This document describes a metal rejection system on a production line designed to detect metal objects, remove them, and count how many are removed. It uses a PLC, motor, sensors, and light tower. Metal objects on a rotating conveyor trip a proximity sensor and are tossed out by a stepper motor. A magnetic sensor counts objects in a chute. If three objects are counted, the system stops until reset. The system can start and stop via buttons and detects speed changes with additional sensors. Diagrams show the hardware layout and ladder logic programming.
The document describes a PLC program for controlling a dual air compressor system using a three-wire motor control logic with fault monitoring and pilot light circuits. The program uses Balluff sensors for safety and a keyed selector switch to control the main rung. Rung 001 monitors the sensors, 002 controls the start button and safety bits, 003 controls the motor starter coil via pressure switches, and 004 controls the compressor switch. Rung 005 monitors the motor starter for faults, with the start button also used to reset faults. The pilot light indicates motor running status and faults.
Hyster c108 (e3.00 xl europe) forklift service repair manualfujdfjjjsekkemme
This document provides information about steering systems for electric lift trucks. It describes the components and operation of power steering and power steering with on-demand systems. The key components are the steering wheel, optical encoder, activator, steering control unit, steering pump motor, steering pump, and hydraulic steering motor or steering cylinder. It also provides repair procedures for the steering wheel and column assembly, including removal and installation of components. Diagrams are included to illustrate the steering system components and hydraulic schematic.
Hyster c203 (a1.50 xl europe) forklift service repair manualfujdfjjskekmwem
This document provides information about steering systems for electric lift trucks, including:
- There are two types of steering systems - power steering and power steering with on-demand. The components differ between the systems.
- Additional details about components like the master drive unit, steering axle, and steering control unit can be found in other sections.
- The steering system uses hydraulics powered by an electric pump motor to steer the truck instead of a direct mechanical connection between the steering wheel and steering components.
- The steering wheel operates an optical encoder and activator which energizes the pump motor. It also operates the steering control unit to direct hydraulic fluid to steer the vehicle.
The document discusses various topics relating to motor speed control including synchronous speed, rotor speed, pole changes in induction motors, separate winding induction motors, Dahlander motors, circuits to control motor speed with two speeds, examples of motor control circuits, cable diameter calculations, carrying out a control panel, fault detection, counters, and an example project controlling conveyors and a piston.
What are the Signs of a Faulty Fuel Rail Pressure Sensor in a CarDell's Service Center
A fuel rail pressure sensor is an electronic device that provides fuel pressure data to the vehicle’s engine control module. The fuel rail is responsible for the supply of fuel to the vehicle’s combustion chamber. And it is the rail sensor that ensures that the engine cylinder is receiving the right amount of fuel at the right pressure. When it goes bad, it will affect the performance of the speed machine adversely. So, be aware of the signs of its failure so that you can replace it timely and keep the vehicle in a good performable state.
Research and Developmetn of an Automated Airbrush Paint Spraying RobotMrbuiltenvironment
This document describes the design and implementation of an automated airbrush painting robot for 3D printed parts. It includes sections on the project planning and requirements, motor requirements, electronics design, and Arduino code. The robot uses a RAMPS 1.4 shield and Arduino Mega to control 4 stepper motors that move the airbrush vertically and horizontally, rotate the part plate, and move a linear guide. The robot is able to automatically paint 3D printed parts and assemblies in a repeatable manner.
The stepper motor control system uses ULN2003 chip to drive. The working voltage is DC5V. It is widely used on ATM machine, inkjet printer
cutting plotter, fax machine,spraying equipment, medical instruments and equipments, PC peripheral, and USB Mass Storage ,precise instrument
industrial control system,office automation,robot areas,etc.
This document describes a microcontroller-based electronic governor and control system for a mini-hydro power plant. The system aims to automate operations, allow remote control, and improve on expensive commercial options. It uses a PIC microcontroller to control components like frequency counters, water level sensors, valve position sensors, and stepper motor drivers. This allows the system to start up and shut down the plant automatically, control output frequency and power levels, and implement safety measures. Future developments could include connecting the system to the internet for remote monitoring and control through a computer.
