Chain conveyors consist of enclosed
tracks, I-Beam, towline, power & free, and hand pushed trolleys.
Conveyor systems are commonly used in many industries, including
the Mining, automotive, agricultural, computer, electronic, food processing,
aerospace, pharmaceutical, chemical, bottling and canning, print finishing and
packaging. Although a wide variety of materials can be conveyed, some of the
most common include food items such as beans and nuts, bottles and cans,
automotive components, scrap metal, pills and powders, wood and furniture
and grain and animal feed. [3]
Many factors are important in the accurate selection of a conveyor
system. It is important to know how the conveyor system will be used
beforehand. Some individual areas that are helpful to consider are the required
conveyor operations, such as transportation, accumulation and sorting, the
material sizes, weights and shapes and where the loading and pickup points
need to be.
A conveyor system that is designed properly will last a long time
with proper maintenance. Here are six of the biggest problems to watch for in
overhead type conveyor systems including I-beam monorails, enclosed track
conveyors and power and free conveyors. Overhead conveyor systems have
been used in numerous applications from shop displays, assembly lines to
paint finishing plants and more.
Poor take-up adjustment: this is a simple adjustment on most
systems yet it is often overlooked. The chain take-up device ensures that the
chain is pulled tight as it leaves the drive unit. As wear occurs and the chain
lengthens, the take-up extends under the force of its springs. As they extend,
the spring force becomes less and the take-up has less effect. Simply
compress the take-up springs and your problem goes away. Failure to do this

20. 8
can result in chain surging, jamming, and extreme wear on the track and
chain. Take-up adjustment is also important for any conveyor using belts as a
means to power rollers, or belts themselves being the mover. With poor-take
up on belt-driven rollers, the belt may twist into the drive unit and cause
damage, or at the least a noticeable decrease or complete loss of performance
may occur. In the case of belt conveyors, a poor take-up may cause drive unit
damage or may let the belt slip off of the side of the chassis.Lack of
lubrication: chain bearings require lubrication in order to reduce friction. The
chain pull that the drive experiences can double if the bearings are not
lubricated. This can cause the system to overload by either its mechanical or
electrical overload protection. On conveyors that go through hot ovens,
lubricators can be left on constantly or set to turn on every few cycles.
Contamination like paint, powder, acid or alkaline fluids, abrasives,
glass bead, steel shot, etc. can all lead to rapid deterioration of track and
chain. Ask any bearing company about the leading cause of bearing failure
and they will point to contamination. Once a foreign substance lands on the
raceway of a bearing or on the track, pitting of the surface will occur, and
once the surface is compromised, wear will accelerate. Building shrouds
around your conveyors can help prevent the ingress of contaminants. Or,
pressurize the contained area using a simple fan and duct arrangement.
Contamination can also apply to belts (causing slippage, or in the case of
some materials premature wear), and of the motors themselves. Since the
motors can generate a considerable amount of heat, keeping the surface clean
is an almost-free maintenance procedure that can keep heat from getting
trapped by dust and grime, which may lead to motor burnout.
Product handling in conveyor systems that may be suited for a wide
variety of products, such as those in distribution centers, it is important that
each new product be deemed acceptable for conveying before being run
through the materials handling equipment. Boxes that are too small, too large,
too heavy, too light, or too awkwardly shaped may not convey, or may cause

21. 9
many problems including jams, excess wear on conveying equipment, motor
overloads, belt breakage, or other damage, and may also consume extra man-
hours in terms of picking up cases that slipped between rollers, or damaged
product that was not meant for materials handling. If a product such as this
manages to make it through most of the system, the sortation system will most
likely be the affected, causing jams and failing to properly place items where
they are assigned. It should also be noted that any and all cartons handled on
any conveyor should be in good shape or spills, jams, downtime, and possible
accidents and injuries may result.
Drive train, notwithstanding the above, involving take-up
adjustment, other parts of the drive train should be kept in proper shape.
Broken O-rings on a Lineshaft, pneumatic parts in disrepair, and motor
reducers should also be inspected. Loss of power to even one or a few rollers
on a conveyor can mean the difference between effective and timely delivery,
and repetitive nuances that can continually cost downtime.
Bad belt tracking or timing in a system that uses precisely controlled
belts, such as a sorter system, regular inspections should be made that all belts
are traveling at the proper speeds at all times. While usually a computer
controls this with Pulse Position Indicators, any belt not controlled must be
monitored to ensure accuracy and reduce the likelihood of problems. Timing
is also important for any equipment that is instructed to precisely meter out
items, such as a merge where one box pulls from all lines at one time. If one
were to be mistimed, product would collide and disrupt operation.
Timing is also important wherever a conveyor must "keep track" of
where a box is, or improper operation will result.Since a conveyor system is a
critical link in a company's ability to move its products in a timely fashion,
any disruption of its operation can be costly. Most downtime can be avoided
by taking steps to ensure a system operates at peak performance, including
regular inspections, close monitoring of motors and reducers, keeping key
parts in stock, and proper training of personnel.

