PLC BASED AUTOMATION PROJECT Plc based inspection, packaging, storage and retrieval application

1. A
PROJECT REPORT
ON
PLC BASED INSPECTION, PACKAGING, STORAGE AND
RETRIEVAL APPLICATION
In partial fulfillment of requirements for the
Degree of Engineering
In
I&C Engineering
Submitted By: - Under the Guidance of:-
Mehul girnari(100200117079) Mr. V.C. RAJYAGURU
Nileshparmar(100200117081)
Maheshshrimali (110203117027)
DEPARTMENT OF INSTRUMENTATION & CONTROL ENGINEERING
GOVERNMENT ENGINEERING COLLEGE
RAJKOT

2. GOVERNMENT ENGINEERING COLLEGE,
RAJKOT
CERTIFICATE
This is to certify that the project entitled “PLC Based Inspection,
Packaging, Storage and Retrieval Application” has been carried out by the
team under my guidance in partial fulfillment of the Degree engineering
in I&C in GTU during the acadmic year 2013(semester 7).
Team:
Mehul girnari (100200117079)
Nilesh parmar (100200117081)
Mahesh shrimali (110203117027)
Date: Signature of the faculty

3. DECLARATION
titled “PLC Based Inspection, Packaging, Storage and
Retrieval We hereby certify the work which is being
presented in project report Application”, is our own work
conducted underthe guidance of Mr. Vipul Rajyguru
(Asst. Professor) Instrumentation & Control Department
of , Government engineering college, Rajkot, Gujarat,
India, We further declare that to the best of our
knowledge, the Project Report for B.E. does not contain
any part of work, which has been submitted for the award
of any degree either in this or any otherUniversity
without properexcitation.
Mehul Girnari Nilesh Parmar Mahesh Shrimali
100200117079 100200117081 110207117027
DATE:-
PALACE:-

4. ABSTRACT
Our system comprises of Inspection, Packing and Automated
Storage and Retrieval of any manufactured component.
Whenever a company manufactures components, they can
substitute our system in place of their quality assurance system,
their packaging system and warehousing system. Using our
application process time and accuracy can be optimized due to
minimum human interaction
Our system may have higher initial cost, but its advantages are
far more beneficial.
Packing that is sound, in line with the warehouse layout, which
also optimizes the utilization of space available and lowers the
freight cost. Minimization of manpower requirements leads to
reduced cost per package.
Our system examines the manufactured component as per
specifications, sorts out the ineligible components, then it packs
them in the shipping box and at last it employs the automated
warehousing system to store and hold the packed box until its
dispatch.
The entire system is controlled by Graphic Operator panel And
Programmable Logic Controller (OPLC) for monotonous tasks.
Our system helps you to understand the whole working of a real
system which is currently employed in the industry.

5. TABLE OF CONTENTS
Chapter No Description Page No
1 Project Introduction… 19-22
2 Mechanical Structure… 23-30
2.1 Conveyor Structure…. 23
2.2 Rejection Assembly… 25
2.3 Elevator Structure… 25
2.4 Pick and Place Assembly… 28
2.5 Storage Rack… 29
2.6
2.7
System Block Diagram
Process Diagram
30
3 Instrumentation Devices… 31-48
3.1 PLC… 31
3.2 Proximity Sensors… 40
3.3 Relay Cards… 42
3.4 DC Motors… 43
3.5 DC Power Supply… 44
3.7 Single Phase MCB… 46
3.8
3.9
Push Buttons & Indicators…
SCADA Software (Intouch wondarware)
47
48
4 Reference
B

6. 1 PROJECT INTRODUCTION
PLC BASED INSPECTION, PACKAGING, STORAGE AND
RETRIEVAL APPLICATION
Our System comprises a miniature model of process of
reception, put-away, storage, retrieval, packaging, shipment
preparation, replenishment, inventory counting, QA with
Sorting.
Our system is distributed in several sections:
A. Inspection of Manufactured Product-
B. Packaging of inspection passed Products
C. Automated Storage of Filled Boxes
D. Automated Retrieval of Stored Boxes as per Order
Processing
The term inspection can be defined as the activity of
examining the products, its components, sub-assemblies, or materials out
of which it is made, and to determine whether they follow to design
specifications. Inspection has become an essential part of any
manufacturing system. It is the means of rejecting nonconformities and
assuring good quality products. Steps of inspection include Presentation