The document describes a PLC program for controlling a dual air compressor system using a three-wire motor control logic with fault monitoring and pilot light circuits. The program uses Balluff sensors for safety and a keyed selector switch to control the main rung. Rung 001 monitors the sensors, 002 controls the start button and safety bits, 003 controls the motor starter coil via pressure switches, and 004 controls the compressor switch. Rung 005 monitors the motor starter for faults, with the start button also used to reset faults. The pilot light indicates motor running status and faults.
Hyster c108 (e3.00 xl europe) forklift service repair manualfujdfjjjsekkemme
This document provides information about steering systems for electric lift trucks. It describes the components and operation of power steering and power steering with on-demand systems. The key components are the steering wheel, optical encoder, activator, steering control unit, steering pump motor, steering pump, and hydraulic steering motor or steering cylinder. It also provides repair procedures for the steering wheel and column assembly, including removal and installation of components. Diagrams are included to illustrate the steering system components and hydraulic schematic.
Hyster c203 (a1.50 xl europe) forklift service repair manualfujdfjjskekmwem
This document provides information about steering systems for electric lift trucks, including:
- There are two types of steering systems - power steering and power steering with on-demand. The components differ between the systems.
- Additional details about components like the master drive unit, steering axle, and steering control unit can be found in other sections.
- The steering system uses hydraulics powered by an electric pump motor to steer the truck instead of a direct mechanical connection between the steering wheel and steering components.
- The steering wheel operates an optical encoder and activator which energizes the pump motor. It also operates the steering control unit to direct hydraulic fluid to steer the vehicle.
The document discusses various topics relating to motor speed control including synchronous speed, rotor speed, pole changes in induction motors, separate winding induction motors, Dahlander motors, circuits to control motor speed with two speeds, examples of motor control circuits, cable diameter calculations, carrying out a control panel, fault detection, counters, and an example project controlling conveyors and a piston.
What are the Signs of a Faulty Fuel Rail Pressure Sensor in a CarDell's Service Center
A fuel rail pressure sensor is an electronic device that provides fuel pressure data to the vehicle’s engine control module. The fuel rail is responsible for the supply of fuel to the vehicle’s combustion chamber. And it is the rail sensor that ensures that the engine cylinder is receiving the right amount of fuel at the right pressure. When it goes bad, it will affect the performance of the speed machine adversely. So, be aware of the signs of its failure so that you can replace it timely and keep the vehicle in a good performable state.
Research and Developmetn of an Automated Airbrush Paint Spraying RobotMrbuiltenvironment
This document describes the design and implementation of an automated airbrush painting robot for 3D printed parts. It includes sections on the project planning and requirements, motor requirements, electronics design, and Arduino code. The robot uses a RAMPS 1.4 shield and Arduino Mega to control 4 stepper motors that move the airbrush vertically and horizontally, rotate the part plate, and move a linear guide. The robot is able to automatically paint 3D printed parts and assemblies in a repeatable manner.
The stepper motor control system uses ULN2003 chip to drive. The working voltage is DC5V. It is widely used on ATM machine, inkjet printer
cutting plotter, fax machine,spraying equipment, medical instruments and equipments, PC peripheral, and USB Mass Storage ,precise instrument
industrial control system,office automation,robot areas,etc.
This document describes a microcontroller-based electronic governor and control system for a mini-hydro power plant. The system aims to automate operations, allow remote control, and improve on expensive commercial options. It uses a PIC microcontroller to control components like frequency counters, water level sensors, valve position sensors, and stepper motor drivers. This allows the system to start up and shut down the plant automatically, control output frequency and power levels, and implement safety measures. Future developments could include connecting the system to the internet for remote monitoring and control through a computer.
IRJET- Design of Diagnosis Device for Electronic Throttle BodyIRJET Journal
1) The document describes the design of a portable diagnostic device for testing the electronic components of an electronic throttle body, including the sensor and motor.
2) The device consists of hardware and software. The hardware includes a microcontroller, sensors to measure throttle position, and a motor driver circuit. The software processes the sensor outputs and displays the results on an LCD screen. It also controls the motor to rotate the throttle plate.
3) The diagnostic device allows testing of the position sensor and motor by displaying the sensor values at different throttle plate positions, and visually inspecting the plate's movement to its mechanical stops. This verifies the components are functioning properly.