22. 10
2.4.1 PNEUMATIC SYSTEMS FOR MATERIAL INSPECTION
Pneumatic systems form the most primitive and distinct class of
mechanical control engineering. They are classified under the term 'Fluid
Power Control', which describes any process or device that converts,
transmits, distributes or controls power through the use of pressurized gas or
liquid. In a pneumatic system, the working fluid is a gas (mostly air) which is
compressed above atmospheric pressure to impart pressure energy to the
molecules. This stored pressure potential is converted to a suitable mechanical
work in an appropriate controlled sequence using control valves and actuators.
Pneumatic systems are well suited for the automation of a simple repetitive
task. The working fluid is abundant in nature and hence the running and
maintenance cost of these systems are exceptionally low. All fluids have the
ability to translate and transfigure and hence pneumatic systems permit
variety of power conversion with minimal mechanical hardware.
The technology of pneumatics deals with study of behavior and
application of compressed air. Today air operated tools and accessories are a
common sight in each every industry, not only in the technologically
advanced countries but even in countries where industrial activities are still at
the stage of sheer infancy. With introduction of pneumatics in the
manufacturing process, the industry is benefited automation which if
judiciously used; many bring down the cost of production to a much lower
level. Nowadays compressed air is used in every walk of industrial life,
starting with pneumatic cranes to the use of air in the brake system of
automobiles, railways coaches, wagons, printing presses, and what not. The
following features are notable for the reason
•Wide availability of air
•Compressibility of air
• Easy transportability of compressed air in pressure vessels
• Fire proof characteristics of the medium

23. 11
• Simple construction of pneumatics elements and easy handling
•High degree of controllability of pressure, speed and force.
•Possibility of easy but reasonably reliable remote controlling
•Easier maintenance
•Explosion proof characteristics of the medium
•Comparatively cheaper in cost than other system.
2.5 CONCLUSION
Thus, research was done regarding this project on various sources of
literature. The many methodologies were studied and this information has
helped to complete the project successfully.

24. 12
CHAPTER 3
DESIGN CALCULATIONS
3.1 INTRODUCTION
This chapter will include the design calculations required for the
automated material inspection and sorting conveyor.
3.2 REQUIRED CALCULATIONS:
WEIGHT:
Mechanical Components:
Roller weight = 850g
Belt weight = 500g
Conveyor platform = 2kg
Supporting columns=1.5kg
Pneumatic cylinder =1kg
Total weight of the mechanical components = 5.85kg
Electrical and electronic components:
Motor weight = 250g
Servo valve = 150g
Servo motor =100g
Regulator unit =150g
Control panel = 650g
Miscellaneous = 200g
Proximity sensor=100g
Weighing sensor=250g
Jam 1,2 =100g
Total weigth of the electrical and electronic components=1.95kg
Total weight of the conveyor= 7.80 kg
Force on the Conveyor = 0.4*9.81
= 3.924 N

25. 13
~ 4 N
Force is maximum when link is in horizontal position
Shaft Diameter of DC motor of above application =12 mm
Radius = 6 mm
Torque required = Force* Radius
= 4*6
= 24 Nmm
= 0.25 kgcm
BELT DIMENSION, CAPACITY AND SPEED:
Belt length is dependent on both the pulley diameters and centre
distances.
V=d×PI(1)
V= Belt speed;
d = diameters of rollers; and
Capacity is the product of speed and belt cross sectional area
Generally, belt capacity (kg/sec) is given as:
B.C = 3.6 × A × 3.14× V
A = belt sectional area (m2);
V = belt speed (m/s) ..(2)
The mass of material Mm (live load) per meter (kg/m) loaded on a belt
conveyor is given as:
Where,
V = belt speed (1.25 m/s).
Mm =0.889 kg.
The magnitude of belt speed V (m/s) can be determined from equations
1, 2, 3 or 6 and can as well be gotten from the catalogue for standard belt.
Belt speed v (m/s) depends
Mm= C/(3.6*v)…(3)
c = Conveyor capacity (4 tones/hr); and

