Programmable logic controllers are widely used in many manufacturing process like machinery packaging
material handling automatic assembly. These are special type of microprocessor based controller used for any
application that needs any kind of electrical controller including lighting controller and HVAC control system.
Automatic conveyor system is a computerized control method of controlling and managing the sorting
mechanism at the same time maintaining the efficiency of the industry & quality of the products.HMI for
automatic conveyor system is considered the primary way of controlling each operation. Text displays are
available as well as graphical touch screens. It is used in touch panels and local monitoring of machines. This
paper deals with the efficient use of PLC in automatic conveyor system and also building the accuracy in it.
Arm Based Real Time Monitoring and Controlling of Industrial Parameters Using...IJTET Journal
Day by day the scope of networked embedded system is rapidly increasing for monitoring & controlling either home
appliances or industry devices. The World Wide Web is a global system of interconnected computer networks that utilizes the
standard Internet Protocol Suite (TCP/IP) and allows the user to interface many real-time Embedded applications similar to data
acquisition, Industrial automations and safety measures etc,. Users can monitor & control remote machines/systems by using an
embedded web server. The main objective of this system is used to monitor the industrial parameters and control the various
machines/systems in the industry from anywhere in the world through embedded web server. The machine/instrument is
monitored and controlled by ARM 7 and in-build web server with GPRS technology. Various sensor’s are used to monitor the
parameters like pressure, speed and temperature in the industry. A relay is used in this system to control the machine/instrument
by giving ON/OFF command in the web page. The embedded device communicates through General Packet Radio Service
(GPRS). GPRS technology along with GSM can be accessed from anywhere in the world.
Micro operations
Fetch, Indirect, Interrupt, Execute, Instruction Cycle
Control Unit
Hardwired Control Unit
Microprogrammed Control Unit
Wilkie's Microprogrammed Control Unit
To impart knowledge about the elements, techniques and sensors involved in mechatronics systems which are very much essential to understand the emerging field of automation.
Arm Based Real Time Monitoring and Controlling of Industrial Parameters Using...IJTET Journal
Day by day the scope of networked embedded system is rapidly increasing for monitoring & controlling either home
appliances or industry devices. The World Wide Web is a global system of interconnected computer networks that utilizes the
standard Internet Protocol Suite (TCP/IP) and allows the user to interface many real-time Embedded applications similar to data
acquisition, Industrial automations and safety measures etc,. Users can monitor & control remote machines/systems by using an
embedded web server. The main objective of this system is used to monitor the industrial parameters and control the various
machines/systems in the industry from anywhere in the world through embedded web server. The machine/instrument is
monitored and controlled by ARM 7 and in-build web server with GPRS technology. Various sensor’s are used to monitor the
parameters like pressure, speed and temperature in the industry. A relay is used in this system to control the machine/instrument
by giving ON/OFF command in the web page. The embedded device communicates through General Packet Radio Service
(GPRS). GPRS technology along with GSM can be accessed from anywhere in the world.
Micro operations
Fetch, Indirect, Interrupt, Execute, Instruction Cycle
Control Unit
Hardwired Control Unit
Microprogrammed Control Unit
Wilkie's Microprogrammed Control Unit
To impart knowledge about the elements, techniques and sensors involved in mechatronics systems which are very much essential to understand the emerging field of automation.
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
Presentation for unit V in Mechatronics excluding case study. Stepper motor, servo motor, design procedure, Traditional and Mechatronic design approach
What is mechatronics
Key elements of Mechatronics
How the mechatronics system work
Understand mechatronics system
Understand measuring system
Understand control system
Benefit and drawback of mechatronics
Application of mechatronics
This PPT is based upon my training in Yokogawa Chennai.
Reference:
# Yokogawa Hand Book on CS 3000
# http://www.slideshare.net/bvent2005/dcs-presentation
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
Presentation for unit V in Mechatronics excluding case study. Stepper motor, servo motor, design procedure, Traditional and Mechatronic design approach
What is mechatronics
Key elements of Mechatronics
How the mechatronics system work
Understand mechatronics system
Understand measuring system
Understand control system
Benefit and drawback of mechatronics
Application of mechatronics
This PPT is based upon my training in Yokogawa Chennai.