An external plunge grinding machine with control panel automation techniqueIAEME Publication
This document describes an external plunge grinding machine automated with a control panel using a Mitsubishi PLC system. It discusses how programmable logic controllers have improved manufacturing productivity by providing flexible, reliable control. The PLC controls inputs like push buttons and outputs like motors and lights. Ladder logic programming is used to automate the machine's grinding and loading/unloading sequences. Servo and induction motors precisely position the grinding wheel. A human-machine interface allows users to input part programs. Communication between the PLC and computer allows storing and monitoring machine data. Overall, automating the machine's control panel with a PLC improves productivity and efficiency compared to traditional control techniques.
This document provides an operating manual for the HGM72 Automatic Generator Module. The module can automatically start and stop a generator based on remote start signals or manually via buttons. It monitors for faults like low oil pressure, high temperature, overspeed, and more. It has LED indicators to display operating status and faults. Parameters like delay times and output configurations can be set via PC connection.
Unity Feedback PD Controller Design for an Electronic Throttle BodySteven Ernst, PE
This document summarizes the design process for developing a closed-loop feedback control system for an electronic throttle body. It involves:
1) Modeling the system to obtain the transfer function.
2) Analyzing the transfer function using MATLAB to determine if the system is stable or oscillatory.
3) Simulating an open-loop model to account for real-world non-idealities.
4) Designing a PD controller to meet specifications and stabilize the oscillatory system. The controller is tuned using MATLAB simulations.
5) Implementing the designed controller in a closed-loop system model in System Vision software.
This document summarizes an experiment conducted with a stepper motor. It introduces stepper motors and describes their operation and components. The experiment uses a Unipolar stepper motor connected to a ULN2003A integrated circuit and controlled through a Visual Basic program. The program allows the stepper motor to rotate clockwise and counter-clockwise in both full and half steps at varying speeds. The conclusions discuss the advantages of stepper motors and their applications in digital control systems.
The document provides instructions for testing and maintaining the RED4 electronically controlled high pressure diesel pump. It describes the pump's structure, working principles, and differences from past mechanical pumps. The RED4 system uses a linear DC motor and sensors to control the fuel injection quantity electronically based on engine speed and other factors. It also outlines testing procedures and maintenance tips for technicians working on these pumps.
Automatic Street Light Operating SystemIRJET Journal
This document describes an automatic street light operating system that uses an Arduino microcontroller to efficiently switch street lights on and off based on light levels and time of day. Lights are divided into two groups that are powered separately. In auto mode, a light dependent resistor and wiper sensor detect light levels and switch lights on at dusk and off at dawn. The system can also be controlled manually from a computer interface to switch specific light groups on and off. A secondary timer circuit provides backup control of lights if the microcontroller fails. This automatic system is estimated to save over 25% of electricity used for street lighting compared to a manual system.
This document provides an overview of the electrical systems at the Kohinoor Energy Limited power plant. It discusses the plant's medium voltage (MV), low voltage (LV), and high voltage (HV) systems. For the MV system, it describes the generators, generator protection relays, current transformers (CTs) and potential transformers (PTs), SF6 circuit breakers, and MV switchgear. Station and main transformers are also discussed. Safety protocols like required protective equipment and sophisticated fire systems are summarized.
A presentation made at A 2-day Annual Symposium, organized by Electrical/Electronic Engineering Department, FUTO, at School of Engineering and Engineering Technology (SEET) Complex Auditorium, FUTO, Imo State. (August 18, 2016)
IRJET- Automated Gear Transmission in Two Wheelers using Embedded SystemIRJET Journal
This document summarizes an embedded system project that aims to automate the manual transmission on motorcycles. The system uses an AVR microcontroller programmed in C to control relays and a stepper motor based on input from a proximity sensor on the rear wheel. This allows the gear selection to shift automatically based on rear wheel speed. The microcontroller is programmed with thresholds for gear changes based on pulses detected by the sensor over time. A flowchart represents the program logic. The system was designed and simulated using Proteus software and the Arduino IDE. It aims to improve driving ease and efficiency over traditional manual transmission motorcycles.
IRJET- Fuzzy Logic based Fault Detection in Induction Machines using CloudIRJET Journal
This document presents a system for online condition monitoring of induction motors using fuzzy logic and cloud computing. It involves two phases:
1) Developing a simulation model in MATLAB/Simulink to monitor motor parameters and detect faults.
