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Application of image processing in material handling and (1)

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Application of image processing in material handling and (1)

  1. 1. Automation of Material Handling and Sorting System Using Image Processing and PLC Prof. S. A. Soundattikar, Mr. Suyash Dani, Md Azhar Shahapure Department of Mechanical Engineering Textile & Engg. Institute Ichalkaranji, India
  2. 2. Introduction 1. Concept of material handling Receiving, identification and sorting, dispatching to storage, storage and retrieval, record keeping of various materials, etc. have traditionally been considered the functions of material handling and storage systems. Warehouse management is also an issue. 2. Manual handling problems Time required is quite large, accuracy and ease of control in sorting is not assured and repetitive work results in operator fatigue. 3. Role of Automation in MHS and sorting
  3. 3. Literature Review 1. The paper included a Mechatronics color sorting system solution with the application of image processing. Supported by MATLAB code image processing in which procedure senses the objects in an image captured in real time by a webcam and then extracts color and position information out of it. This information is passed as a signal of sorting commands to the microcontroller and then the depending on this signal will be given to the servomotor that does pick-and-place mechanism. Extensive testing proves that this color based object sorting system works 100% accurate under ideal condition in term of adequate illumination, circular objects’ shape and color. 2. The Mitsubishi FX series programmable logic controller is used to mechanize the system. Sensors such as proximity and load sensor are used to provide the input to the system. The motors, pneumatics, and also the solenoids serve as the output. The researchers used a ladder diagram as a software that control the whole system between its input and output components. It is found out that the system decreases time and manpower requirements for every station as compared with traditional manual system. A reduction of 50% to 75% was observed in terms of time allotment for filling, weighing, and sealing stations. About 90% of full automation without human is specified also in the system. 3. A similar but simplified system which will sort the objects according to different parameters such as color and shape using simple image processing technique. The system is trained initially with a set of images defined as the reference images. Then while execution, real time images are compared with the reference image parameters and respective output is then fed to the placing system through parallel port of the computer.
  4. 4. Proposed Design
  5. 5. Programmable Logic Controllers 1. Basic structure
  6. 6. 2. Components - 1. Electric Motors 2. Pneumatic Cylinders 3. Solenoids 4. Conveyor assembly 5. Camera 3. User interface – RS 232 cable, USB to parallel adapter 4. Programming 1.RSLogix 500 software is used to design the ladder program for the system. 2.The pneumatic system was designed and verified using FluidSim software.
  7. 7. Image Processing  Steps Of Image Processing 1. Shape wise sorting 1. Capture image 2. Converting RGB image to Black and White 3. Recognize boundaries of objects 4. Finding areas of objects and area filtering 5. Finding bounding box of the object 6. Finding ratio of areas for given object 2. Color recognition 1. Capture image 2. Extract R,G,B component 3. Calculate mean of each component 4. Take decision based on the mean comparison
  8. 8. Applications, Advantages & Limitations of image processing in material handling & sorting system • Applications 1. In small scale and large scale industries. To sort the products based on the various parameters like diameter, material shape etc 2. Can be used in store department as AS/RS 3. In malls and small shops for sorting material 4. In medicals and wine industries to sort the bottles of various sizes 5. In food industries to identify the rotten fruits. 6. Packaging and logistic industries to sorting and handling of material for shipping
  9. 9. • Advantages 1. High efficiency: the sorting speed can be very high. 2. High precision: the margin of error can be reduced to great extent. 3. This type of sorter can be used for various objects or vegetables of different colors. Also suit to select pears, orange and other fruits of this kind 4. High degree of intelligence if used with PLC control. The machine with a high degree of intelligent , can control it. 5. Good quality and low failure rate with long life. 6. Reliable operation and maintenance. • Limitations 1. Skilled worker required to change the programs 2. If job changes its required to take new photos and create new program 3. Initial cost for implementation is more 4. Because of sensitivity system required to be used in clean area
  10. 10. Conclusion The project can work successfully and can sort the object depending on their color or shape. We have primarily sense three colors RED, GREEN and BLUE. We placed object on one side of conveyer belt it was successfully placed red object at 90 degree position, green at 180 degree position and blue at -90 degree position. The another sorting technique we used is shape wise sorting system. We have basically used three basic shapes square, circular and triangular object. The system successfully detect the shape of object and pick the object and placed that at programmed location. The system successfully placed the square object at 90 degree position, circular object at 180 degree position and triangular object at -90 degree position. Also we have tested non specified colors and shapes object. The system detect fault in object and reject to pick the object from conveyor . In this situation the conveyor start in reverse direction and object falls at rejected object area. .
