This document describes the design of a mechatronics system using a programmable logic controller (PLC) for metrological inspection of clevises. The system uses pneumatic cylinders controlled by a PLC to extend gauges and check the dimensions of clevises placed in a fixture. If the gauges move smoothly through the holes, the dimensions are within specifications. The PLC programming controls the timing of the cylinder extensions and retractions. Experimental results showed the PLC-controlled inspection inspected 2 to 2.15 times more pieces per day than manual inspection, improving inspection efficiency.
The document provides an introduction to functional safety standards ISO 13849 and EN 62061. It discusses the EU Machinery Directive and how compliance with European harmonized standards ensures compliance with the directive. It describes the terminology and standards used in functional safety, including performance levels, safety integrity levels, and design categories. It also discusses how to select the appropriate standard, assess risk, design safety functions, and validate safety control system designs.
This document presents a method for automatically tuning PID controllers using particle swarm optimization (PSO) algorithm. It describes PID controllers and common tuning methods like Ziegler-Nichols. It then provides an overview of PSO algorithm and how it can be applied to optimize PID parameters to minimize a performance index for a DC motor model. Simulation results show the PSO-tuned PID controller provides improved rise time, settling time and overshoot compared to Ziegler-Nichols tuning.
IRJET- Trouble Shooting of Rotary Equipments using Vibration AnaysisIRJET Journal
This document discusses vibration analysis as a technique for troubleshooting and predicting failures in rotary equipment. It begins with an introduction to predictive maintenance using condition monitoring tools like vibration analysis. Next, it covers causes of vibration in rotating machines, vibration measurement and analysis methods, and the instruments used. Key points made include that vibration analysis can identify specific machine faults from vibration signatures, and that periodic vibration monitoring allows problems to be detected early before failures occur. The goals of a vibration analysis program are to minimize downtime and maintenance costs in industrial operations.
IRJET- Soldier Security using GCRT Devices in Truculent SituationIRJET Journal
This document summarizes a system for soldier security tracking using biomedical sensors and GPS in dangerous situations. The proposed system monitors a soldier's health using sensors to measure heartbeat, temperature and location via GPS. It then transmits this health and location data to a base station using GSM communication. The system aims to improve soldier safety and security by allowing remote health monitoring and tracking in critical situations like warfare. It uses low-cost, lightweight sensors and wireless transmission for real-time soldier monitoring with high reliability.
IRJET- FPGA Implementation of an Improved Watchdog Timer for Safety-Critical ...IRJET Journal
This document describes the design and implementation of an improved watchdog timer for use in safety-critical applications such as space launch vehicles. The proposed watchdog timer operates independently of the processor using its own clock. It includes multiple "windows" to check parameters individually, allowing faults to be detected earlier than existing sequential designs. The watchdog was designed, simulated, and implemented in an FPGA to be configurable and adaptable. Its effectiveness at detecting injected faults was validated through hardware testing. Implementing this improved watchdog timer could help ensure reliability for safety-critical systems like space launch vehicles.
The document discusses burner management systems (BMS) and how programmable electronic systems (PES) can be used for burner control while ensuring safety. It outlines several key requirements for PES-based BMS to be certified, including using redundant safety-related PES, obtaining independent safety certification, and the designer demonstrating proper development and testing practices. The document also describes various safety features that can be designed into BMS, such as input/output monitoring, guarded outputs, processor watchdog timers, and power monitoring. It discusses architectures for safety programmable logic controllers (PLCs) including 1oo1D (one out of one with diagnostics) and 1oo2D (one out of two with diagnostics).
This project presents a new strategy to approach cascade control tuning by using image processing and machine learning to generate required control parameters to be set into the controller. For test bed purpose a ball balance upon a horizontal beam is used which is actuated with a stepper motor, angle of the balance to be scanned by a camera and analyzed using python alongside an ultrasonic sensor to measure real time distance to the ball, set point to be set by user and control action generated upon generating required information from hardware frame.
IRJET- FPGA Implementation of an Improved Watchdog Timer for Safety Critical ...IRJET Journal
This document describes the design and implementation of an improved configurable windowed watchdog timer that can be used in safety-critical applications. The proposed watchdog timer operates independently of the processor using a dedicated clock. It uses a windowed approach with service, frame, and controller windows that can be configured via software. The design was implemented in an FPGA and its effectiveness in detecting faults was validated by injecting faults through software. It was also implemented and tested in applications like an ATM and space launch vehicle control systems.
The document provides an introduction to functional safety standards ISO 13849 and EN 62061. It discusses the EU Machinery Directive and how compliance with European harmonized standards ensures compliance with the directive. It describes the terminology and standards used in functional safety, including performance levels, safety integrity levels, and design categories. It also discusses how to select the appropriate standard, assess risk, design safety functions, and validate safety control system designs.
This document presents a method for automatically tuning PID controllers using particle swarm optimization (PSO) algorithm. It describes PID controllers and common tuning methods like Ziegler-Nichols. It then provides an overview of PSO algorithm and how it can be applied to optimize PID parameters to minimize a performance index for a DC motor model. Simulation results show the PSO-tuned PID controller provides improved rise time, settling time and overshoot compared to Ziegler-Nichols tuning.