Reference:
# Yokogawa Hand Book on CS 3000
# http://www.slideshare.net/bvent2005/dcs-presentation
Presentation on Industrial Automation by Vivek Atalkar Vivek Atalkar
Industrial automation is the use of technology and control systems to operate, monitor, and optimize industrial processes, machinery, and equipment. It involves the use of various technologies, including programmable logic controllers (PLCs), sensors, and robotics, to automate repetitive and complex tasks, improve efficiency, and reduce costs.
The primary benefit of industrial automation is improved productivity. By automating repetitive tasks, machines can work faster and more accurately, leading to increased output and lower production costs. Automation can also lead to better quality control, reducing defects and waste. Industrial automation can also help businesses to save on labor costs, as machines can perform tasks that would otherwise require human labor.
Another significant benefit of industrial automation is increased safety. Automation can help to reduce the risk of injury to workers by performing hazardous tasks or operating in dangerous environments. It can also help to reduce the risk of human error, which can lead to accidents and injuries.
There are several types of industrial automation, including process automation, discrete automation, and hybrid automation. Process automation involves controlling the flow of materials and products through a manufacturing process. This type of automation is commonly used in chemical plants, food processing, and other industries where there is a continuous flow of materials.
Discrete automation involves controlling individual machines or components, such as robotic arms, conveyors, or assembly lines. This type of automation is commonly used in automotive manufacturing, electronics, and other industries where there is a need to perform specific tasks.
Hybrid automation involves combining process and discrete automation to optimize production. This type of automation is commonly used in industries such as aerospace, defense, and medical device manufacturing, where there is a need to balance the efficiency of the manufacturing process with the precision and accuracy required to produce complex products.
Industrial automation also offers several advantages beyond increased productivity, safety, and quality control. It can help to improve energy efficiency and reduce environmental impact by optimizing the use of resources such as water, electricity, and raw materials. Automation can also improve data collection and analysis, providing valuable insights into production processes that can help to identify areas for improvement and optimize performance.
In recent years, industrial automation has become increasingly accessible to smaller businesses, thanks to advancements in technology and the availability of off-the-shelf automation solutions. As a result, industrial automation is no longer just for large corporations with vast resources, but is becoming more widely adopted across a range of industries and business sizes.
This paper Presentation(ppt) is totally on Industrial Automation for seminar along with project ( PLC based water bottle filling system) which work on the principle of Industrial Automation .
A Novel Idea on Semi-Automated Operation Theatre Assistance for Doctors Based...theijes
The idea of this article is to develop a robotic assistant for handling surgical instruments in Operation Theatres. Hence it is possible to minimize human intervention in turn the risk of contamination and the probability of human error. The robotic system principally has three functional parts : locomotion controlled by Bluetooth from an android device; rotatory array of medical instruments governed by a stepper motor that functions over a voice input and a robotic arm made of Gripper motor controlled remotely.