2) Implementing an online condition monitoring system using a Raspberry Pi, sensors to measure motor vibrations, temperature etc., and a cloud platform to remotely store and access data in real-time.
Fuzzy logic is used to analyze sensor data and detect faults based on defined rules and membership functions. The system aims to monitor key parameters of induction motors and identify failures to enable safe and efficient operation in industrial applications.
IRJET- Automation of Heat Treatment Process line using PLCIRJET Journal
This document describes an automated material handling system for heat treatment processes using a programmable logic controller (PLC). The system uses pneumatic cylinders and a ladder-like structure to move materials into and out of a furnace for annealing and hardening. It was designed to reduce labor costs and improve safety compared to manual handling. The system loads materials into the furnace, allows them to undergo heat treatment for a set time delay, then removes and positions them for further processing. The material movements are controlled by a ladder logic program in a PLC. Testing showed the automated system could successfully handle materials through the entire heat treatment process sequence. The system provides a prototype for automating heat treatment material handling in industry to reduce errors and increase
Part 1: frequently asked electrical engineering interview questionsPoonam Kherde
This document contains frequently asked electrical engineering interview questions and their answers. It discusses system definitions, types of control systems including open loop and closed loop systems, latching current which is the minimum current needed to keep a thyristor switched on, reverse power relays which prevent power flow from the grid to a generator, and knee point voltage which is the saturation point of a current transformer. The document is divided into multiple sections with questions and detailed answers to help electrical engineering graduates prepare for interviews.
Zigbee based dc motors remote monitoring and controlUmar Shuaib
This document describes a project to design a remote control system for DC motors using a Zigbee wireless protocol. The system has two microcontrollers, one in the control and monitoring section and one at the remote location. The control panel uses buttons to send commands via Zigbee modules to the remote controller, which controls the motor rotation and monitors feedback from encoders to detect failures. The system allows controlling machines remotely to minimize hazards in industries like nuclear and chemical plants.
Probe And Revealing Faults In Three Phase System.IRJET Journal
This document discusses a project to detect and identify faults in a three-phase power system. The system uses current and voltage sensors to monitor the supply, and a microcontroller to analyze the sensor data and detect any faults. If a fault is detected, the microcontroller will trip a relay to disconnect the faulty circuit, display the type of fault on a 7-segment display, and light an LED indicator. The system can detect various faults such as high or low voltage/current, dry run faults, and phase or supply reversal faults. The goal is to quickly identify faults to protect equipment and reduce outage times.
This document provides information about engine components and the engine control unit's (ECU) operation on a diesel engine. It discusses:
1. The major engine sensors that provide input to the ECU like temperature, pressure, and position sensors.
2. How the ECU controls injection timing and fuel pressure based on sensor inputs to optimize power and emissions under different operating conditions. It uses multi-injection strategies and closed-loop control of fuel pressure.
3. The ECU's control of injection timing factors like temperature, pressure, and exhaust gas recirculation (EGR) to improve combustion and reduce emissions.
Position control of a single arm manipulator using ga pid controllerIAEME Publication
This document discusses using a genetic algorithm to optimize the gains of a PID controller for a fixed arm manipulator system. It begins by describing the hardware and software implementation of the fixed arm system, including sensors, actuators, and control interfaces. It then applies a system identification technique to develop a transfer function model of the system based on experimental input/output data. Finally, it uses a genetic algorithm offline to search for the optimal PID gain values that minimize errors for the identified system model. The optimal PID gains found using the genetic algorithm are then applied to the real fixed arm system for control.
IRJET- Design of Diagnosis Device for Electronic Throttle BodyIRJET Journal
1) The document describes the design of a portable diagnostic device for testing the electronic components of an electronic throttle body, including the sensor and motor.
2) The device consists of hardware and software. The hardware includes a microcontroller, sensors to measure throttle position, and a motor driver circuit. The software processes the sensor outputs and displays the results on an LCD screen. It also controls the motor to rotate the throttle plate.
3) The diagnostic device allows testing of the position sensor and motor by displaying the sensor values at different throttle plate positions, and visually inspecting the plate's movement to its mechanical stops. This verifies the components are functioning properly.
