This document describes an automated inspection, packaging and packing machine system controlled using a Programmable Logic Controller (PLC). The system uses two conveyor belts (horizontal and vertical) to transport samples from the loading point through inspection to packaging and packing in boxes. Sensors including photo sensors and inductive sensors are used to count samples, detect box filling levels, and control conveyor and motor movements. Experimental results found the automatic PLC-controlled system could pack 24 boxes per hour, significantly faster than the 17 boxes packed manually in the same time period. The system aims to improve production efficiency by reducing manual labor and product handling times.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Robots can be autonomous, semi-autonomous or
remotely controlled [6].
The robot arm is widely used in many industries and dangerous areas. Automatic control of the robotic
manipulator involves study of kinematic. The kinematic problem is defined as the transformation from the
Cartesian space to the joint space and vice versa This system include the kinematic control which is used for
picking and placing the object in its workspace. There are many types of robot arm in the world of engineering.
This research describes design of jointed robot arm control system using kinematic modelling. The main focus of
this system is to control the end-effector of robot arm to achieve the desired position in the workspace using
MATLAB programming, microcontroller and inverse kinematic modelling. The MATLAB window(GUI) is used
the inverse kinematic for the requirement data for the specified angle of the arm and displayed on the computer.
The description of this system is to implement the hardware components for the moving process and to control
servo motors with pulse width driving circuit. PIC and Max-232 been used to drive for the servo motors of the
control system and receiving serial data from the computer. The control program is written in Mikro-C
programming language.
Automation is a preferred for faster and precise operations as compare to manual operation. This paper provides a mean of simple yet effective fixed type of automation for sorting the products. Two products identical in shape and size are sorted out automatically on the basis of drilled or undrilled product. LED and photo transistor arrangement is used for hole detection. Vertical zigzag conveyor is employed instead of usual flat belt conveyor in order to utilise gravitational force as a driving force for feeding the products. 8051 Microcontroller is used for controlling the sorting mechanism by using program or coding. The cost of project is nearly negligible as it is made from the waste except electrical components used for the project. Sincere efforts are taken to set an example of a inexpensive, reliable and easy to manufacture automated machine. The Paper focuses on the aspect of sorting mechanism with microcontroller programming and the automation tasks and solutions is obtained.
Design and implementation of robot control system for multistory buildingsTELKOMNIKA JOURNAL
The advancement of technology, make robots have more attention from researchers to make life of mankind comfortable. This paper deals with the design of an itemized control system prepared for window cleaning/maintenance of towers and multistory buildings which can be aided to simulating human activities. These activities (washing, coating, wiping, climbing, and maintenance events) normally achieved by specialized personal. The designed control system was prepared to guide the units of the required job to move freely along the outside surface of a window with a fairly enough area and mediate time for achieving the desired goal. The system design is implemented using Arduino kit, due to facilities in program and control of cleaning windows through infer the stepper motor movement and rotation. The controller has been achieved as real time system (30 msec.), it is done throw control of three stepper motor by taken in consideration the speed of the motors (π/3000 rad/sec) and the time can be adjustable within the cleaning area that the device covering it.
Abstract A conveyor control system project was implemented using software LabVIEW and interfacing electronics such that it mimics the operation of a conveyor used in a bottling plant with beginning, filling and ending stations. Conveyors are used for automated transportation of materials. For this project, the conveyor simulator is equipped with a dc motor mounted directly to an axle for driving the conveyor belt, a freely rotating axle for the opposite side of the conveyor belt. Three IR proximity sensors, positioned at the middle and both the ends, are used to detect the position of bottle on the conveyor. A load sensor is employed at the middle to measure the volume of fluid in the bottle. Suitable displays were incorporated in the software. A PC based control system enables fast communication between controls programming and equipment. Key Words: conveyor control system, LabVIEW, sensors
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Robots can be autonomous, semi-autonomous or
remotely controlled [6].
The robot arm is widely used in many industries and dangerous areas. Automatic control of the robotic
manipulator involves study of kinematic. The kinematic problem is defined as the transformation from the
Cartesian space to the joint space and vice versa This system include the kinematic control which is used for
picking and placing the object in its workspace. There are many types of robot arm in the world of engineering.
This research describes design of jointed robot arm control system using kinematic modelling. The main focus of
this system is to control the end-effector of robot arm to achieve the desired position in the workspace using
MATLAB programming, microcontroller and inverse kinematic modelling. The MATLAB window(GUI) is used
the inverse kinematic for the requirement data for the specified angle of the arm and displayed on the computer.