IRJET- Trouble Shooting of Rotary Equipments using Vibration AnaysisIRJET Journal
This document discusses vibration analysis as a technique for troubleshooting and predicting failures in rotary equipment. It begins with an introduction to predictive maintenance using condition monitoring tools like vibration analysis. Next, it covers causes of vibration in rotating machines, vibration measurement and analysis methods, and the instruments used. Key points made include that vibration analysis can identify specific machine faults from vibration signatures, and that periodic vibration monitoring allows problems to be detected early before failures occur. The goals of a vibration analysis program are to minimize downtime and maintenance costs in industrial operations.
IRJET- Soldier Security using GCRT Devices in Truculent SituationIRJET Journal
This document summarizes a system for soldier security tracking using biomedical sensors and GPS in dangerous situations. The proposed system monitors a soldier's health using sensors to measure heartbeat, temperature and location via GPS. It then transmits this health and location data to a base station using GSM communication. The system aims to improve soldier safety and security by allowing remote health monitoring and tracking in critical situations like warfare. It uses low-cost, lightweight sensors and wireless transmission for real-time soldier monitoring with high reliability.
IRJET- FPGA Implementation of an Improved Watchdog Timer for Safety-Critical ...IRJET Journal
This document describes the design and implementation of an improved watchdog timer for use in safety-critical applications such as space launch vehicles. The proposed watchdog timer operates independently of the processor using its own clock. It includes multiple "windows" to check parameters individually, allowing faults to be detected earlier than existing sequential designs. The watchdog was designed, simulated, and implemented in an FPGA to be configurable and adaptable. Its effectiveness at detecting injected faults was validated through hardware testing. Implementing this improved watchdog timer could help ensure reliability for safety-critical systems like space launch vehicles.
The document discusses burner management systems (BMS) and how programmable electronic systems (PES) can be used for burner control while ensuring safety. It outlines several key requirements for PES-based BMS to be certified, including using redundant safety-related PES, obtaining independent safety certification, and the designer demonstrating proper development and testing practices. The document also describes various safety features that can be designed into BMS, such as input/output monitoring, guarded outputs, processor watchdog timers, and power monitoring. It discusses architectures for safety programmable logic controllers (PLCs) including 1oo1D (one out of one with diagnostics) and 1oo2D (one out of two with diagnostics).
This project presents a new strategy to approach cascade control tuning by using image processing and machine learning to generate required control parameters to be set into the controller. For test bed purpose a ball balance upon a horizontal beam is used which is actuated with a stepper motor, angle of the balance to be scanned by a camera and analyzed using python alongside an ultrasonic sensor to measure real time distance to the ball, set point to be set by user and control action generated upon generating required information from hardware frame.
IRJET- FPGA Implementation of an Improved Watchdog Timer for Safety Critical ...IRJET Journal
This document describes the design and implementation of an improved configurable windowed watchdog timer that can be used in safety-critical applications. The proposed watchdog timer operates independently of the processor using a dedicated clock. It uses a windowed approach with service, frame, and controller windows that can be configured via software. The design was implemented in an FPGA and its effectiveness in detecting faults was validated by injecting faults through software. It was also implemented and tested in applications like an ATM and space launch vehicle control systems.
This document discusses functional safety standards and how to determine safety integrity levels and performance levels for machine safety. It provides an overview of key standards including IEC 61508, IEC 62061, ISO 13849-1, ISO 12100 and the Machinery Directive. The document uses an example of a robot cell to demonstrate applying a risk assessment process and decomposing safety functions to determine the required performance level for the safety control system based on ISO 13849-1.
This document provides an introduction to functional safety for machinery. It defines functional safety and explains that it involves ensuring automatic actions occur to reach a safe state. The document discusses relevant functional safety standards like ISO 13849 and IEC 61508. It also examines functional safety concepts like risk assessments, safety integrity levels, safety elements involving structure, reliability, diagnostics and systematic capability. The document uses an example safety circuit diagram to demonstrate functional safety concepts like input channel fault detection.
This document summarizes research on tuning an I-PD controller to control a highly oscillating second-order industrial process. The process has an 85.45% maximum overshoot and 8 second settling time. An I-PD controller is tuned using MATLAB optimization to minimize the integral of the squared error. The tuned controller completely cancels the overshoot and decreases the settling time to 1.46 seconds without undershoot, demonstrating improved performance over standard tuning techniques for controlling highly oscillating processes.
IRJET- Microcontroller based Anesthesia InjectorIRJET Journal
1) The document describes a microcontroller-based anesthesia injector system that automatically and precisely administers anesthesia to patients during surgeries based on biomedical sensor readings.
2) The system uses a microcontroller along with sensors for temperature, blood pressure, and heart rate to monitor the patient's condition. Based on the sensor values, the microcontroller controls a DC motor and syringe pump to administer the correct amount of anesthesia.
3) The automatic system aims to overcome issues with manual administration of anesthesia by ensuring the proper amount is delivered at the necessary intervals throughout long surgeries, avoiding risks to patients from human error or oversight.
Proposed Algorithm for Surveillance ApplicationsEditor IJCATR
Technological systems are vulnerable to faults. In many fault situations, the system operation has to be stopped to avoid
damage to machinery and humans. As a consequence, the detection and the handling of faults play an increasing role in modern
technology, where many highly automated components interact in a complex way such that a fault in a single component may cause
the malfunction of the whole system. This work introduces the main ideas of fault diagnosis and fault-tolerant control under the optics
of various research work done in this area. It presents the Arduino technology in both hardware and software sides. The purpose of this
paper is to propose a diagnostic algorithm based on this technology. A case study is proposed for this setting. Moreover, we explained
and discussed the result of our algorithm.