An external plunge grinding machine with control panel automation techniqueIAEME Publication
This document describes an external plunge grinding machine automated with a control panel using a Mitsubishi PLC system. It discusses how programmable logic controllers have improved manufacturing productivity by providing flexible, reliable control. The PLC controls inputs like push buttons and outputs like motors and lights. Ladder logic programming is used to automate the machine's grinding and loading/unloading sequences. Servo and induction motors precisely position the grinding wheel. A human-machine interface allows users to input part programs. Communication between the PLC and computer allows storing and monitoring machine data. Overall, automating the machine's control panel with a PLC improves productivity and efficiency compared to traditional control techniques.
This document provides an operating manual for the HGM72 Automatic Generator Module. The module can automatically start and stop a generator based on remote start signals or manually via buttons. It monitors for faults like low oil pressure, high temperature, overspeed, and more. It has LED indicators to display operating status and faults. Parameters like delay times and output configurations can be set via PC connection.
Unity Feedback PD Controller Design for an Electronic Throttle BodySteven Ernst, PE
This document summarizes the design process for developing a closed-loop feedback control system for an electronic throttle body. It involves:
1) Modeling the system to obtain the transfer function.
2) Analyzing the transfer function using MATLAB to determine if the system is stable or oscillatory.
3) Simulating an open-loop model to account for real-world non-idealities.
4) Designing a PD controller to meet specifications and stabilize the oscillatory system. The controller is tuned using MATLAB simulations.
5) Implementing the designed controller in a closed-loop system model in System Vision software.
This document summarizes an experiment conducted with a stepper motor. It introduces stepper motors and describes their operation and components. The experiment uses a Unipolar stepper motor connected to a ULN2003A integrated circuit and controlled through a Visual Basic program. The program allows the stepper motor to rotate clockwise and counter-clockwise in both full and half steps at varying speeds. The conclusions discuss the advantages of stepper motors and their applications in digital control systems.
The document provides instructions for testing and maintaining the RED4 electronically controlled high pressure diesel pump. It describes the pump's structure, working principles, and differences from past mechanical pumps. The RED4 system uses a linear DC motor and sensors to control the fuel injection quantity electronically based on engine speed and other factors. It also outlines testing procedures and maintenance tips for technicians working on these pumps.
Automatic Street Light Operating SystemIRJET Journal
This document describes an automatic street light operating system that uses an Arduino microcontroller to efficiently switch street lights on and off based on light levels and time of day. Lights are divided into two groups that are powered separately. In auto mode, a light dependent resistor and wiper sensor detect light levels and switch lights on at dusk and off at dawn. The system can also be controlled manually from a computer interface to switch specific light groups on and off. A secondary timer circuit provides backup control of lights if the microcontroller fails. This automatic system is estimated to save over 25% of electricity used for street lighting compared to a manual system.
This document provides an overview of the electrical systems at the Kohinoor Energy Limited power plant. It discusses the plant's medium voltage (MV), low voltage (LV), and high voltage (HV) systems. For the MV system, it describes the generators, generator protection relays, current transformers (CTs) and potential transformers (PTs), SF6 circuit breakers, and MV switchgear. Station and main transformers are also discussed. Safety protocols like required protective equipment and sophisticated fire systems are summarized.
A presentation made at A 2-day Annual Symposium, organized by Electrical/Electronic Engineering Department, FUTO, at School of Engineering and Engineering Technology (SEET) Complex Auditorium, FUTO, Imo State. (August 18, 2016)
IRJET- Automated Gear Transmission in Two Wheelers using Embedded SystemIRJET Journal
This document summarizes an embedded system project that aims to automate the manual transmission on motorcycles. The system uses an AVR microcontroller programmed in C to control relays and a stepper motor based on input from a proximity sensor on the rear wheel. This allows the gear selection to shift automatically based on rear wheel speed. The microcontroller is programmed with thresholds for gear changes based on pulses detected by the sensor over time. A flowchart represents the program logic. The system was designed and simulated using Proteus software and the Arduino IDE. It aims to improve driving ease and efficiency over traditional manual transmission motorcycles.
IRJET- Fuzzy Logic based Fault Detection in Induction Machines using CloudIRJET Journal
This document presents a system for online condition monitoring of induction motors using fuzzy logic and cloud computing. It involves two phases:
1) Developing a simulation model in MATLAB/Simulink to monitor motor parameters and detect faults.
2) Implementing an online condition monitoring system using a Raspberry Pi, sensors to measure motor vibrations, temperature etc., and a cloud platform to remotely store and access data in real-time.