The description of this system is to implement the hardware components for the moving process and to control
servo motors with pulse width driving circuit. PIC and Max-232 been used to drive for the servo motors of the
control system and receiving serial data from the computer. The control program is written in Mikro-C
programming language.
Automation is a preferred for faster and precise operations as compare to manual operation. This paper provides a mean of simple yet effective fixed type of automation for sorting the products. Two products identical in shape and size are sorted out automatically on the basis of drilled or undrilled product. LED and photo transistor arrangement is used for hole detection. Vertical zigzag conveyor is employed instead of usual flat belt conveyor in order to utilise gravitational force as a driving force for feeding the products. 8051 Microcontroller is used for controlling the sorting mechanism by using program or coding. The cost of project is nearly negligible as it is made from the waste except electrical components used for the project. Sincere efforts are taken to set an example of a inexpensive, reliable and easy to manufacture automated machine. The Paper focuses on the aspect of sorting mechanism with microcontroller programming and the automation tasks and solutions is obtained.
Design and implementation of robot control system for multistory buildingsTELKOMNIKA JOURNAL
The advancement of technology, make robots have more attention from researchers to make life of mankind comfortable. This paper deals with the design of an itemized control system prepared for window cleaning/maintenance of towers and multistory buildings which can be aided to simulating human activities. These activities (washing, coating, wiping, climbing, and maintenance events) normally achieved by specialized personal. The designed control system was prepared to guide the units of the required job to move freely along the outside surface of a window with a fairly enough area and mediate time for achieving the desired goal. The system design is implemented using Arduino kit, due to facilities in program and control of cleaning windows through infer the stepper motor movement and rotation. The controller has been achieved as real time system (30 msec.), it is done throw control of three stepper motor by taken in consideration the speed of the motors (π/3000 rad/sec) and the time can be adjustable within the cleaning area that the device covering it.
Abstract A conveyor control system project was implemented using software LabVIEW and interfacing electronics such that it mimics the operation of a conveyor used in a bottling plant with beginning, filling and ending stations. Conveyors are used for automated transportation of materials. For this project, the conveyor simulator is equipped with a dc motor mounted directly to an axle for driving the conveyor belt, a freely rotating axle for the opposite side of the conveyor belt. Three IR proximity sensors, positioned at the middle and both the ends, are used to detect the position of bottle on the conveyor. A load sensor is employed at the middle to measure the volume of fluid in the bottle. Suitable displays were incorporated in the software. A PC based control system enables fast communication between controls programming and equipment. Key Words: conveyor control system, LabVIEW, sensors
The application of integrated robotics is becoming increasingly commonplace in day to day applications. The idea presented in this paper seeks to provide a convenient and a hassle-free means of cleaning public toilets whilst maintaining hygienic and sanitary standards. By using a counter to record the number of times of usage, a line follower mechanism to guide the robot and an RFID module to initiate the auto-flushing, the cleaning operation is fully automated and requires low operational power. Furthermore, a robotic arm is part of the module, so as to thoroughly clean the toilet bowl. Such a provision will curtail the role of manpower in maintenance of public toilets to a great degree, and thus, serves as a win-win situation; a revolting objective is accomplished with considerable ease.
This paper presents final year project prototype with the use of programmable logic controller in automation industry for packaging process. The main idea of the project is to design and fabricate a small and simple conveyor belt system, and automate the process for packaging small cubic pieces (2 × 1.4 × 1) cm3 of wood into small paper box (3 × 2 × 3) cm3. Inductive sensor and photoelectric sensor were used to provide the information to the controller. Electrical DC motors used as output actuators for the system to move the conveyor belts after get the orders from the control system. Programmable logic controller Mitsubishi FX2n-32MT was used to control and automate the system by ladder logic diagram software. The experimental result of the prototype was able to fully automate the packaging system. This results show that the machine were done to package 21 boxes in one minute. In addition, the results obtained show that the system able to decreases product time, and increase product rate as compared with traditional manual system
This paper presents final year project prototype with the use of programmable logic controller in automation industry for packaging process. The main idea of the project is to design and fabricate a small and simple conveyor belt system, and automate the process for packaging small cubic pieces (2 × 1.4 × 1) cm3 of wood into small paper box (3 × 2 × 3) cm3. Inductive sensor and photoelectric sensor were used to provide the information to the controller. Electrical DC motors used as output actuators for the system to move the conveyor belts after get the orders from the control system. Programmable logic controller Mitsubishi FX2n-32MT was used to control and automate the system by ladder logic diagram software. The experimental result of the prototype was able to fully automate the packaging system. This results show that the machine were done to package 21 boxes in one minute. In addition, the results obtained show that the system able to decreases product time, and increase product rate as compared with traditional manual system.