Health Monitoring of Industrial and Electrical EquipmentMAJAHARUL IMAM
It Detects if motor, generator or any Industrial Equipments having any faults,
excess heating and more vibration. Then sound up alarm to minimize the problems
Safety of machinery - Application of standard EN ISO 13849-1dnunez1984
This document provides an overview and comparison of two machinery safety standards: EN 62061 and EN ISO 13849-1. It outlines the basic procedures for complying with machinery directives, including performing a risk assessment. EN 62061 focuses on functional safety for electrical/electronic control systems, using Safety Integrity Levels (SILs). EN ISO 13849-1 applies to all machinery and determines Performance Levels (PLs) based on factors like categories and probability of failure. The document provides details on how each standard specifies safety parameters and calculations for achieving the required safety level.
Since 2007 there has been a choice of harmonised standards
to use for Functional Safety in the machinery sector.
The choices are:
ISO standard EN ISO 13849
IEC standard EN 62061
source TUV-SUD
www.regeltechnieken.org
www.ie-net.be/reg
Review of Online Monitoring of status of air for Automation with alarmiosrjce
IOSR Journal of Electronics and Communication Engineering(IOSR-JECE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of electronics and communication engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in electronics and communication engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Triconex is a leading supplier of emergency shutdown (ESD) systems that protect personnel, equipment, and the environment from hazardous situations. Their ESD systems use triple modular redundancy technology to ensure extremely high reliability and availability. By choosing a Triconex ESD system, customers can feel confident that their system will safely shutdown processes in an emergency without any single point of failure.
- A power generation facility was looking for safer, more efficient ways to conduct preventative maintenance inspections on electrical equipment like switchgear. Regular inspections required hazardous work removing panel covers that was restrictive and costly.
- Infrared windows were proposed as an alternative to allow inspections without removing panel covers. This eliminated safety hazards and reduced costs by not requiring protective equipment or electricians to assist.
- The power plant installed infrared windows on 95 pieces of electrical equipment, allowing previously uninspectable areas to now be inspected safely. This reduced inspection costs from $45,484 per survey to just $33 with a one-person team and no panel removal required.
This document provides an overview of exida, an international functional safety and cyber security consultancy firm. It discusses exida's services, customers, and experts. The document then summarizes Koen Leekens' presentation on IEC 62061, which introduces machinery safety standards, situates IEC 62061 in the regulatory environment, and outlines the 8 steps of the IEC 62061 safety lifecycle including management of functional safety, hazard and risk assessment, and determining safety-related control functions. The presentation emphasizes that the majority of accidents are preventable through a systematic, risk-based approach.
Yokogawa in the Petrochemical Industry | VigilantPlantYokogawa
Brochure about Yokogawa's presence in the Petrochemical industry. Yokogawa's VigilantPlant solutions deliver visibility, predictability and agility for your petrochemical business.
The document discusses Safety Instrumented Systems (SIS) and the Safety Life Cycle as defined by ANSI/ISA 84.00.01-2004. It outlines the steps in the Safety Life Cycle from initial Hazard and Risk Assessment to determine Safety Instrumented Functions (SIFs) and required Safety Integrity Levels (SILs), to design, installation, and ongoing maintenance of SIS including functional proof testing. The Safety Life Cycle is meant to guide safety systems through all stages from initial assessment to eventual decommissioning to minimize risk in industrial processes.
Design & Fabrication of Electro-Pneumatic Gantry Type Sorting RobotIRJET Journal
This document describes the design and fabrication of an electro-pneumatic gantry type sorting robot. The robot uses sensors like proximity sensors and photoelectric sensors connected to a programmable logic controller (PLC) to sort objects on a conveyor belt based on their properties. A human machine interface (HMI) is used to monitor and control the sorting process. Pneumatic cylinders and solenoid valves controlled by the PLC move a gantry system to pick and place objects into different trays for sorting. Calculations are provided on the required forces and selection of components like the conveyor motor and pneumatic cylinders. The PLC controls the sorting process and sequencing of the robot through ladder logic programming.
This document discusses control system tuning methods. It introduces the continuous cycling method developed by Ziegler and Nichols, which determines controller parameters by increasing proportional gain until sustained oscillations occur. The ultimate gain and period are then used to calculate PID settings. Issues with this method include the trial and error nature and potential for process instability. The step test method is also presented, which applies a step input in open loop to determine time delay and time constant from the response curve. These values are then used to calculate PID parameters. Examples are given to illustrate application of these tuning techniques.
This document discusses PID (proportional-integral-derivative) control and methods for tuning PID controller parameters. It begins with an overview of PID control and common PID configurations. It then covers the functions and effects of the proportional, integral and derivative terms. The document introduces the Ziegler-Nichols continuous cycling method for experimentally determining PID settings based on measuring the ultimate gain and period of sustained oscillations. An example is provided to demonstrate calculating PID settings using this Ziegler-Nichols method.
IRJET- Remote Health Monitoring of Ankle Edema by using E- Textile Techno...IRJET Journal
This document describes a remote health monitoring system to detect and monitor ankle edema using e-textile technology. The system uses wearable sensors including temperature, flex bend, and humidity sensors embedded in fabric to continuously monitor changes in leg circumference and activity levels as indicators of ankle swelling. The sensor data is processed using machine learning algorithms and transmitted wirelessly to provide remote, non-invasive edema monitoring and prevent more severe health issues associated with fluid buildup. Experimental testing on human subjects showed the system can accurately and reliably assess edema levels through activity-dependent measurements of the lower leg.