Feasible Interfacing and Programming of Industrial Control Technology Unit wi...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Simulation and Implementation of PLC Based for Detecting Burned Potato Chips ...ijtsrd
This paper describes about to use the PLC techniques for automation of industrial product manufacturing to achieve high throughput and improved quality and consistency. In this system, PLC is used the heart of the system. Light dependent sensor, push button switch, light source, conveyor and blower is controlled by PLC. The proposed system of operation is devised by ladder diagram. Software implementation is used for demonstrating the ease of operation with this control along with tuning of the entire system is offered. This paper presents a study by simulation and experimental models for proposed system of PLCs. In this paper, consideration was given to the design of an HMI for an automated burn chips removed from conveyor which can be operated automatically by the press of start buttons. The design stages included screen interfacing for the HMI, programming the HMI by assigning tags, integration into Step 7 brand of PLC using Ethernet, simulation of the program using "PLCSIM" and the programming codes of the automated burn chips. The designed HMI will be useful to manufacturing industries having industrial automated systems. Htet Htet Aung | Thu Zar Thein "Simulation and Implementation of PLC Based for Detecting Burned Potato Chips and Remove using PLCSIM and HMI" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-5 , August 2019, URL: https://www.ijtsrd.com/papers/ijtsrd26724.pdf Paper URL: https://www.ijtsrd.com/engineering/electronics-and-communication-engineering/26724/simulation-and-implementation-of-plc-based-for-detecting-burned-potato-chips-and-remove-using-plcsim-and-hmi/htet-htet-aung
Implementation of T-Junction Traffic Light Control System Using Simatic S7-20...IJERA Editor
A conventional traffic light control system is designed by using devices such as timers, relays and
contactors etc. The critical timing operation is required to be carried out under the existence of heavy
traffic situations. This conventional practice leads to many problems that need additional maintenance
cost and subsequent delay for a long time. With the help of a PLC, the requirement of fast automation
and effective optimization of traffic light control system can be achieved. Use of PLC helps us to
develop this process not only for traffic signal on the roads, but also on the movement of trains and
the transfer of containers in ports in maritime works. In order to provide a solution to the above
problem, this paper introduces an execution and implementation of T-junction traffic control system
using SEIMENS S7-200 PLC. Programming in PLC is written in ladder logic with the help of STEP7
MICROWIN software
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology.
PLC based Segregation of Scrap MaterialIJERA Editor
This paper describe segregation of scrap materials using automation system. With the growing population rate, the amount of waste being produced is also increasing at a very faster rate. It is also posing a very serious problem at the industrial and domestic level to manage the wastes being dumped everywhere as landfill waste. So, it is very crucial to have some system to manage waste automatically which is currently not there. Prime Minister Modi’s mission of Swaccha Bharat Abhiyan can also be successfully implemented by the proposed system. The paper proposes a novel method where the provision is given to separate out metal and nonmetal waste into respective bins by the sensing of different sensors incorporated along the conveyor belt. Pieces of glass, paper, wood and metallic materials are separated out from proposed work. Using the segregation, most of the metal and nonmetal components like paper, glass, plastic increases the economic value of the waste to its best. For every scrap separation system, a higher level of automation demands more and more accurate programming device. So, we are using programmable logic controller (PLC) as main component
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Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
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Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
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Collaborators and co editors: Charlie Sims and Connor Healey.
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About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Automatic convey or System with In–Process Sorting Mechanism using PLC and HMI System
1. Y V Aruna et al. Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 11, (Part - 3) November 2015, pp.37-42
www.ijera.com 37 | P a g e
Automatic convey or System with In–Process Sorting Mechanism
using PLC and HMI System
Y V Aruna*, Beena S**
*(Department of Electrical & Electronics Engg., Cambridge Institute Of Technology, Bangalore-36)
**(Department of Electrical & Electronics Engg., Cambridge Institute Of Technology, Bangalore-36)
ABSTRACT
Programmable logic controllers are widely used in many manufacturing process like machinery packaging
material handling automatic assembly. These are special type of microprocessor based controller used for any
application that needs any kind of electrical controller including lighting controller and HVAC control system.
Automatic conveyor system is a computerized control method of controlling and managing the sorting
mechanism at the same time maintaining the efficiency of the industry & quality of the products.HMI for
automatic conveyor system is considered the primary way of controlling each operation. Text displays are
available as well as graphical touch screens. It is used in touch panels and local monitoring of machines. This
paper deals with the efficient use of PLC in automatic conveyor system and also building the accuracy in it.
Keywords: Automatic conveyor, Human Machine Interface, High Voltage Alternating Current, Programmable
Logic Controller.