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
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.
The Automatic Sorting Machine is used to sort different types of products or commodities based on the barcode provided on them. This gives a provision to reduce the manual effort and hence human error by replacing the conventional methods of sorting in areas involving hectic sorting. The system comes into play in airports and other industrial distribution centres where the products or commodities have to be sorted into batches in order to take them to their respective destination. The products are put on a conveyer system where they are scanned for the particular barcode provided on them. Depending on the barcode, they are placed on the respective carriers automatically where these carriers dispatch them to the corresponding destinations.
Design and development of a delta robot system to classify objects using imag...IJECEIAES
In this paper, a delta robot is designed to grasp objects in an automatic sorting system. The system consists of a delta robot arm for grasping objects, a belt conveyor for transmitting objects, a camera mounted above the conveyor to capture images of objects, and a computer for processing images to classify objects. The delta robot is driven by three direct current (DC) servo motors. The controller is implemented by an Arduino board and Raspberry Pi 4 computer. The Arduino is programmed to provide rotation to each corresponding motor. The Raspberry Pi 4 computer is used to process images of objects to classify objects according to their color. An image processing algorithm is developed to classify objects by color. The blue, green, red (BGR) image of objects is converted to HSV color space and then different thresholds are applied to recognize the object’s color. The robot grasps objects and put them in the correct position according to information received from Raspberry. Experimental results show that the accuracy when classifying red and yellow objects is 100%, and for green objects is 97.5%. The system takes an average of 1.8 s to sort an object.
Automatic convey or System with In–Process Sorting Mechanism using PLC and HM...IJERA Editor
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.
Design and development of touch screen controlled stairs climbing roboteSAT Journals
Abstract This paper presents a method of developing a stairs climbing robot with self balancing chair mounted on the top of the robot. It is one of the major task in the field of Mechatronics require a mechanical arrangement and electronics based control of the actuators using wireless technology. In most of the mechanism it is hard to maintain the slope position of the seat while carrying some goods on it, so taking in action all these condition the robot is to design and develop [1] which will climb on the stairs and adjust themselves as per environmental condition. Keywords:- Accelerometer, CC2500, Touch Screen, Microcontroller, Relays
The application of integrated robotics is becoming increasingly commonplace in day to day applications. The idea presented in this paper seeks to provide a convenient and a hassle-free means of cleaning public toilets whilst maintaining hygienic and sanitary standards. By using a counter to record the number of times of usage, a line follower mechanism to guide the robot and an RFID module to initiate the auto-flushing, the cleaning operation is fully automated and requires low operational power. Furthermore, a robotic arm is part of the module, so as to thoroughly clean the toilet bowl. Such a provision will curtail the role of manpower in maintenance of public toilets to a great degree, and thus, serves as a win-win situation; a revolting objective is accomplished with considerable ease.
This paper presents final year project prototype with the use of programmable logic controller in automation industry for packaging process. The main idea of the project is to design and fabricate a small and simple conveyor belt system, and automate the process for packaging small cubic pieces (2 × 1.4 × 1) cm3 of wood into small paper box (3 × 2 × 3) cm3. Inductive sensor and photoelectric sensor were used to provide the information to the controller. Electrical DC motors used as output actuators for the system to move the conveyor belts after get the orders from the control system. Programmable logic controller Mitsubishi FX2n-32MT was used to control and automate the system by ladder logic diagram software. The experimental result of the prototype was able to fully automate the packaging system. This results show that the machine were done to package 21 boxes in one minute. In addition, the results obtained show that the system able to decreases product time, and increase product rate as compared with traditional manual system
This paper presents final year project prototype with the use of programmable logic controller in automation industry for packaging process. The main idea of the project is to design and fabricate a small and simple conveyor belt system, and automate the process for packaging small cubic pieces (2 × 1.4 × 1) cm3 of wood into small paper box (3 × 2 × 3) cm3. Inductive sensor and photoelectric sensor were used to provide the information to the controller. Electrical DC motors used as output actuators for the system to move the conveyor belts after get the orders from the control system. Programmable logic controller Mitsubishi FX2n-32MT was used to control and automate the system by ladder logic diagram software. The experimental result of the prototype was able to fully automate the packaging system. This results show that the machine were done to package 21 boxes in one minute. In addition, the results obtained show that the system able to decreases product time, and increase product rate as compared with traditional manual system.