Fuzzy logic is used to analyze sensor data and detect faults based on defined rules and membership functions. The system aims to monitor key parameters of induction motors and identify failures to enable safe and efficient operation in industrial applications.
IRJET- Automation of Heat Treatment Process line using PLCIRJET Journal
This document describes an automated material handling system for heat treatment processes using a programmable logic controller (PLC). The system uses pneumatic cylinders and a ladder-like structure to move materials into and out of a furnace for annealing and hardening. It was designed to reduce labor costs and improve safety compared to manual handling. The system loads materials into the furnace, allows them to undergo heat treatment for a set time delay, then removes and positions them for further processing. The material movements are controlled by a ladder logic program in a PLC. Testing showed the automated system could successfully handle materials through the entire heat treatment process sequence. The system provides a prototype for automating heat treatment material handling in industry to reduce errors and increase
Part 1: frequently asked electrical engineering interview questionsPoonam Kherde
This document contains frequently asked electrical engineering interview questions and their answers. It discusses system definitions, types of control systems including open loop and closed loop systems, latching current which is the minimum current needed to keep a thyristor switched on, reverse power relays which prevent power flow from the grid to a generator, and knee point voltage which is the saturation point of a current transformer. The document is divided into multiple sections with questions and detailed answers to help electrical engineering graduates prepare for interviews.
Zigbee based dc motors remote monitoring and controlUmar Shuaib
This document describes a project to design a remote control system for DC motors using a Zigbee wireless protocol. The system has two microcontrollers, one in the control and monitoring section and one at the remote location. The control panel uses buttons to send commands via Zigbee modules to the remote controller, which controls the motor rotation and monitors feedback from encoders to detect failures. The system allows controlling machines remotely to minimize hazards in industries like nuclear and chemical plants.
Probe And Revealing Faults In Three Phase System.IRJET Journal
This document discusses a project to detect and identify faults in a three-phase power system. The system uses current and voltage sensors to monitor the supply, and a microcontroller to analyze the sensor data and detect any faults. If a fault is detected, the microcontroller will trip a relay to disconnect the faulty circuit, display the type of fault on a 7-segment display, and light an LED indicator. The system can detect various faults such as high or low voltage/current, dry run faults, and phase or supply reversal faults. The goal is to quickly identify faults to protect equipment and reduce outage times.
This document provides information about engine components and the engine control unit's (ECU) operation on a diesel engine. It discusses:
1. The major engine sensors that provide input to the ECU like temperature, pressure, and position sensors.
2. How the ECU controls injection timing and fuel pressure based on sensor inputs to optimize power and emissions under different operating conditions. It uses multi-injection strategies and closed-loop control of fuel pressure.
3. The ECU's control of injection timing factors like temperature, pressure, and exhaust gas recirculation (EGR) to improve combustion and reduce emissions.
Position control of a single arm manipulator using ga pid controllerIAEME Publication
This document discusses using a genetic algorithm to optimize the gains of a PID controller for a fixed arm manipulator system. It begins by describing the hardware and software implementation of the fixed arm system, including sensors, actuators, and control interfaces. It then applies a system identification technique to develop a transfer function model of the system based on experimental input/output data. Finally, it uses a genetic algorithm offline to search for the optimal PID gain values that minimize errors for the identified system model. The optimal PID gains found using the genetic algorithm are then applied to the real fixed arm system for control.
Position control of a single arm manipulator using ga pid controller
EGRE 553-Industrial Controls
1. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
EGRE 553 – Industrial Controls
Metal Rejection System
Jose Ramirez
Rahel Mekonnen
2. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Final Design: Metal Rejection System on a Production Line.
Consider a production line of consumed goods. This production line has eatable goods
that are on their way to the customers. During this production process it is necessary to avoid
defects such as the presence of metal that may be mixed with the product. The system is
designed to detect the presence of metal, eliminate it, and keep track of how many specimens of
metal are being eliminated from the production line autonomously.
Procedure:
A metal object is placed on top of a rotary table that is driven by a variable frequency
drive motor. When the system is powered on, the red light is on, pressing the green momentary
push button when the motor is not active, should turn on the green light output on the light tower
and start the motor at 60rpm or at a frequency of 1Hz, rotating a disk connected to the AC motor.