I. INTRODUCTION
Automating every sector of industry is an
important step toward increasing efficiency and
reducing human related errors, here we try to
automate the sorting process by using PLC. In many
industries job pieces of various sizes are moved on
same conveyor belt these need to separate at various
locations in the manufacturing line. For this purpose
we are using the automated process which is used to
sort the materials which are of different sizes. After
completion of manufacturing the products
automatically move on the conveyor belts. Sensors at
different places sense and detect the job pieces of
different sizes.
They get sorted at different places based upon
their sizes. The entire process is controlled by the
program dumped in PLC. 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.
1.1 Programmable Logic Controller System
A programmable logic controller (PLC) is an
industrial computerised control system that
continuously monitors the states of input devices and
makes decisions based upon a custom program to
control the state of output devices. A fixed PLC is
usually small, has little memory, and a limited
number of inputs and outputs, or I/O as typically
referred to fig.1.1. The CPU, power supply, and I/O
system are all constructed as a single entity.
Fig.1.1 PLC System
The input sensing devices is fed to the input
module which acts like an optical isolation. What is
connected to the main device CPU and memory data.
The monitor who acts like a programming device
where it displays the given. Then the entire system is
connected to the output block where the outputs are
the lamp, motor, etc.
II. HUMAN MACHINE INTERFACE
The HMI (Human Machine Interface) system
represents the interface between man (operator) and
process (machine/plant). The PLC is the actual unit
which controls the process. Hence, there is an
interface between the operator and WinCC flexible
(at the HMI device) and an interface between WinCC
flexible and the PLC. An HMI system assumes the
following tasks:
Process visualization
Operator control of the process
Displaying alarms
Archiving process values and alarms
RESEARCH ARTICLE OPEN ACCESS
2. Y V Aruna et al. Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 11, (Part - 3) November 2015, pp.37-42
www.ijera.com 38 | P a g e
Process values and alarms logging
Process and machine parameter management
WinCC flexible Engineering System
1.2.1 Win CC flexible Engineering System
The Win CC flexible Engineering System is the
software for handling all your essential configuring
tasks. The Win CC flexible edition determines which
HMI devices in the SIMATIC Communication with
the automation systems. On-screen visualization of
images Operating the process.
For example, by setting set point values or
opening and closing valves. Archiving of current
runtime data, e.g. process values and alarm events.
1.2.1.1 Automation concept with Wincc flexible
Win CC flexible supports the configuration of
many different automation concepts. The following
automation concepts can be implemented by default
using WinCC flexible.
Control with one HMI device
An HMI device which is directly connected to
the PLC via the process bus is referred to as a single-
user system shown in fig.1.2.1.1.Single-user systems
are generally used near production, but can also be
deployed to operate and monitor independent part
processes or system sections.
Fig.1.2.1.1 Single-user HMI System
1.2.2 HMI System with centralized functions
An HMI system is connected to a PC via
Ethernet. The upstream PC assumes central
functions, e.g. recipe management. The necessary
recipe data records are provided by the subordinate
HMI system as in fig 1.2.2.
Fig.1.2.2. HMI System with centralized functions
1.2.2.1 Support for Mobile Units
Mobile units are mainly implemented in large
production plants, long production lines or in
conveyor technology, but can also be implemented in
systems in which direct visual contact with the
process is necessary. The machines to be operated are
equipped with several interfaces to which the Mobile
Panel 170, for example, can be connected.
1.2.2.2 Remote access to HMI
By using the Smart Service option, it is possible
to connect to an HMI device from a workstation via a
network (Internet, LAN).
Example: A medium-sized production company has a
service contract with an external service company.
When servicing is required, the service technician
responsible can remotely access the HMI device and
display its user interface directly on his workstation.
In this way, updated projects can be transferred more
quickly which, in turn, reduces machine downtime.
III. HARDWARE CONFIGURATION
Fig.1.3.Block diagram of Automatic conveyor system
with PLC& HMI
Fig.1.3 shows the block diagram which 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.