26. 14
V = belt speed (1.25 m/s).
Mm =0.889 kg.
CAPACITY OF THE CONVEYOR:
C = cT*1000*cf*v / 1000…(4)
C = Capacity in tones/hr of a belt conveyor
cT = Capacity of td belts for 3 roll equal le;
cf = Capacity factor (1.08); and
V = Belt speed in m/s (1.25)
= 4 tonnes/hr
ROLLER DIAMETER:
n = (V *1000 *60 )/D*3.14
n = no of revolution per minute;
D = roller diameter (mm); and
V = belt speed (m/s)
From Equation (6), the no of revolution per minute n = 220 rpm
The inclination angle is 100, the conveyor length is 100 m, and the
conveyor height is 10 m.
Belt basic length = 2 × length along conveying route ..(8)
From Equation (8), basic belt length = 2 × 14 = 28 m
The roll diameter for belt is given as,
D = sqrt((d*d)+(0.001273*L*G))
Where,
D = overall diameter (m);
D = core diameter (m);
L = Belt length (m); and
G = Belt Thickness (mm)
The length of a belt on roll is given as:
L = (d+((D-d)/2)*3.14*N)…….(10)

27. 15
Where,
D = outside diameter of the roll (m);
d = diameter of the roll centre (m);
N = no.of.wraps of the belt
BELT POWER AND TENSION:
The power Pp (kW) at drive pulley drum is
Pp = Fu*V /1000
Where,
Fu = Total tangential force at the periphery of the drive pulley (N);
V = Belt speed (1.25 m/sec); and
Fu = Pp*V /1000
Pp = power required for conveyor (kW);
where ,
C = conveyor capacity (4 tones/hr) = (3.9375 kg/sec); and
L = Lift(1.5m)
P = 3.7kW.
Te = Total empty friction + Load friction + load slope tension
= 1.141KN
The belt power (kW) is given as
Pb =Te *V
Te = effective tension (1.141 KN)
V = Belt speed (1.25 m/sec)
Pb = 1.43 kW
σc < σt
Therefore, design is safe.
T = 30 kgcm
= 3 Nm
ρ = (2π*30*3)/260
= 3π

28. 16
= 10 N
“Link material is mild steel”
l = 160 mm
W = 150 g
σc = (0.1)/(16*b)
COLUMN :
Area (A) = (20*20) – (16*16)
= 144 mm2
Length (L) = 240 mm2
= 0.240m
For column both the ends are fixed, so n=4
Critical load (Pc) = (nπ2EI)/(L2)
For mild steel, (E) = 200*109 GPa
Area moment of inertia,I = (a04- ai4)/12
= (204-164)/12
= 7782*10-12 kgcm
Pc = (4*3.142*200*109*7872*10-12)/(0.24)2
Pc = 1077 KN > 26N
Hence design is safe.
l = 250 mm
Area moment of inertia,I = (a14- a24)/12
= (204-164)/12
= 7782 mm4
Sectional area,A = 144 mm2
K1 = √(7872144)
= 7.35
Yield stress,σy/2 = nπ2E/(1/k)2
297/2 = 4*π2*200*1000/(1/k)2
Yield stress of mild steel,σy = 297 Mpa(Design data book)

29. 17
K2 = 0.00433
K1 > K2
So, the screw should be long column.
BENDING MOMENT
Ra = Rb = (5*9.81)/2
= 24.53 N
Mc = Rb*110
= 24.53*110
= 2697.75 Nmm
!
Fig 3.1 Bending Moment of beams 1 and 2

30. 18
RA = RB = 1.23N
Mc = RB*110
= 1.23*110
= 134.89 Nmm
!
Fig 3.2 Bending Moment of beams 3 and 4