Subsequent pushes of the green momentary push button to increase by 1Hz and up to a frequency
5Hz, Pressing the red momentary push button should decrease the FreqCommand by 1Hz,
decreasing frequency to 0Hz gives the motor the active motor stop command. Whenever the
motor is accelerating or decelerating the yellow light blinks.
As a metal object trips metal proximity sensor, a timed stepper motor is activated tossing
the metal object out to a chute where a trap door is tripped triggering a magnetic proximity
sensor that keeps count of how many metal objects go down the chute. If three trips of the
magnetic proximity sensor are detected, the system is given the active motor stop command and
the system shuts off. A limit switch is triggered to reset the count on the objects, signifying the
system is reset and it may continue operation. If at any point Emergency button is pressed the
system stops what is doing, the motor is given the motor stop command and the red light turns
on. If the red light is turned on, the motor may not be started using the green momentary push
button until the Emergency button is reset and system resumes operation.
System Hardware layout:
This system uses a PLC controller, Input Modules, and Output Modules. A light tower,
two momentary push buttons, one emergency push button, a limit switch, a PowerFlex 525 AC
VFD Controller, an AC motor, an arm processor, a 24 to 5V transformer, one stepper motor, one
metal proximity sensor, and a magnetic proximity sensor.
As seen in Figure 1, Schematic for this system. The green and red momentary buttons are
connected to their respected input on the terminal modules as Normally Open connections (NO),
and the system is connected in sourcing mode. The green momentary button is connected to
Input 0, and the red momentary button is connected to Input 1 on the input terminal module. The
emergency stop button is connected to Input 2 on the input terminal module, as a Normally
Closed Connection (NC). The Limit switch for the operation is connected to Input 3 on the
terminal module. The metal proximity sensor is connected to Input 4 and the magnetic proximity
sensor at Input 5.
3. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
The output of the system is the light tower that consists of a red, yellow, and green light.
The green light of the light tower is connected to Output 0, on the output terminal module, the
yellow light connects to Output 1, and the red light connects to Output 2. The stepper motors
processor is connected on Output 3 of the system.
The system is powered by a 24V source that connects to each of the terminal modules.
LED on the terminal module are powered by a 24V source on the input terminal, and ground on
the output module. These connections can be seen leading to the back of the output and input
module. The PowerFlex 525 VFD Controller, is connected to the PLC controller via Ethernet,
where the AC motor connects to the PowerFlex Drive.
Figure 1: Schematic of System layout with wiring for the input and output devices.
Mechanical Hardware Design of the System Shown below in Figures 1.1- 1.8 . Show an
accurate representation of what the final design of the system looked like in proportion to the AC
motor and the Powerflex 525. All parts of the system are shown and described as they were built
in the system.
4. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 1.1: Front View of overall System including all parts.
Figure 1.2: Top View of Overall System
5. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 1.3: Gear system that drives the circular conveyor.
Figure 1.4: Gear system close up
Figures 1.3 and 1.4 shows the custom gear system build for this machine. Due the fact that the
AC motor could not be slowed down to a speed lower than what is allowed and the need for
horizontal rotation for the system, the system utilizes several small gears in series implemented
to decrease the rotational speed of the circular conveyer belt to a crawl. This allows for the
system to work as intended and keep the pieces on top of the conveyer until removed by the
stepper motor. Lowering the speed allowed for a smoother operation and the reduction of
centripetal force.
6. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 1.5: Frame that holds the Metal Proximity Sensor and stepper motor at an approximate
half an inch above the circular conveyer belt on which the metal objects are placed.
Figure 1.6: Close look of placement of Metal proximity sensor and stepper motor for system.
7. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 1.7: Overall view of Chute in which parts are discarded to by the stepper motor.
Figure 1.8: Close up of Chute shows placement of the Magnetic Proximity Sensor and the
Magnet which triggers it via trap door.
As the objects falls through the chute, the trap door is trigger moving the magnet closer to the
magnetic proximity sensor, enabling the sensor on.
8. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
System software
System utilizes EQU and LEQ instructions to maintain the system within limits of
allowed frequency. ADD and SUB instructions increase or decrease the frequency command
value, FreqCommand, accordingly for desired output. Rung 0 is enabled by green_button bit
which sets true enable_light and motor start output. Rung 1 is enabled by the pressing the
red_button or the enable_light bit on Rung 0 enabling the yellow_light output. Rung 2 and 3
used to set the upper and lower boundaries of the system that affect the yellow_light ouput. If
either Rung 2 or 3 become true, XIO instructions on Rung 1 will enable and yellow_light ouput
will not be disabled. Rung 4 implements the ADD for every subsequent press of the
green_button. Rung 5 works in unison for when is true, Halt output is enabled enabling its XIO
instruction on Rung 4. This will not allow the FreqCommand exceed its limit. ONS (one shot)
instruction is used on Rung 4 make sure the rung is only enabled for one scan cycle as the button
is pressed preventing the frequency to increase with unintended results. Rung 6 controls when
the green_light output may be enabled. Only if Rung 0 or green_button is enabled, and the EQU
instruction holds true. Similarly as Rung 4 and 5, Rung 7 and 8 holds the same logic but to
decrease the FreqCommand to the limit of 0Hz every subsequent press of the red_button input.
Rung 9 is enabled at the press of the Emergency_button or when FreqCommand is equal to 0Hz
or if the total metal in box is greater than 3. At which point the motor stop output command is
enabled, red_light output is enabled, and diable_light_yellow_zero and disable_light_green bits
are enabled to disable the green_light and yellow_light outputs on Rungs 1 and 6.
In Rung 10 When the proximity sensor is energized or the stepper motor timer is enabled
and the stepper motor trigger timer is not done timing, then it enabled the output enable_timer
Boolean. In rung 11 when the enable_timer is energized then there will be continuity in this rung
which then starts the Stepper_Motor_Trigger_Timer. In rung 12, when the accumulator value of
the Stepper_Motor_Trigger_Timer is greater than 2500 then turn the stepper motor on. In
addition, in rung 13 it is observed that when the proximity sensory inside the box is triggered and
for the first scan and the drive motor is not stopped then the ADD instruction will add the value
of Source B to Source A. Ultimately, rung 14 shows normally closed limit switch is pressed it
energizes the rung and allows continuity which then energizes the MOV instruction. Likewise,
the MOV instruction moves a value of zero to the Total_Metal_In_Box tag value. Which resets
the total count of the metals in the box.
This may be visually and descriptively followed in more detail on Figure 2 , Figure 2.1
and Figure 2.2 ladder diagrams below.
9. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 2: Ladder Diagram for System
10. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 2.1: Ladder Diagram for System
11. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
Figure 2.2: Ladder Diagram for System
12. Jose Ramirez, Rahel Mekonnen EGRE 553: Industrial Controls May 4, 2015
System Operation
When the user presses the green momentary push button, the AC motor starts and the
circular conveyor begins to rotate clockwise with metal objects placed on its surface. As these
objects are moving in a circular path on the rotary conveyer, the object passes through a
proximity sensor which detects its presence. As the metal object is detected , a delay after, a
stepper motor turns on tossing the metal object onto a chute. Every time a mental object is
dropped into the chute it passes through a trap door holding a magnet which triggers a magnetic
proximity sensor. Each trigger of the Magnetic proximity sensor counts how many objects are
tossed inside the chute. If three objects trigger the magnetic proximity sensor the system shuts
off until an operator resets the system by triggering the limit switch and the system may resume
operation. If at any point the user decides to press the Emergency stop button. The motor
decelerates to a stop and the red light output on the tower turns on. If the red light is turned on,
the user may not start the motor using the green momentary push button until the user
Emergency button is reset. At which point the user may press the green momentary push button
to start the motor again and resume operation.
Original design of the system was not able to be implemented due to the fact that the
order of parts that were necessary for the system were delivered incorrectly multiple instances. A
redesign of the idea was implemented which worked to an advantage and still was able to
demonstrate the proof of concept intended. One limitation that the system encountered was the
fact that that it had mechanical issues. Due to the fact that it was built with a limited amount of
time and limited resources. An improvement to the system may have been to use more
mechanically stable materials to insure stability and durability. Because the system had issues
mechanically, consistency in the output was the issue. The gears would pop out of place and the
system will stop or the stepper motor would lose its timing. Other than the physical limitations of
the system. The system preformed as expected and the proof of concept was demonstrated. The
system successfully detected the presence of metal, eliminated it, and kept track of how many
specimens of metal were being eliminated from the production line autonomously.