7. of item, Examination for non-conforming features, Decision based on
evaluation and Action depending on Decision (accept or reject item)
What is Automated Inspection and Packaging of Product?
Automated inspection is defined as the automation of one or more steps
involved in the inspection procedure. Completely automated inspection
system in which steps of presentation, examination, decisions and action
are performed automatically. Automated system operates with high
accuracy for simple inspection tasks such as automatic gauging of a
simple dimension on a part. With the increase in complexity of
inspection, the error rate tends to decreases, compared to manual
inspection. The process of automated packaging of inspection passed
item is also an advantage. For safety of item during shipping and
handling certain standards have to be followed.
What is Automated Storage and Retrieval System?
Automated Warehousing is based on Automatic Storage and Retrieval
Systems (AS/RS), automated robotic systems for storing and retrieving
items in a warehouse. Solutions are tailored for industry purposes such
as production storage, cold or deep-freeze storage, distribution centers.
Modern warehouse system design offers infinite innovative possibilities.
The main taken into consideration are product type, product diversity,
number of articles.

8. Advantages:-
nd retrieved day
and/ hour)
-time between order and delivery
.
Applications of Our Project: -
Industrial Spare Parts Manufacturing
Retail & Apparel
Electronics
Entertainment
Publishing
Pharmaceutical & Bio-Medical
Food and Beverage
Automotive

9. Our project is comprises of following:
Mechanical Structure: -
Instrumentation Devices: -
- DELTA
- 13
-:2
-: 2
-12 V DC Power Supply
y Switch, Indicators,

10. 2 Mechanical Structure
2.1 Conveyor Structure: -
It consists of conveyor belt placed on to the platform & will be rotated
on rollers by 12V DC motor. The product which is manufactured will be
placed on to the conveyor platform for transportation and then it will
undergo inspection counting and packing. The conveyor platform is the
essential part of any process.
Structure Dimensions: - 1200mm * 125mm * 350mm
Belt Dimension: 2100mm *80mm*1mm
Fig.2.1

11. Fig.2.2 Conveyer Bearing Fig. 2.3 Conveyer Pulley
Fig. 2.4 Conveyer Belt

12. 2.2 Rejection Assembly: -
It performs on-line/post-process inspection. It consists of Rejection
Mechanism with 5V DC Motor and Two Proximity Sensors for Hole
Inspection of the Metal Article. The motor in Rejection Mechanism
converts rotational movement in Prismatic Movement for Rejection
Arm. It will reject the article if it does not fulfill design specification of
the product
2.3 Elevator Structure: -
It has belt and pulley type arrangement for space constrained
area. For proper alignment of vertical movement of elevator we have
used two polished metal guides. By using this type of arrangement, we
can avail the Automated Storage and Retrieval of packed boxes from
Storage Racks. We have employed a 12V DC Geared motor for the
vertical to and fro of elevator. We also have equipped the elevator with 5
inductive proximity Sensors for accurate placement of boxes on the
Storage Rack. After lifting up the object from upper to bottom side, the
elevator left the object on railing platform. For the safety we have placed
a N.O. contact type Limit Switch on the top of elevator structure. That

13. limit switch will actuate an alarm in for of audible as well as visible
signal.
Fig.2.6 Elevator Structure

14. Elevator Structure Components:
Fig.2.7 C-Steel Channel Fig. 2.8 Timing Pulley
Fig. 2.9 Timing Belt

15. 2.4 Pick and Place Assembly:-
It is a Prismatic Arm which places the boxes on the Storage Rack and
also picks them up from Storage Rack and places them in the Dispatch
Bay. It comprises of 5V DC motor, which is geared for accurate
movement of the arm.
Fig.2.10 Pick and Place Assembly
2.5 Storage Rack:-
It is the Storage Bay for packed boxes of manufactured articles until
they are dispatched for shipping and handling to the customer. It has 4
different levels, first 3 levels are for storage and 4th level is for dispatch.
We have equipped 4 inductive proximity sensors on all four levels for
current availability of empty space.