31. 19
Weight of Beam 1 = 5.3 Kg
= 51.993 N
~ 52 N
Weight of Beam 2 = 5.3 Kg
= 51.993 N
~ 52 N
Weight of Beam 3 = 0.55 Kg
= 5.395 N
~ 5.4 N
RA + RB = 54.7 N
RA = 54.7 N – RB
MBF = 0
0 = (26*120) – (RB *310) + (26*108) +
(2.7*66) – (RA *26)
26 RA *310 RB = 6760 + 178.2 + 2808
= 9746.2 N
MRB = 0
0 = (26*50) – (26*201) + (2.7*242) – (RA *282)
282 RA = 1300 + 5252 + 653.4
RA = 25.55 N
310 RB = 9081.97 N
RB = 29.29 N

32. 20
!
Fig 3.3 Bending Moment of beams 5 and 6
WELDING CLAMPS :
Area for welding (A) = (50*30) – (40*20)
= 700 mm2
Height of welding = 5 mm
Then Volume of weld (V) = (700*5)/2 = 1750 mm3
Density of alloy carbon steel = 7.86 gm/cm3
Weight of weld steel = v*ρ
= 1750*7.86*103
= 83.16 g
σc = 6*Mb/l*h2
Mb = F*r
= 30*10

33. 21
= 300 Nmm
Length,l = 50 mm
Height,h = 30 mm
σc = 6*300/50*302
= 1.2 N/mm2
σt = 242N/mm2
σc < σt
Therefore, design is safe.
L CLAMP :
Ra = 600*10
= 6000 Nmm2 = 600 kgmm
Area moment of inertia (I) = (b*d3)/12 = (20*103)/12
= 1666.67 mm2
Bending stress,
σ/y = M/I
σ = My/I
= 600*5/1666.67
= 1.8 kg/mm2
For steel yield strength is, 25 kg/mm2 > 1.8 kg/mm2
Hence, design is safe.
For angle from horizontal of 60°
Mass flow % = 25 % ,Sheet metal material is chosen.
σty = 290 N/mm2
σ = 50/32*t
= 29 N/mm2
t = 0.6 to 1 mm
σ = 500/32*8
= 1.95 N/mm2
Critical load,Pcr = (nπ2EI)/(1/K)2
= (4*π2*200*103*144)/(1/7.35)2

34. 22
= 6.136*1010 N
Calculated load,Pcal = 26 N
Pcr > Pcal
Hence, Design is safe.
3.3 CONCLUSION
Thus, the design calculations for the machine were done. These
calculations were done keeping in mind the dimensional restrictions for this
project, along with economic views. The values are well within the limit and
the design is safe and accurate.

35. 23
CHAPTER 4
ASSEMBLY AND PART DRAWINGS
4.1 INTRODUCTION
This chapter consists of assembly drawings and part drawings of the
main components of the automated material inspection and sorting conveyor.
The drawings are designed using Solidworks to generate the 2D and 3D
models of the system and its components.
Based on the design calculations in the previous chapter the
drawings are designed respective of its dimension.
4.2 2D DIAGRAM
Fig 4.2.1 2D Diagram

36. 24
Fig 4.2.1 represents the 2D Dimensional of automated material
inspection and sorting conveyor.
4.3 PART DIAGRAMS
Fig 4.3.1 Bearing
Fig 4.2.1 represents the 2D Dimensional view of bearing used in
automated material inspection and sorting conveyor with the specific
dimensions drawn using Solid works software.

37. 25
Fig 4.3.2 Pneumatic cylinder
Fig 4.3.2 represents the 2D Dimensional view of pneumatic
cylinder used in automated material inspection and sorting conveyor with the
specific dimensions drawn using Solid works software.

38. 26
Fig 4.3.3 Supporting column
Fig 4.3.3 represents the 2D Dimensional view of supporting
column used in automated material inspection and sorting conveyor with the
specific dimensions drawn using Solid works software.

39. 27
Fig 4.3.4 Roller
Fig 4.3.4 represents the 2D Dimensional view of roller used in
automated material inspection and sorting conveyor with the specific
dimensions drawn using Solid works software.

40. 28
Fig 4.3.5 Belt Conveyor
Fig 4.3.3 represents the 2D Dimensional view of belt conveyor
used in automated material inspection and sorting conveyor with the specific
dimensions drawn using Solid works software.

41. 29
4.4 3D SOLID MODEL
Fig 4.4 Assembly View
Fig 4.4 represents the assembly view of automated material
inspection and sorting conveyor with the specific dimensions drawn using
Solid works software.