3. Y V Aruna et al. Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 11, (Part - 3) November 2015, pp.37-42
www.ijera.com 39 | P a g e
1.3.1 Inductive Proximity Sensor [Metal Sensor]
A metal detector is an electronic
instrument which detects the presence of metal
nearby. Metal detectors are useful for finding metal
inclusions hidden within objects. Proximity sensors
(refer fig.1.3.1) are generally constructed with four
main elements:
a coil and ferrite core assembly
an oscillator
a convertor/trigger circuit (detector)
output device
Fig.1.3.1.Schematic diagram of Proximity sensor
1.3.1.1Specifications
Table.1.3.1.1 Specification of Proximity sensor
1.3.2 Ultrasonic Level Sensor
The principle of operation of the ultrasonic
sensor system is to use the ultrasonic pulses which
are transmitted by the transducer to the surface to be
monitored and are reflected back to the transducer,
the time period between transmission and reception
of the sound pulses is directly proportional to the
distance between the transducer and surface, A
micro-controller computes this time period for all
echoes received and analyses them to determine
which is the correct reflection from the material
surface, it uses this data as the basis for giving
control outputs and displays in usable engineering
units.Refer Table 1.3.2 for the general specifications
of the sensor.
General Specification
Sensing range 70…1000 mm
Adjustment range 90…1000 mm
Unusable area 0 … 70 mm
Standard Target
area
100mm x 100mm
Transducer
frequency
Approx.KHZ
Response delay Approx.125ms
Table.1.3.2. Specification of Ultrasonic level sensor
1.3.3 Geared DC Motor
30 RPM Side Shaft 37mm diameter compact DC
Gear Motor is suitable for small robots / automation
systems Motor runs smoothly from 4V to 12V and
gives 30 RPM at 12V.Motor has 6mm diameter,
22mm length drive shaft with D shape for excellent
coupling.
1.3.4 Pneumatics:
In a pneumatic system, energy is stored in a
potential state under the form of compressed air.
Working energy (kinetic energy and pressure) results
in a pneumatic system when the compressed air is
allowed to expand. To perform any applicable
amount of work then, a device is needed which can
supply an air tank with a sufficient amount of air at a
desired pressure. There are many different cylinder
types. The cylinders used in our paper are listed
below:
1. Single acting spring return cylinder
2. Double acting cylinder
3. Directional Control Valves
4. FOUR Way Valve
Fig.1.3.4 Pneumatic system
1.3.5.Basic procedures for configuring hardware
Window for configuring a programmable
controller involves the use of two windows. The
station window in which you place racks for the
station structure. The “hardware catalogue” window
from which you select the required hardware
components,for example racks , modules and
interface sub modules displaying the hardware
catalogue if the “hardware catalogue” window is not
displayed, select the menu command view >
catalogue. This command toggles the display of the
hardware catalogue on and off.fig.1.3.5 shows the
hardware configuration of the system.
Basic steps for configuring a station independent
of which structure a station has you always configure
using the following steps
1. Select a hardware component in the “hardware
catalogue” window.
2. Copy the selected component to the station
window using drag and drop.
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Fig.1.3.5.Overview of hardware configuration
IV. Design of Automatic Conveyor
System
The main objective of the system is automatic
sorting of materials which can be applied to
industries as in fig1.4.1.Here, by operating push
button switch the conveyor starts to move and the
items are being sorted.
Fig. 1.4.1 Design of Automatic Conveyor System
The ultrasonic level sensor and inductive
proximity metal sensor are mounted on the model
and are connected to the SEIMENS PLC kit. When
the objects are detected by the level sensor the signal
is sent to the SEIMENS PLC kit where according to
the programmed ladder logic the conditions are
analyzed and the output is given to pneumatic valves
which activates pistons for sorting.
Fig. 1.4.2.Circuit diagram
Meanwhile, the metal detector which is
connected to SEIMENS PLC kit. when the objects
that contain hidden metal in them are detected and
signal is given to the PLC where according to the
ladder logic the objects with metal are rejected from
the conveyor by activating the pistons and hence
carrying out the sorting mechanisms. Since we are
sorting the height of the object. If any objects which
are over height than the required height are rejected
from the conveyor to avoid inconvenience.