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
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.
The Automatic Sorting Machine is used to sort different types of products or commodities based on the barcode provided on them. This gives a provision to reduce the manual effort and hence human error by replacing the conventional methods of sorting in areas involving hectic sorting. The system comes into play in airports and other industrial distribution centres where the products or commodities have to be sorted into batches in order to take them to their respective destination. The products are put on a conveyer system where they are scanned for the particular barcode provided on them. Depending on the barcode, they are placed on the respective carriers automatically where these carriers dispatch them to the corresponding destinations.
Design and development of a delta robot system to classify objects using imag...IJECEIAES
In this paper, a delta robot is designed to grasp objects in an automatic sorting system. The system consists of a delta robot arm for grasping objects, a belt conveyor for transmitting objects, a camera mounted above the conveyor to capture images of objects, and a computer for processing images to classify objects. The delta robot is driven by three direct current (DC) servo motors. The controller is implemented by an Arduino board and Raspberry Pi 4 computer. The Arduino is programmed to provide rotation to each corresponding motor. The Raspberry Pi 4 computer is used to process images of objects to classify objects according to their color. An image processing algorithm is developed to classify objects by color. The blue, green, red (BGR) image of objects is converted to HSV color space and then different thresholds are applied to recognize the object’s color. The robot grasps objects and put them in the correct position according to information received from Raspberry. Experimental results show that the accuracy when classifying red and yellow objects is 100%, and for green objects is 97.5%. The system takes an average of 1.8 s to sort an object.
Automatic convey or System with In–Process Sorting Mechanism using PLC and HM...IJERA Editor
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.
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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
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paper deals with the efficient use of PLC in automatic conveyor system and also building the accuracy in it.
Design and development of touch screen controlled stairs climbing roboteSAT Journals
Abstract This paper presents a method of developing a stairs climbing robot with self balancing chair mounted on the top of the robot. It is one of the major task in the field of Mechatronics require a mechanical arrangement and electronics based control of the actuators using wireless technology. In most of the mechanism it is hard to maintain the slope position of the seat while carrying some goods on it, so taking in action all these condition the robot is to design and develop [1] which will climb on the stairs and adjust themselves as per environmental condition. Keywords:- Accelerometer, CC2500, Touch Screen, Microcontroller, Relays
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Inspection, Packaging and Packing Machine Development Based PLC
1. Libyan International Conference on Electrical Engineering and Technologies (LICEET2018)
7–3 March 2018, Tripoli - Libya
LICEET13732018
785
Inspection, Packaging and Packing Machine
Development Based PLC
Yousef Moh. Abueejela
Control Engineering Department
College of Electronic Technology
BaniWalid, Libya
Yousef.yaqa@gmail.com
Abdulhameed K. Belkasem
Control Engineering Department
College of Electronic Technology
BaniWalid, Libya
Hamidkhalefa1994@gmail.com
Abstract—this paper presents an automated controlling system
based programmable logic controller (PLC) that consists of
two different transporting conveyors; vertical and horizontal.
The samples were placed on the horizontal conveyor for
transportation from loaded point to packaging point. After the
DC motor that drives the horizontal conveyor is energized, the
samples move along the conveyor before they reach an
inspection sensor that separates the two types of products and
drop the chosen sample inside a filling box. When the box is
filled with the right amount of samples, the vertical conveyor
picks and places these boxes inside vertical shelves. This
process is controlled using a Programmable Logic Controllers
(PLC)Mitsubishi FX2n-32MT. The experimental results of the
prototype were able to fully automate the system and improve
the time of inspection and packing. The results show that the
machine was done to inspect, package and pack24 boxes (96
samples) in one hour. In addition, the results obtained show
that the system able to decreases product time, and increase
product rate as compared with traditional manual system.
Keywords- PLC; packaging; inspection; conveyor belt;
inductive sensor;photo sensor;Mitsubishi FX2n-32MT.
I. INTRODUCTION
Automation is to use control systems and information
technologies to reduce the need for human work in the
production of goods and services. In the scope of in
deserialization, automation is a step beyond mechanization.
Whereas mechanization provided human operators with
machinery to assist them with the muscular requirements of
work, automation greatly decreases the need for human
sensory and mental requirements as will. Automation plays
an increasingly important role in the world economy and in
daily experience [1].