42. 30
4.5 ASSEMBLY DRAWING
Fig 4.5 Assembly Diagram
4.4 CONCLUSION
Thus the assembly drawings and part drawings of the main
components of the automated material inspection and sorting conveyor were
designed using Solidworks to generate the 2D and 3D models of the system
and its components. Based on the design, the machine is fabricated.

43. 31
CHAPTER 5
SYSTEM DESIGN
5.1 INTRODUCTION
This chapter consists of the complete system architecture of the
electronic components. The system architecture shows the layout of the unit
and the communication cables used for interconnection of various parts of the
system.
5.2 MODEL OF THE SETUP
Fig 5.2.1 Circuit Diagram

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The circuit diagram consists of three units- sensing units,
controlling units, sorting units.The sensing units consists of ultrasonic level
sensor and an inductive proximity sensor.These are the inputs and the
pneumatic valves are the outputs based on the inputs the PLC processes the
input and HMI controls the outputs based on the logic and the pneumatic
valves are been actuated and the sorting mechanism is been carried out. The
entire mechanism can be visualized at the touch screen HMI panel.
Fig 5.2.2 Working module

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A programmable logic controller (PLC) or programmable
controller is a digital computer used for automation of electromechanical
processes, such as control of machinery on factory assembly lines,
amusement rides, or lighting fixtures. PLCs are used in many industries and
machines, such as packaging and semiconductor machines. Unlike general-
purpose computer, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. A very commonly used method of
programming PLC’s is based on the use of ladder diagrams. Writing a
program is the equivalent to drawing a switching circuit. Circuits are
connected as horizontal lines, that is, the rungs of the ladder, between these
two vertical lines. In drawing a ladder diagram, certain conventions are
adopted.
Many types of proximity sensors have been built the simplest
sensors are proximity switches capable of merely detecting the presence or
absence of an object in the sensors proximity. More complex proximity
sensors have the capability of determining continuous three dimensional
positions and other information such as intensity and orientation. Different
proximity sensors employ various media including magnetic field, electric
filed, electric field, air pressure, ultrasonic sound, and light recent advance in
inexpensive electro-optical component also has made optical methods
attractive.

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5.3 CONCLUSION
Thus the system design has been illustrated by providing the
architecture of electronic process of automated material inspection and sorting
conveyor.

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CHAPTER 6
PROCESS SHEET
6.1 INTRODUCTION
The prime motive of the ‘PROCESS SHEET’ chapter is to provide
the fine details about the components being used, their material and quantity
of each component involved in the project. It also illustrates the processing
steps to complete the project.
6.2 COMPONENT SPECIFICATIONS
6.2.1 Project Specification
Table 6.1 Component specification
PARAMETER TYPE
SIEMENS PLC S7-200
Pneumatic systems As required
Sensors Weighing sensors and Proximity
Sensors
Connecting wires As required
Valves Servo valves
DC motor 12 volts

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6.2.2 COMPONENTS OF PNEUMATIC SYSTEM
AIR COMPRESSOR
Though not directly connected to the pneumatic system, the air
compressor plays a vital role in the overall system performance. Various types
of air compressors are used in the industry. But positive displacement
compressors are more popular. The air receiver is important equipment in the
compressor family. For uninterrupted supply of compressed air, receiver with
to optimum size is to be selected.
FRL UNIT
The FRL unit consists of the following separate components, filter,
regulator and lubricator. They are packaged to supply the cleaned lubricated
and regulated air to the actuator.
FILTER
Even very small particle containing in air may be produce wear by
lapping action in the parts. Therefore the air is filtered to remove dirt, rest
particles and other air borne matter in line. The air is filtered before entering
the compressor. However, the passage of the air stream through the distributor
system often contaminates it with oxidation deposits on the sides of the steel
piping.
REGULATOR
Independent pressure control is necessary for air distribution in
pneumat ic circuitry. Pneumatic circuitry uses an outlet side piloted pressure
reducing valve to limit pressure only to desired circuit these specialized
pneumatic pressure reducing valves are known as regulators.