For example consider the height of the objects
4cm, 8cm and 12cm for sorting as shown in fig.1.4.3.
When the ultrasonic level sensor senses the height of
the object if it is 4cm it should be segregated in bin 1,
8cm at bin 2 and 12cm at bin 3. Suppose the objects
contain hidden metal in them then it is sensed by the
metal sensor and rejected before going to sorting
process
Fig. 1.4.3.Real time Sorting system
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V. HMI DESIGN
The following are the screens for our HMI panel
where the screens are programmed and the whole
automation can be controlled by HMI.
SCREEN 1
The welcome screen is the screen which
navigates the operator to the next screens.
SCREEN 2
The authorization screen which has a user id and
password for the administrator and other users to use
the HMI panel.
SCREEN 3
The MENU screen helps the operator to control
the sorting system by providing the options on the
screen.
SCREEN 4
The CONVEYOR MONITORING screen
provides access for starting and stopping the sorting
process.
SCREEN 5
The REPORT screen provides information of the
number of parts sorted.
SCREEN 6
The LEVEL SETTINGS gives control for the
operator to enter desired height of the parts to be
sorted.
SCREEN 7
The INFO screen provides information about the
sorting process.
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VI. ADVANTAGES
Time saving and efficient.
Increases in production capacity and quality.
Decreases in total manufacturing cost.
Less manual work.
Easy analysis.
Improves productivity
VII. DISADVANTAGES
Costly for small scale industries
The sorting mechanism is time based hence
frequent monitoring is required.
PLC devices are proprietary
Unemployment rate increases
VIII. APPLICATIONS
Manufacturing / machining
Food / beverage
Textile industry
Printing industry
IX. CONCLUSION
In present day scenario automation is of vital
importance. Automation is very efficiently put up in
practice in many ways; one of them is automatic
conveyor system with in-process sorting mechanism.
The main advantage of PLC is it is been controlling
multiple inputs and outputs, the entire conveyor
model can be controlled by a single PLC along with
sensors installed throughout.
The use of PLC and HMI in automation
applications has grown in recent years. The
economics of PLC based solutions mean that
automatic conveyor and HMI solutions can be
applied even more widely. This will help the utilities
respond to the challenges presented by the
deregulations. As the use of PLCs in automatic
conveyor increases the criteria for selection of control
system integrators, engineering firms and consultants
will become and extremely important factor in
success of PLC based automation and HMI projects.
One of the most important criteria in the control
system integrator- the engineering firm the consultant
has sound business practices in place. They should
also have a project management methodology in
place to assure the success of these projects.
REFERENCES
[1]. Keller, William L Jr.Grafcet, A Functional
Chart for Sequential Processes, 14th Annual
International Programmable Controllers
Conference Proceedings, 1984, p. 71-96.
[2]. Kinner, Russell H., P.E. Designing
Programmable Controller Application
Programs Using More than One
Designer.14th
Annual International
Programmable Controllers Conference
Proceedings, 1985, p. 97-110.
[3]. Maher, Michael J.Real-Time Control and
Communications. 18th Annual ESD/SMI
International Programmable Controllers
Conference Proceedings, 1989, p. 431-436.
[4]. Yang, G., Rasis, Y., “Teaching PLC in
Automation – A Case Study”, ASEE Annual
Conference &Exposition, 2003
[5]. Guo, L., Pecen, R., “Design Projects in a
Programmable Logic Controller (PLC)
Course in Electrical Engineering
Technology”, ASEE Annual Conference &
Exposition, 2008
Books:
[1]. W. Bolton,Programmable Logic
Controllers, (Fifth Edition, Newnes, 2009
ISBN 978-1-85617-751-1,Chapter 1)
[2]. Johnson, C. D., Process Control
Instrumentation Technology, (Prentice Hall,
2006).
[3]. Petruzella, F. D., Programmable Logic
Controllers, (McGraw Hill, 2005).