Development of PLC based Transdermal Patch Evaluation SystemIRJET Journal
This document describes the development of a PLC-based system to evaluate the adhesion of transdermal drug patches. The system uses a load cell to measure the peeling force as a patch is removed from a substrate at controlled speeds by a servomotor. The PLC controls the motor and reads the load cell output to perform 180 and 90 degree peel tests according to industry standards. This allows automated testing to improve quality by maintaining consistent test parameters compared to manual methods. The system is designed to objectively measure patch adhesion strength across multiple batches over time to ensure transdermal drug delivery performance.
The document describes INDEC vacuum inspection systems produced by KoCoS audentec GmbH. These systems use optical or inductive sensors to check vacuum packaging for food containers on production lines at speeds up to 1,200 containers per minute. The sensors detect defects by measuring vacuum levels and ensuring tight closures. The systems have intuitive interfaces and are modular for flexibility. They reliably identify defective containers for automatic rejection.
This document describes a system for monitoring transformer oil temperature using a PIC microcontroller. The system continuously monitors the oil temperature and automatically shuts down the transformer if the temperature exceeds safe limits. It displays the temperature readings for users. The system is designed to make transformers more secure and intelligent by detecting problems early to prevent costly failures or loss of service. It can cut operational and maintenance costs for transformers.
This document discusses functional safety standards and how to determine safety integrity levels and performance levels for machine safety. It provides an overview of key standards including IEC 61508, IEC 62061, ISO 13849-1, ISO 12100 and the Machinery Directive. The document uses an example of a robot cell to demonstrate applying a risk assessment process and decomposing safety functions to determine the required performance level for the safety control system based on ISO 13849-1.
This document provides an introduction to functional safety for machinery. It defines functional safety and explains that it involves ensuring automatic actions occur to reach a safe state. The document discusses relevant functional safety standards like ISO 13849 and IEC 61508. It also examines functional safety concepts like risk assessments, safety integrity levels, safety elements involving structure, reliability, diagnostics and systematic capability. The document uses an example safety circuit diagram to demonstrate functional safety concepts like input channel fault detection.
This document summarizes research on tuning an I-PD controller to control a highly oscillating second-order industrial process. The process has an 85.45% maximum overshoot and 8 second settling time. An I-PD controller is tuned using MATLAB optimization to minimize the integral of the squared error. The tuned controller completely cancels the overshoot and decreases the settling time to 1.46 seconds without undershoot, demonstrating improved performance over standard tuning techniques for controlling highly oscillating processes.
IRJET- Microcontroller based Anesthesia InjectorIRJET Journal
1) The document describes a microcontroller-based anesthesia injector system that automatically and precisely administers anesthesia to patients during surgeries based on biomedical sensor readings.
2) The system uses a microcontroller along with sensors for temperature, blood pressure, and heart rate to monitor the patient's condition. Based on the sensor values, the microcontroller controls a DC motor and syringe pump to administer the correct amount of anesthesia.
3) The automatic system aims to overcome issues with manual administration of anesthesia by ensuring the proper amount is delivered at the necessary intervals throughout long surgeries, avoiding risks to patients from human error or oversight.
Proposed Algorithm for Surveillance ApplicationsEditor IJCATR
Technological systems are vulnerable to faults. In many fault situations, the system operation has to be stopped to avoid
damage to machinery and humans. As a consequence, the detection and the handling of faults play an increasing role in modern
technology, where many highly automated components interact in a complex way such that a fault in a single component may cause
the malfunction of the whole system. This work introduces the main ideas of fault diagnosis and fault-tolerant control under the optics
of various research work done in this area. It presents the Arduino technology in both hardware and software sides. The purpose of this
paper is to propose a diagnostic algorithm based on this technology. A case study is proposed for this setting. Moreover, we explained
and discussed the result of our algorithm.
Health Monitoring of Industrial and Electrical EquipmentMAJAHARUL IMAM
It Detects if motor, generator or any Industrial Equipments having any faults,
excess heating and more vibration. Then sound up alarm to minimize the problems
Safety of machinery - Application of standard EN ISO 13849-1dnunez1984
This document provides an overview and comparison of two machinery safety standards: EN 62061 and EN ISO 13849-1. It outlines the basic procedures for complying with machinery directives, including performing a risk assessment. EN 62061 focuses on functional safety for electrical/electronic control systems, using Safety Integrity Levels (SILs). EN ISO 13849-1 applies to all machinery and determines Performance Levels (PLs) based on factors like categories and probability of failure. The document provides details on how each standard specifies safety parameters and calculations for achieving the required safety level.
Since 2007 there has been a choice of harmonised standards
to use for Functional Safety in the machinery sector.
The choices are:
ISO standard EN ISO 13849
IEC standard EN 62061
source TUV-SUD
www.regeltechnieken.org
www.ie-net.be/reg
Review of Online Monitoring of status of air for Automation with alarmiosrjce
IOSR Journal of Electronics and Communication Engineering(IOSR-JECE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of electronics and communication engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in electronics and communication engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Triconex is a leading supplier of emergency shutdown (ESD) systems that protect personnel, equipment, and the environment from hazardous situations. Their ESD systems use triple modular redundancy technology to ensure extremely high reliability and availability. By choosing a Triconex ESD system, customers can feel confident that their system will safely shutdown processes in an emergency without any single point of failure.
- A power generation facility was looking for safer, more efficient ways to conduct preventative maintenance inspections on electrical equipment like switchgear. Regular inspections required hazardous work removing panel covers that was restrictive and costly.