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LUBRICATOR
Pneumatic systems are not self lubricat ing. Pneumatic
components need lubrication for its smooth functioning. Therefore a
lubricator is used in the FRL unit to add a small amount of oil to the dry air.
PNEUMATIC ACTUATORS
Pneumatic cylinders offer a straight rectilinear motion to
mechanical elements. Cylinders are classified as light, medium, heavy duty
with respect to their application. Selection of materials for cylinder depends
greatly on this factor. Functionally cylinders may be single or double acting.
They may be further classified as diaphragm cylinder, duplex cylinder,
through rod cylinder etc. end position cushioning of cylinder as certain times
may be of almost important.
PNEUMATIC VALVES
The pneumatic energy is regulated and controlled by pneumatic
valves. Functionally the valves are divided into four major groups, viz.
directional control, floe control, pressure control, non return and special type
va lves. As pre construction the valves are sub grouped as seat valves sliding
or spool valves. Both these of constructions are frequently used in pneumatic
valves. However the spool valves are easier to manufacture. Valves are
actuated in various methods, viz. manually, mechanically, electrically,
pneumatically and by various combined mode of actuation. Specially
designed valves like quick exhaust time delay shuttle and twin pressure
valves are used to impart various special functions to pneumatic circuits.

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PLC SPECIFICATION
Fig 6.2 Table 6.2 S7-200 CPU specification

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6.2.3 PROGRAMMABLE LOGIC CONTROLLER
A programmable logic controller is a digital computer used for
automation of electromechanical processes. A programmable logic controller
(PLC) or programmable controller is a digital computer used for automation
of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or lighting fixtures. PLCs are used in many
industries and machines, such as packaging and semiconductor machines.
Industrial PLC describes the computing unit of any industrial automation
system and therefore need to meet several challenging requirements such as
high reliability, environmental noise and influence immunity and also
enhanced protection classes (e.g. water-resistant and dust sealed).
PLCs also satisfy the needs of continuous 24 hours/7 days
operation and availability over a wide environmental temperature range as
well as real-time operation capability and security and safety enhancements.
The input/output arrangements may be built into a simple PLC, or the PLC
may have external I/O modules attached to a computer network that plugs into
the PLC. The communications interface is used to receive and transmit data
on communication networks from or to other remote PLCs. [4]
It is concerned with such actions as device verification, data
acquisition, synchronization between user applications and connection
management.Some of the advantages of using PLC include:
• Programming the PLC is easier than wiring the relay control panel
• PLC takes less floor space then relay control panels.
• Maintenance of the PLC is easier, and reliability is greater.
• PLC can be connected to the plant computer systems more easily
than relays.

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6.3 PROCESS FLOWCHART
Fig 6.1 Process flow chart
Switch on the system
Place the materials on the
conveyor
Sensing using PLC and sensors
Inappropriate materials are
pushed to tray
Correct material follows through
the conveyor
Unloading.components

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6.4 CONCLUSION
Thus the process sheet has been illustrated by tabulating all the
process took place during the design of automated material inspection and
sorting conveyor. The tables contains the product specification used at this
level of fabrication.

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CHAPTER 7
PLC PROGRAMMING
7.1 INTRODUCTION
This chapter involves the PLC programming of the material
inspection conveyor by using ladder logic diagram.
7.2 PLC PROGRAMMING
The PLC programming is done by using ladder logic diagram using
ABB control builder plus software.
Ladder logic is widely used to program PLCs, where sequential
control of a process or manufacturing operation is required. Ladder logic is
useful for simple but critical control systems or for reworking old hardwired
relay circuits. As programmable logic controllers became more sophisticated
it has also been used in very complex automation systems. Often the ladder
logic program is used in conjunction with an HMI program operating on a
computer workstation.[5]
Ladder logic can be thought of as a rule-based language rather
than a procedural language. A "rung" in the ladder represents a rule. When
implemented with relays and other electromechanical devices, the various
rules "execute" simultaneously and immediately. When implemented in a
programmable logic controller, the rules are typically executed sequentially
by software, in a continuous loop (scan). By executing the loop fast enough,
typically many times per second, the effect of simultaneous and immediate
execution is achieved, if considering intervals greater than the "scan time"
required to execute all the rungs of the program. Proper use of programmable
controllers requires understanding the limitations of the execution order of
rungs.

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7.3 LADDER LOGIC
Fig 7.3 Ladder logic diagram

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7.4 CONCLUSION
Thus the control of the automated material inspection and sorting
conveyor programming is done using PLC programming.