PLC plays an important role in the world of automation
industry. PLC reduces complexity, increases safety, cheap
and PLC based automation system not only guarantees
reduced production time, but also a higher productivity both
in terms of quantity and quality. PLC is being used in many
sectors. A few examples are manufacturing industries, travel
industries, printing industries, food industries, plastic
industries, leisure (Roller coaster ride and effects control
system) etc [2].
In this paper, the main goal is to design and
implementation the machine of an automated system that
consists of two different transporting conveyors as shown in
Fig. 1; vertical and horizontal. The samples are placed on
the horizontal conveyor for transportation from loading
node to packaging node. A DC motor used to drive the
horizontal conveyor in order to move samples along the
conveyor, inspection stage used during the transportation on
the horizontal conveyor before they reach the final node,
then the samples will counted by photo sensor before the
conveyor drop them inside a filling box. When the box is
filled with the right amount of samples, the vertical
conveyor carry and places these boxes inside vertical
shelves. This process is controlled using a Programmable
Logic Controllers (PLC)Mitsubishi FX2n-32MT.
Figure 1. System Prototype.
II. LITERATURE SURVEY
Kiran A. Gupta, Neha Armani, T. C. Manjunath and H. V.
Manjunath designed and fabricate an automatic mixing
system with conveyor belt based on PLC, to achieve high
throughput and improve quality and consistency [3].
Shweta Honrao1 and others, designed and implemented
inspection and stored machine based on PLC with
implementing a new technique [4].
Rakshak T.B., Mr. Shivashankara B. S proposed a method to
Control Automated Multiple Conveyor System for Sorting
Process by using PLC. The developed Model sorts Metals
40cm
95cm
54cm
2. Libyan International Conference on Electrical Engineering and Technologies (LICEET2018)
7–3 March 2018, Tripoli - Libya
LICEET13732018
786
and Non-metals by using PLC with Economical user
friendly, Low cost, high accuracy, Reliable [5].
D. S. V. Siva Vardhan, Y. Shivraj Narayan designed and
fabricated a machine for simultaneous automatic monitoring
and control of two different objects i.e. bottles and trays on a
single belt conveyor efficiently using Programmable Logic
Controller [6].
III. HARDWARE STRUCTURE AND COMPONENTS
The Automatic inspection, packaging and packing machine
system is a combination of electronic, electrical and
mechanical parts. Fig. 2 shows block diagram of the system.
• The input devices are devices used to get and give
information about the system state, which consists
switches (toggle switch and pushbuttons) and sensors
(photo and inductive sensors), in order to feed the
controller (PLC) by information about the belts status
and objects.
• The controller, which is the main element that operate
the whole system, by using the information from the
sensors to take the counting and movement decision
before sending the orders to the output devices by the
actuators and the relays.
• The output devices are the actuators that convert an
electrical signal into mechanical movement; the
principle types of actuators are relays and motors
Figure 2. Block Diagram of the System..
A. Sensors
Sensors are devices that measure a particular characteristic
of an object or system. Sensors are used in everyday objects
such as touch-sensitive elevator buttons (tactile sensor) and
lamps, which dim or brighten by touching the base. There
are also innumerable applications for sensors, which include
cars, machines, aerospace, medicine, manufacturing and
robotics [7]. In this paper there are six sensors were used (5
inductive sensors and 1 photo sensor).
1) Inductive Proximity Sensors
Five sensors have been used (inductive sensor) and installed
in the prototype. Sensor (A) is located above the horizontal
conveyor belt to inspection coming samples, while sensor
(C) is used to stop the first box at the first level. Sensor (D)
is used to reserve a place for the first box in first level.
Sensor (E) is used to stop the second box at the second
level, while sensor (F) is used to reserve a place for the
second box as shown in Fig.3and Fig.4.
Figure 3. Inspection sensorsInstalled on horizintal conveyor.
Figure 4. Inductive sensors location on vertical Conveyor.
2) Photoelectric Sensor
The photoelectric sensor (B) is installed at the end of the
horizontal conveyor belt in order to count coming samples
before packaging; this sensor is responsible for sample
numbers filled in the box as shown in Fig.5.
Figure 5. Photoelectric Sensor Setup on the Project.
B. Actuators
Actuation defines as the result of a direct physical action on
the process, such as motoring and relays. Four motors were
installed on the project to perform three different actions.
A
C
D
F
E
B
3. Libyan International Conference on Electrical Engineering and Technologies (LICEET2018)
7–3 March 2018, Tripoli - Libya
LICEET13732018
787
Motor (A) is used to move the horizontal conveyor belt,
motor (B) is used to reject out unwanted samples, while
motor (C) is used to raise the boxes up and down, and motor
(D) is used to put boxes in empty shelves as shown in Fig.6
and Fig.7.