- Infrared windows were proposed as an alternative to allow inspections without removing panel covers. This eliminated safety hazards and reduced costs by not requiring protective equipment or electricians to assist.
- The power plant installed infrared windows on 95 pieces of electrical equipment, allowing previously uninspectable areas to now be inspected safely. This reduced inspection costs from $45,484 per survey to just $33 with a one-person team and no panel removal required.
This document provides an overview of exida, an international functional safety and cyber security consultancy firm. It discusses exida's services, customers, and experts. The document then summarizes Koen Leekens' presentation on IEC 62061, which introduces machinery safety standards, situates IEC 62061 in the regulatory environment, and outlines the 8 steps of the IEC 62061 safety lifecycle including management of functional safety, hazard and risk assessment, and determining safety-related control functions. The presentation emphasizes that the majority of accidents are preventable through a systematic, risk-based approach.
Yokogawa in the Petrochemical Industry | VigilantPlantYokogawa
Brochure about Yokogawa's presence in the Petrochemical industry. Yokogawa's VigilantPlant solutions deliver visibility, predictability and agility for your petrochemical business.
The document discusses Safety Instrumented Systems (SIS) and the Safety Life Cycle as defined by ANSI/ISA 84.00.01-2004. It outlines the steps in the Safety Life Cycle from initial Hazard and Risk Assessment to determine Safety Instrumented Functions (SIFs) and required Safety Integrity Levels (SILs), to design, installation, and ongoing maintenance of SIS including functional proof testing. The Safety Life Cycle is meant to guide safety systems through all stages from initial assessment to eventual decommissioning to minimize risk in industrial processes.
Design & Fabrication of Electro-Pneumatic Gantry Type Sorting RobotIRJET Journal
This document describes the design and fabrication of an electro-pneumatic gantry type sorting robot. The robot uses sensors like proximity sensors and photoelectric sensors connected to a programmable logic controller (PLC) to sort objects on a conveyor belt based on their properties. A human machine interface (HMI) is used to monitor and control the sorting process. Pneumatic cylinders and solenoid valves controlled by the PLC move a gantry system to pick and place objects into different trays for sorting. Calculations are provided on the required forces and selection of components like the conveyor motor and pneumatic cylinders. The PLC controls the sorting process and sequencing of the robot through ladder logic programming.
This document discusses control system tuning methods. It introduces the continuous cycling method developed by Ziegler and Nichols, which determines controller parameters by increasing proportional gain until sustained oscillations occur. The ultimate gain and period are then used to calculate PID settings. Issues with this method include the trial and error nature and potential for process instability. The step test method is also presented, which applies a step input in open loop to determine time delay and time constant from the response curve. These values are then used to calculate PID parameters. Examples are given to illustrate application of these tuning techniques.
This document discusses PID (proportional-integral-derivative) control and methods for tuning PID controller parameters. It begins with an overview of PID control and common PID configurations. It then covers the functions and effects of the proportional, integral and derivative terms. The document introduces the Ziegler-Nichols continuous cycling method for experimentally determining PID settings based on measuring the ultimate gain and period of sustained oscillations. An example is provided to demonstrate calculating PID settings using this Ziegler-Nichols method.
IRJET- Remote Health Monitoring of Ankle Edema by using E- Textile Techno...IRJET Journal
This document describes a remote health monitoring system to detect and monitor ankle edema using e-textile technology. The system uses wearable sensors including temperature, flex bend, and humidity sensors embedded in fabric to continuously monitor changes in leg circumference and activity levels as indicators of ankle swelling. The sensor data is processed using machine learning algorithms and transmitted wirelessly to provide remote, non-invasive edema monitoring and prevent more severe health issues associated with fluid buildup. Experimental testing on human subjects showed the system can accurately and reliably assess edema levels through activity-dependent measurements of the lower leg.
Development of PLC based Transdermal Patch Evaluation SystemIRJET Journal
This document describes the development of a PLC-based system to evaluate the adhesion of transdermal drug patches. The system uses a load cell to measure the peeling force as a patch is removed from a substrate at controlled speeds by a servomotor. The PLC controls the motor and reads the load cell output to perform 180 and 90 degree peel tests according to industry standards. This allows automated testing to improve quality by maintaining consistent test parameters compared to manual methods. The system is designed to objectively measure patch adhesion strength across multiple batches over time to ensure transdermal drug delivery performance.
The document describes INDEC vacuum inspection systems produced by KoCoS audentec GmbH. These systems use optical or inductive sensors to check vacuum packaging for food containers on production lines at speeds up to 1,200 containers per minute. The sensors detect defects by measuring vacuum levels and ensuring tight closures. The systems have intuitive interfaces and are modular for flexibility. They reliably identify defective containers for automatic rejection.
This document describes a system for monitoring transformer oil temperature using a PIC microcontroller. The system continuously monitors the oil temperature and automatically shuts down the transformer if the temperature exceeds safe limits. It displays the temperature readings for users. The system is designed to make transformers more secure and intelligent by detecting problems early to prevent costly failures or loss of service. It can cut operational and maintenance costs for transformers.
This document discusses methods for improving conveyor belt reliability through predictive maintenance of conveyor idlers. It proposes monitoring idler condition using thermal imaging and sound monitoring to detect failures early. Specifically, it recommends using infrared cameras to monitor idler temperatures and acoustic equipment to analyze bearing sounds for signs of failure. Detecting issues early through these condition monitoring techniques can help reduce downtime compared to the traditional preventative maintenance approach of manual inspections.