  11. 11. Future work • The further modification can be the use of encoders for the arm position • Horizontal arm can be replaced by the linear drive for horizontal movement • Sorting system can be modified to matrix format i.e. m x n • The whole system can be redesigned with SCADA as per the application
  12. 12. References [1]. Ashik Chandramohan, Krishna Murthy K. R. Sowmya G. , Surya Prasad P. A., Vijay Krishna V. , Peeyush K. P. Cost Effective Object Recognition And Sorting Robot Using Embedded Image Processing Techniques ,Ijitee Issn: 2278-3075, Vol-3, Issue-11. April 2014 [2]. Joanna Marie M, Ricamara, Baroro, Melchizedek I, Beltrana Jr. ,Automation Of Packaging And Material Handling Using Programmable Logical Control Ijset Vol.No. 3, Issue No. 6 Pp:767-770, Issn 2277- 1581, 1 June 2014 [3]. Bikarna Pokharel, Machine Vision And Object Sorting PLC Communication With Labview Using OPC Bachelor’s Thesis Degree Programme In Automation Engineering Valkeakoski, May 2013 [4]. Monal S. Telgote, Ganesh S. Sable, Object Sorting System In Matlab Using Robotic Arm, International Journal Of Science And Engineering Investigations Vol. 2, Issue 22, Issn: 2251-8843 November 2013 [5]. Vishnu R. Kale , V. A. Kulkarni, Object Sorting System Using Robotic Arm, International Journal Of Advanced Research In Electrical, Electronics And Instrumentation Engineering Vol. 2, Issue 7, July 2013 [6]. Sanket Rege, Rajendra Memane, Mihir Phatak, Parag Agarwal, 2d Geometric Shape And Color Recognition Using Digital Image Processing, International Journal Of Advanced Research In Electrical, Electronics And Instrumentation Engineering Vol. 2, Issue 6, Issn (Print) : 2320 – 3765, Issn (Online): 2278 – 8875 June 2013 [7]. Atef. A. Ata, Sohair F. Rezeka, Ahmed El-Shenawy, Mohammed Diab, Design And Development Of 5-Dof Color Sorting manipulator For Industrial Applications, World Academy Of Science, Engineering And Technology International Journal Of Mechanical, Aerospace, Industrial And Mechatronics Engineering Vol:7 Issue No:12, 2013 [8]. J. D. Gavade (Dept.Of Electronics Textile & Engg Institute, Ichalkaranji), P. K. Kharat (Dept. Of I.T. Walchand College Of Engg,Sangli), S. K. Laga (Dept.Of Electronics Textile & Engg Institute, Ichalkaranji), Cost Effective Approach For Object Sorting, International Journal Of Computer Applications Issn: 0975 – 8887 Volume 52– No.16, August 2012
  13. 13. References [9]. Vindhya Devalla, Dr. Rajesh Singh, Amit Kumar Mondal, Vivek Kaundal , Design And Development Of Object Recognition And Sorting Robot For Material Handling In Packaging And Logistic Industries, International Journal Of Science And Advanced Technology Issn 2221-8386 Volume 2 No 9 September 2012 [10]. Thomus Devich, Material Handling Solutions A Look Into Automated Robotics , 9th January, 2010 [11]. Vishnu R. Kale, V. A. Kulkarni, Automation Of Object Sorting System Using Pick & Place Robotic Arm & Image Processing [12]. Arko Djajadi, Fiona Laoda, Rusman Rusyadi, Tutuko Prajogo, Maralo Sinaga, A Model Vision Of Sorting System Application Using Robotic Manipulator, Terakreditasi Dikti, Issn: 1693-6930, Sk No: 51/Dikti/Kep/2010 Page No. 137-148. [13]. Prof.(Dr) V.V.Sople, Itm Business School, Navi Mumbai, Material Handling Equipment: Exploiting Productivity Potential In Supply Chain, Article Published In 'Search', Issue Vol 10, No.10, October 2007 [14]. Pavel Pacli´K Æ Raimund Leitner Æ Robert P. W. Duin, A Study On Design Of Object Sorting Algorithms In The Industrial Application Using Hyperspectral Imaging, J Real-Time Image Proc Doi 10.1007/S11554-006-0018-5 Special Issue Received: 27 June 2006 / Accepted: 16 October 2006 Springer-Verlag 2006 [15]. Kulak. O, A decision support system for fuzzy multi attribute selection of material handling equipments, Expert systems with applications 29(2). 310-319, 2005 [16]. Devadas D. Pillai Srini R. Srinivasan Intel Corporation Technology & Manufacturing Engineering, Material Handling Automation - Trends, Vision, And Future Plans , Proceedings From ISSM ’96, Tokyo, Japan. [17]. Ritendra Datta Jia Li James Z. Wang, Content-Based Image Retrieval - Approaches and Trends of the New Age, The Pennsylvania State University, University Park, PA 16802, USA. [18]. E. A. Parr, Industrial Control Handbook, Industrial Press Inc., 1999 ISBN 0-8311-3085-7 [19]. "The father of invention: Dick Morley looks back on the 40th anniversary of the PLC". Manufacturing Automation. 12 September 2008
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