Figure 6. DC Motors for Horizintal Belt and Rejected Samples.
Figure 7. DC Motors for Vertical Belt and Shelves.
C. Control Board and Indicators
The system is controlled using two different methods. The
first one is the automatic method which uses a
Programmable Logic Controller (PLC) with some relays to
control the whole system. The second method is manual
control to control the system by manual operation through
the use of push buttons as shown in Fig.8.
Figure 8. Control Board and Indicators Board..
•Red indicator: To indicate fully box situation.
•Green1 indicator: To indicate that the system is working.
•Yellow indicator: To indicate inspection process
for samples.
•Green2 indicator: To indicate packing process.
D. System Wiring and Addressed assigned
The complete system works on 24, 12 volts dc power
supply. DC motors works on 12 volts dc with speed of 28
rpm is used to run the conveyor belt. All the sensors are
connected to the PLC inputs module and 24 volts dc with
common node.Fig.9 and Table 1 show the wiring and
addressed of all the sensors and motors.
Figure 9. Wiring Diagram of the System..
Table 1: Address Assignment
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IV. EXPERIMENTAL RESULTS
The system is running by the user which choose type of
operation (manual or Automatic), then after bush button
starts, Proximity sensor (A) is used to detect the samples. If
the sample is silver, then the sensor stops the conveyor belt
and the rejected motor (B) running out to move out the
sample (unwanted sample) from the belt as shown in Fig.10.
Figure 10. Unwanted Sample rejected out.
Photo sensor (B) is placed at the end of conveyor belt before
packaging node, to count number of samples packaged into
the box. As the number of packaged samples reached, the
sensor stops the horizontal belt and running the vertical belt
for sorting.
Figure 11. Unwanted Sample rejected out.
The vertical belt is moving up till get an empty shelve to get
the box into till all shelves sorted by boxes as shown in
Fig.12.
Figure 12. Unwanted Sample rejected out.
A. Fixed parameters of the system
These parameters are fixed for the system designed
Horizontal and vertical belt speed 28 rpm
Wood samples (6×6×5) cm (WLH)
Silver samples (6×6×5) cm (WLH)
Filling Box (12.5×21.5×9) cm
Sensors positions
Three shelves
V. RESULTS
A. Experiment I : Motor Speed 28rpm, 3shleves
Figure 13. Comparasion between manual and automatic mode.
In Fig. 13, the vertical line indicates the number of boxes
sorted in the shelves vs horizontal lines which indicate day
hours. it is clearly that the automatic control is about 141 %
of manual control.
B. Experiment II : Motor Speed 60rpm, 3shleves
Figure 14. Automatic mode with high speed.
In experimental II, the speed of the motor for horizontal and
vertical belt increased twice, here, the number of boxes that
filled in one hour was increase which met the project goals
for increase products and decrease time for automation
systems.
1 2 3 4 5 6 7 8
manual 17 34 51 68 85 102 119 136
automatic 24 48 72 96 120 144 168 192
0
50
100
150
200
250
Numberofsamples
Manual vs Automatic
1 2 3 4 5 6 7 8
automatic 51 102 153 204 255 306 357 357
samples 204 408 612 8161020122414281428
0
500
1000
1500
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7–3 March 2018, Tripoli - Libya
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Table 2: Products Rate
VI. CONCLUSION
An automated inspection, packaging and packing
machine prototype using PLC Mitsubishi FX 2N has been
successfully design, constructed and implement based on
control system concepts. Mitsubishi ladder diagram applied
for the programming and operation of the presented
prototype, during system testing process, the unwanted
samples got examined, number of samples to be filled inside
the container and the placing process of the containers inside
the shelves can be controlled and performed by the system in
an efficiently short time. From the experimental result, the
automatic inspection, packaging and packing machine was
able to packing 24 boxes per one hour, otherwise the manual
packing able to packing just 17 boxes.
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[4] Shweta Honrao1 , Radhika Pol2 , Radha Kausale3 and Asst.
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[5] Rakshak T.B., Mr. Shivashankara B. S. "PLC Controlled
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[6] D. S. V. Siva Vardhan, Y. Shivraj Narayan. " Development of
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525p.
28 rpm 60 rpm
Product Time
Manual
Machine
Automatic
Machine
Automatic
Machine
One hour 17 box 24 box 51 box
One day (8 hours) 137 box 192 box 408
One week (6
working days)
822 1152 2448