This document describes a virtual instrumentation-based surveillance system for monitoring hazardous industrial environments. It uses sensors to detect gas leaks, temperature changes, smoke, and obstacles. A microcontroller programmed with GENIE software analyzes the sensor data and sends alerts via ZigBee wireless modules to a LabVIEW interface. The system allows unmanned monitoring of inaccessible areas. It aims to prevent disasters by quickly detecting issues like fires or gas leaks and notifying operators. The document outlines the sensor components, microcontroller programming, wireless transmission, and graphical user interface of the proposed monitoring system.
IRJET- Smart System for Sorting Defective Parts and Distribution Line using PLCIRJET Journal
The document describes a smart system for sorting defective parts using a programmable logic controller (PLC). Reed switches are used as sensors to detect objects on conveyor belts and send signals to the PLC. Based on object height, the PLC controls DC motors to rotate belts and a pusher arm to sort objects into bins. This automated system reduces manual labor, increases sorting accuracy, and improves production efficiency compared to existing solutions. It is intended for use in small-scale industries to provide a low-cost sorting solution.
Productivity Studies of Ultra High Density (UHD) Stitching Processidescitation
This paper focuses on Ultra High Density (UHD) stitching process of connectors,
where the company relies on 100% manual inspection in UHD connectors. Based on
historical data on production of UHD connectors, typically labour cost involved in
inspection and testing is around 15% of the total manufacturing cost. This poses both
challenges and opportunities for improvement in the bottleneck process, which is the
inspection process. The female connectors quantity produced is on the average of 2000
parts/shift. It takes around 47 sec of visual inspection per connector and around 2.89 sec per
piece for go-gauge inspection. Considering these factors, the objectives of the study was to
understand the whole process in its entirety and then use this knowledge to re-organize the
stages staring from the automatic stitching process. By using process improvement tools of
time study, methods and process mapping, a process re-orientation and re-organization has
been carried out. This resulted in not only reduction of time of inspection and testing of the
connectors, but also the piece inspection process reduced from an average total time of
112.59 sec to 86.15 sec. Overall improvement was also increased from 56% to 79.5%.
COAL MINE SAFETY INTELLIGENT MONITORING BASED ON WIRELESS SENSOR NETWORKIRJET Journal
The document describes a proposed wireless sensor network system for monitoring coal mine safety. The system would use sensors to monitor temperature, gas levels, and other factors. An ESP32 controller would collect data from the sensors. A LoRa module would transmit the sensor data wirelessly to a receiving station. The receiving station would analyze the data and alert workers if dangerous conditions were detected. The system aims to improve safety monitoring and response times in coal mines.
METAL PRODUCTS DESIGN AND FABRICATION OF SMART SHELF SYSTEMIRJET Journal
1. The document describes the design and fabrication of a smart shelf system that uses sensors to automatically track inventory levels in an industrial setting.
2. Key components of the smart shelf system include a load cell and HX711 module to measure the weight of items on the shelf and detect when stock is running low, as well as a Node MCU microcontroller to connect the shelf sensors to WiFi and provide data to users.
3. The system is intended to help industries better manage inventory, reduce out-of-stock issues, and provide real-time information on product usage to optimize operations.
DESIGN THINKING ON FAULT DIAGNOSIS OF FLOATING WIND TURBINE GENERATOR USING A...IRJET Journal
This document discusses using artificial intelligence techniques for fault diagnosis of floating wind turbine generators. It proposes an intelligent fault diagnosis system framework based on AI technology. Specifically, it suggests using an expert system knowledge base and artificial neural networks. Neural networks can continuously learn from the expert system data to improve diagnosis efficiency and accuracy over time. The document provides background on AI and neural networks, reviews related literature, and describes common hardware components used in wind turbine generators like temperature sensors, vibration sensors and PIC microcontrollers.
Design a WSN Control System for Filter Backwashing ProcessIJMERJOURNAL
ABSTRACT: Day by day, there is a higher rate of need for accurate automation system to be used in industries and environment monitoring and control. In water treatment plants during the filtration phase, there is a process called backwashing, which particles suspended in the filter basin are removed. in this process the water are forcedly pumped through the filter in upward direction at enough speed to expand the filter media. Therefore, various types of valves used, which are opened and closed in a time sequencing manner. The paper proposed an automation control system for the backwashing process to be initiated and completed automatically using PLC, level sensors and valves installed inside the filter basin. Practically, a control system has been applied which all valves are opened and closed according to wireless signals coming from PLCs on its suitable time. In summary, the control in the process demonstrated that the proposed system is efficient, effective, and able to be reliable. Besides, the results increase the productivity at a low-cost mode.
This document discusses the development of firefighting drones. It proposes attaching fire extinguisher balls and cameras with heat/temperature sensors to drones to help control the spread of fires. The drones could quickly be sent to fire-affected areas and also be used for surveillance. An alert would be sent to authorities informing them about detected fires using IOT. The document describes the hardware used to build the drones, including propellers, motors, ESC, flight controller and frame. It outlines the planned work and provides references for further research on drone applications.