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CHAPTER 8
COST OF THE PROJECT
8.1 INTRODUCTION
This chapter lists the approximate cost of various components used
in the project.
8.2 COST TABLE
Table 8.1 Cost estimation
Material/material
type
Quantity Cost
1 Roller(mild steel) 5 5600
2 Stand(Iron) 1 3000
3 Pneumatic cylinders 2 6000
4 Servo valve 1 1500
5 Belt 1 4000
6 DC Motor 1 3500
7 Tray(plastic) 3 3000
8 Bearing(roller) 12 18000
9 Air filter unit 1 3500
Total 48100

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8.3 CONCLUSION
Thus the components were chosen with cost as a parameter to
optimize the development of the system.

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CHAPTER 9
FABRICATION OF THE PROJECT
9.1 INTRODUCTION
This chapter lists the fabrication photos taken while doing the
fabrication of material inspection and sorting conveyor.
9.2 FABRICATION PHOTOS
Fig 9.2.1 Conveyor model

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Fig 9.2.2 Conveyor model

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9.3 CONCLUSION
Thus the material inspection and sorting conveyor which is capable
of inspecting components without human intervention was fabricated
successfully.

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CHAPTER 10
CONCLUSION
10.1 INTRODUCTION
Thus the material inspection and sorting conveyor which is capable of inspecting
components without human intervention is designed and fabricated with the help of
pneumatic systems.
10.2 FUTURE SCOPE OF THE PROJECT
By producing such system, the scope is in the field of Manufacturing ,identification
of suitable solution, evaluation processes , design the proposal, to build the
prototype .Also we can use such system with some modification for various types of
inspection such as
• Inspection Parameter
• Diameter, hole diameter
• Height
• Thickness
• Surface defect
• Crack, burr
• Roundness
• Minor and major diameter
• Chamfer angle etc.
10.3 CONCLUSION
The project is successfully completed and tested. All the specified
requirements were fulfilled upon completing the project

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REFERENCES
1. Sambathkumar N. and Siva kumar K,‘‘Design and Fabrication of
Material Inspection Conveyor”,Research paper in International Journal of
Mechanical Engineering and Robotics Research, April 2014
2. Aniket A Jagtap ,“Design of Material Handling Equipment’,Research
paper in International Journal of Mechanical Engineering and Robotics
Research,March 2015
3. Anath K N and Rakesh V, “Design and Selecting Proper Conveyor Belt”,
Int. Journal of Advanced Technology”, Vol. 4, No. 2, pp. 43-49,2015
4. Petruzella, F. D, “Programmable Logic Controllers, McGraw Hill, 2005”.
5. Yang, G., Rasis, Y “Teaching PLC in Automation – A Case Study”, ASEE
Annual Conference &Exposition,June 2005
6.Roberts, A.W., Hayes, J.W. and Scott, 0.J.,"Optimum Design of Continuous
Conveyors". Bulk Solids Handling, Vol. 1, No. 2, 1981.
7. Harrison, A., "Flexural Behaviour of Tensioned Conveyor Belts",
Mech.Eng.Trans. IE (Aust.), Vol. MES (1983), No. 3.
8. Harrison, A. and Roberts, A.W., "Technical Requirements for Operating
Conveyor Belts at High Speed", Bulk Solids Handing, Vol. 4 (1984), No. 1,
pp.99-104.
9. Harrison, A., "Criteria for Minimising Transient Stress in Conveyor Belts",
Mech.Eng.Trans IE(Aust), Vol. ME8 (1983), No. 3, pp. 129-134.
10. Roberts, A.W., Harrison, A. and Hayes, J.W., "Economic Factors Relating
to the Design of Belt Conveyors for Long Distance Transportation of Bulk

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Solids", Int. Jnl. of Bulk Solids Handling, Vol. 5, No. 6, December 1985 (pp.
1 143-1149).

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APPENDIX
Fw = Force due to weight
us = Friction coefficient
ur = Rolling friction coefficient
b = Rolling resistance
W = Load or Weight of machine
P = Force required for movement
b = Distance of contact
Ra,Rb = Reactive forces on beams
Mc = Bending moment
Mt = Torsional moment of shaft
d = Diameter of shaft
σ = Stress of link
σc = Calculated stress
σt = Maximum stress that can be withstand
l = Length of link
Pcr = Crippling load for column
Pcal = Applied load for column
E = Young’s Modulus
I = Area moment of Inertia
A = Area of cross section of column
1/k = Slenderness Ratio
h = Height of welding
ϴ = Angle of inclination

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