16. Fig.2.11 Storage and Retrieval

17. Block Diagram:
Fig.2.12

18. Process Diagarm:
Our project is combine approach of three different kind of
operation:
1. Inspection
2. Transportation
3. Storage and retrieval (main part of our project)
1. Inspection :
 Inspection is one of the most important operations in this
project.
 Inspection is the process in which faulty/damaged product
can be identified and rejected with the help of several
mechanisms to prevent hazards that will occurs due to use of
undesired product.
In this project we can do inspection of product by two
Proximity sensor
1. Inductive type proximity
 To check whether the product is completely
made of metal or not

19. A B A B
0 0 (Initial) 0 0
1 0 1 0
0 1 (product pass) 1 1(product rejected)
0 0 0 0
2. Transportation :
 From the load cell if the product weight is in desired
weight range than it will be pushed on the conveyor belt.
 The conveyor belt is rotated with the use of 12v DC motor
of 30rpm.
 Conveyor system transport product from a product arrival
system to the container into which product is packaged.
InspectionTotal count
Passcount
Rejectionarm
Container

20. 3. Storage and retrieval system :
 Containers filled with predetermine value of products, after
then stacker lift move to the storage location.
 Storage area will be constructed in the form of matrix or
linear position.

21. 3 Instrumentation Devices
3.1.1 Introduction PLC
RS 232/ RS 485 serial ports Used for:
Application
Download/Upload
Application Testing
(Debug)
I/O expansion port Up to 128 additional I/Os,
including digital & analog
I/Os, RTD and more
Graphic display
Graphic display STN, LCD display
Illumination backlight LED Yellow Green
Display resolution 128x64 pixels
Miscellaneous
Clock (RTC) Real-time clock functions
(Date and time).
Battery back-up 7 years typical battery
back-up for RTC and
system data.
Battery Coin type, 3V lithium
battery,
Weight 270 g
Operational temperature
Storage temperature
0 to 50°C (32 to 122°F)
-20 to 60°C (-4 to 140°F)
Relative Humidity (RH) 5% to 95% (non-
condensing)
Mounting method DIN-rail mounted
Panel mounted
Keypad

22. Keypad Sealed membrane
Number of keys 16
Program
Timers 192
Counters 24
Data Tables 120K (RAM) / 64K
(FLASH)
HMI displays Up to 255
Execution time 0.8μs for bit operations
Diagram Pin Number RS232: Function
1 DTR signal
2 0V reference
3 TxD signal
4 RxD signal
5 0V reference
6 DSR signal
4.2 Proximity Sensors

23. Proximity sensors are entirely solid state electronic controls that contain
no moving parts to wear out as do mechanical Switches. They
necessitate no physical contact for actuation, no cams or linkages, have
no contacts to bounce or arc and are fully encapsulated.
Inductive Proximity Sensor:
Two, three, or four-wire proximity sensors contain a transistor
oscillator and a snap-action amplifier. This provides exceedingly high
accuracy to a set switching point, even with very slowly approaching
targets.
The sensors can drive electromechanical relays, counters, solenoids,
or electronic modules, and interface directly with logic systems or
programmable controllers without additional interface circuitry.
They are available with either NPN output transistors (current
sinking) or PNP output transistors (current sourcing).
PRINCIPLE
Fig. 4.6 Inductive Proximity Sensor Principle

24. Fig. 4.7 Proximity Sensor Output -PNP
Fig. 4.8 Proximity Sensor Circuit
for behind the elevator structure and 5 for storage and retrieval platform.
will be generate a signal proportionally so object will be stopped.

25. Fig. 4.9 Inductive Proximity Sensor Specification
Two wire Three wire
Supply voltage
24V DC 24V DC
Range
8 mm 6 mm
LED Indication Color
Yellow Green
Proxy Diameter
16 mm 14 mm

26. 4.3 Relay Cards
In this project, we have taken 7 outputs through this relay cards & outputs will be
taken from NO/NC logic.
Purpose
ladder program.
ection from clockwise to anti clockwise and vice versa.
Fig.4.10 Relay Card
Features:
.7 mA to 100 mA)

27. 4.4 DC Motors
Here we have used 4 DC Motors.
- Elevator Structure - Conveyer Structure
Fig.4.11 12V DC Motor
Specifications:
- Rejection Structure
- Pick and Place Assembly

28. 4.5 DC Power Supply
5- 24V Power Supply: it is used to convert the single phase 230V AC into
24V DC and provide it to PLC, Relay Cards, all proximity sensors, and limit
switch.
2. 5-24V DC Power Supply: It is used to convert the single phase 230V AC into
5-24V DC and provide it to DC Motor.
Fig.4.14 5/12V DC Power Supply
Specifications:

29. 4.7 Single Phase MCB
Functions:
-circuit currents

30. 4.8 Push Buttons & Indicators
In this project, we have been used 2 push buttons for start & stop purposes & also
it contains their each indicator with it.
Start Push Button: - Normally NO
Stop Push Button: - Normally NC
Supply: - 24V DC
Fig. 4.17 Push Buttons & Indicators