Mechatronic based energy management and automation system for agro industrieseSAT Journals
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61 programmable
1. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11316
Programmable Logic Controller based
Mechatronics System for Metrological
Inspection of Clevis
P.R. SenthilMurugan1
, C.Prasanth2
Assistant Professor, Department of Mechatronics Engineering,K.S.RangasamyCollege of Technology, Tiruchengode,
TamilNadu, India1
UG Student, Department of Mechatronics Engineering, K.S.Rangasamy College of Technology, Tiruchengode,
TamilNadu,India2
Abstract:In industries, inspection is one of the crucial factors to ensure quality of the product before reaching the
market.The objective of this project is to design a Mechatronics system to monitor the dimensions of the product
(clevis) using the pneumatics system with the help of Programmable Logic Controller (PLC).The clevis is placed in the
clevis holder, which is used to hold the work piece tightly. Then the pneumatic cylinders which are controlled by PLC
XE 102 extends and retracts based on the ladder logic diagram. The calibrated gauges are attached in the pneumatic
cylinders, if the GO/no GO gauge travels smoothly inside the hole, it can be concluded that the dimensions of the hole
is in accordance to the specified standard dimensions. This system improves the dimensional inspection and also
eliminates the human errors andcan be done at lower cost.
Keywords:Metrological inspection, Clevis, PLC, Dimensional measurement, Pneumatic system, Pneumatic circuit.
I. INTRODUCTION
Inspection of finished products in manufacturing industries for quality is one of the important factors. It can be done
either manually or by using automation. Over the years the demand for high quality, greater efficiency and automated
machines has increased in the industrial sector.Finished products require continuous monitoring and inspection at
frequent intervals. There are possibilities of errors at measuring and various stages involved with human workers and
also the lack of few features of microcontrollers. Thus this project takes a sincere attempt to explain the advantages the
companies will face by implementing automation into them. Here we are going to discuss about the automation of a
quality inspection process and its advantages over the manual inspection method.
II. LITERATURE SURVEY
Y.S Liu, T.Q Wang, X.Y Ma , Y.P Ning (2011) in their work “Hole straightness measurement ofAutomatic Control
System Design” designedan instrument which works based on the principle of the measurement method of straightness
error measurement of deep hole, the design technologies of A/D converters, automatic control and computer are used.
The instrument can automatically acquire data, the process of acquire data is convenient, fast, safe and the data is
reliable. Mohammed J. Islam, Saleh M. Basalamah, Majid Ahmadi, Maher A. Sid-Ahmed (2012) in theirwork
“Computer Vision-Based Quality Inspection System of Transparent Gelatin Capsules in Pharmaceutical Applications”
designed a computer-vision based system and a digital image obtained by a digital camera would usually have 24-bit
color image. The analysis of an image with that many levels might require complicated image processing
techniques.They have developed an image processing system using edge-based image segmentation techniques for
quality inspection that satisfy the industrial requirements in pharmaceutical applications to pass the accepted and
rejected capsules.
2. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11317
III. METROLOGICAL INSPECTION OF CLEVIS
The product is placed in the fixture. The fixture holds the product in position during the inspection .The Gauges fitted
in the pneumatic cylinders extend to check the dimension of the product. Hence the dimensions of the product is
verified with standard dimensions. Based on the dimension product is either selected (or) rejected. A device for
determining whether or not one or more dimensions of a manufactured part are within specified limits A plug gage is
a cylinder designed to check the component tolerance of a hole in a product. The plug gage has been found to be
highly accurate, economical and convenient for small hole inspection where a determination is made of compliance
with designed limits.
IV.EXPERIMENTAL SETUP
Fig. 1: Top view of experimental setup
Fig. 2: Front view of experimental setup
3. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11318
Fig.3: Experimental setup
V. SPECIFICATION OF CLEVIS
Hole Diameter = 10.0 mm; Go Width = 9.8 mm; No-Go Width = 10.2
mm; Length = 43 mm
Fig.4: Clevis
VI.FLOW CHART OF THE PROCESS
The Working of the Automation system is based on control of inspection process using the Programmable
LogicController (PLC) and the Pneumatic Circuit.The pneumatic circuit is designed first and then the PLC
programming is designed for the pneumatic circuit. Then the interfacing is established between the PLC and the
pneumatic circuit. Then the Clevis is placed in the fixture, the pneumatic circuit is actuated to check the dimensions of
the clevis. Whenever the inspection is failed, the Clevis is sent for the rework or it is considered as scrap. The Clevis
which passes the inspection is only used in automobiles or it is considered fit to use.
4. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11319
Fig. 5: Flow chart of the process
VII. SEQUENTIAL DESCRIPTION OF PROCESS
.
When the cycle start pushbutton is pushed, it actuates the solenoid1.then the cylinder 1 attached with the movable block
extends to hold the work piece in position .Thus it acts as a fixture. When the solenoid1 is actuated the timer for the
solenoid3 is also activated at the same time. Then the solenoid3 is activated after the pre-set time (1sec) in the timer.
Due to the activation of solenoid3 the cylinder2 connected to it gets actuated. Then the cylindrical gauge fixed to it also
extends along with it to inspect the quality of the dimension of the work piece. During the same time when the
solenoid3 is activated the timer for the solenoid4 gets activated .After the pre-set time in the timer the timer activates
the solenoid4.the solenoid4 makes the cylinder2 to retract to its initial position. After the cylinder2 retracts solenoid5
gets activated which extends the cylinder3.then the rectangular gauge attached with the cylinder3 move along with it to
inspect the gap in the component. Then the solenoid6 gets activated after the pre-set time to retract the cylinder3, back
to its initial position. After the cylinder3 retract the solenoid2 gets activated which retracts the cylinder1 back to its
initial position. If the gauges get stuck in the component the stop button can be used to stop the entire process which
de-activates all the solenoid valves connected to the PLC. In case of emergency situation the emergency pushbutton is
turned on this cut the air supply to the entire system. Thus one cycle of the process is over this is repeated continuously
for inspection of each component.
5. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11320
Fig.6: Pneumatic Circuit
VIII. SELECTING A PLC
A PLC is a device used for automation processes in industrial environments. It uses a programmable memory for the
internal storage of user-orientated instructions for implementing specific functions such as arithmetic, counting, logic,
sequencing, and timing. Input devices and output devices of the process are connected to the PLC and the control
program is entered into the PLC memory. The type of PLC used in this project is horner XE102.
IX.FEATURES OF XE102
Bright, graphical LCD display. Display of complex graphical objects including trends, gauges, meters and animations
Advanced control capabilities including floating point, multiple auto-tuning PID loops and string handling capabilities
CsCAN networking port (optional) for communication with remote I/O, other controllers or PCs Cscape programming
software that allows all aspects of the XES to be programmed and configured from one integrated application.
X. LADDER - CONTROLLED SERIAL COMMUNICATION
Using Serial Communication function blocks, both MJ1 and MJ2 support Generic, Modbus Master and Modbus Slave
Protocols. In addition, external modems can be connected and accessed using Init, Dial and Answer Modem function
blocks.
6. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11321
XI.INPUTS AND OUTPUTS
The XLe/XLt is a compact unit that contains high density, very versatile I/O. Using the I/O properly requires wiring to
the proper terminals, configuring jumpers inside the XLe/XLt unit and configuring Cscape properly. Some I/O
configurations require jumper settings to be changed inside the XLe/XLt unit. Examples of these settings are setting
positive or negative logic on digital inputs or setting current or voltage on analog inputs. Each XLe/XLt I/O jumper is
set to a factory default. There are eight inputs and six outputs used in this PLC controller.
XII. PLC PROGRAMMING
Once the pneumatic system is designed the next step is to create a suitable ladder logic diagram for the inspection of
the dimensions of the product. The programming is based on the arrangement of the pneumatic cylinders. The Ladder
logic Diagram is a method in which each logical step of the whole process is divided into ladders. The ladders contain
the logic in the form of relay, switches and coils through which the program will be executed. The program is done
using a software in the computer which will then import the program into the PLC kit through the Interface connection.
Apart from the cylinder Arrangement Various Factors are also to be considered for the Programming .They are timing
for extension and retraction of the cylinders, Position of the fixtures, pressure level of the cylinders.
XIII. RESULT
Fig.7: Days vs No. of pieces
As shown in the bar chart on day1 the number of pieces tested manually are 1000 but the number of pieces tested by
PLC controlled machine are 2000 which is 2 times of the manual inspection, On day 2 the number of pieces tested
manually are 932 and number of pieces tested by machine are 1906 which is 2.04 times the manual inspection, On day
3 the number of pieces tested manually are 967 and the number of pieces tested by machine are 2080 which is 2.15,
even on day 4 the number of pieces tested manually are 894 and the number of pieces tested by machine are 1898
which is 2.12 times the manual inspection. This bar chart shows that the number of inspection of clevis has been
improved when compared with the manual inspection.
7. ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 3, Issue 4, April 2014
Copyright to IJIRSET www.ijirset.com 11322
REFERENCES
[1] Haibin Zhao, Jean-PierreKruth , Nick Van Gestel ,Bart Boeckmans , Philip Bley “Automated dimensional inspection planning using the
combination of laser scanner and tactile probe” in Journal of measurement ,Vol.45 in June 2012.
[2] Mohammed J.Islam1, Saleh M. Basalamah2, Majid Ahmadi3, Maher A. Sid-Ahmed3 on” Computer Vision-Based Quality Inspection System
of Transparent Gelatine Capsules in Pharmaceutical Applications” in American Journal of Intelligent Systems in 2012.
[3] Habibullah Akbar and Anton SatriaPrabuwono in “Webcam Based System for Press Part Industrial Inspection” International Journal of
Computer Science and Network Security, VOL.8 No.10, October 2008.
[4] Y.S Liu, T.Q Wang, X.Y Ma,Y.PNing in “Hole straightness measurement of Automatic Control System design” in Science Direct, Vol.15 in
Dec 2011.
[5] EberhardManske and GerdJäger in “Multi-sensor Approach for Multivalent Applications in Nanometrology” in International Journal of
Automation and Smart Technology VOL.2.,No.2,June 2012.
[6] Susanne Topfer ,Gerhard Linz, UweNehse in “Inspection Strategy and Inspection Planning for Dimensional Measurements of Micro and
Nano-Structured components using cascaded sensor systems” in Joint International IMEKO TC1+TC7 SymposiumSep 2005.
[7] William R. Scott ,Gerhard Roth, Jean-Franc¸ OisRivest ”View Planning for Automated Three-Dimensional Object Reconstruction and
Inspection “ACM Computing Surveys, Vol. 35, No. 1, March 2003.
[8] S.Pratheesh Kumar, S.R.Devadasan,” Standardization of Inspection Processes Incorporated in a Precision Machining Centre”.International
Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-2, Issue-6, May 2013.
[9] Abha Sharma, Sugandha Arora,in” Inspection and Classification of Defects in Pharmaceutical Capsules Using Neural Network”
inInternational Journal of Engineering Research and Development ISSN: 2278-067X, Volume 1, Issue 10 (June 2012).