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2. Introduction
AProgrammable controller is a solid state user programmable control system with
functions to control logic, sequencing, timing, arithmetic data manipulation and counting
capabilities. It can be viewed as an industrial computer that has a central processor unit,
memory, input output interface and a programming device. The central processing unit
provides the intelligence of the controller. It accepts data, status information from various
sensing devices like limit switches, proximity switches, executes the user control program
store in the memory and gives appropriate output commands to devices like solenoid valves,
switches etc.
Input output interface is the communication link between field devices and the controllers;
field devices are wired to the I/O interfaces. Through these interfaces the processor can
sense and measure physical quantities regarding a machine or process, such as, proximity,
position, motion, level etc. Based on status sensed, the PLC issues command to output
devices such as valves, motors, alarms, etc.
Programmer unit provides the man machine interface. It is used to enter the application
program, which often uses a simple user-friendly logic.
BENEFITS OF PROGRAMMABLE CONTROLLERS
Programmable controllers are made of solid state components and hence provide high
reliability.
They are flexible and changes in sequence of operation can easily be incorporated due to
programmability. They may be modular in nature and thus expandability and easy
installation is possible.
Use of PLC results in appreciable savings in Hardware and wiring cost.
They are compact and occupy less space.
Eliminate hardware items like Timers, counters and Auxiliary relays. The presence for
timers and counters has easy accessibility.
PLC can control a variety of devices and eliminates the need for customized controls.
Easy diagnostic facilities are provided as a part of the system. Diagnosis of the external
systems also becomes very simple. Thus easy service/maintenance.
Programming devices provide operator friendly interface with the machine. Being an
outcome of the latest art of electronics technology, Programmable controllers provide higher
level of performance with computers is possible. Useful management data can be obtained
and maintained.
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It has total protections against obsolescence and has wide scope for upgrade
GENERAL
The IC 150 is fully automatic intermittent horizontal cartoners that automatically
open/fold cartons, infeed products, insert leaflet into the cartons, coding and then
automatically close the carton. The IC 150 can be fitted with a wide range of feeding units
which automatically separate and orientate the product before it is carefully introduced into
the previously opened and erected carton. The PLC automatically controls and manages all
packaging steps with any malfunction being indicated on the display, stopping the machine if
necessary so in order for any remedial action to be taken
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Machine Layout
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3. Process Description
3.1 Product Infeed
Blister Dispensing
Blister Magazine: Here blister arrives in blister magazine through adjustable extension
conveyor of Blister forming machine. The extension conveyor mounted on blister magazine
& it is fixed with knob. Blister magazine is equipped with two capacitive sensor ‘Blister
minimum load sensor’ & ‘Blister maximum load sensor’
Keyence PLC: A Keyence KV 10T PLC used here which controls various operation of
Blister dispensing .It works on 24V dc supply. Input to Keyence PLC is given by main PLC
through alleged connector. Blister dispensing works due to proper synchronization of
Keyence PLC & main PLC. Keyence PLC has four outputs two of which are further
connected to four EM coils & remaining two are connected to sensors.
Electromagnetic Coils: Four EM coils holds blister inside blister magazine when it gets
energized it allow dropping blister inside each pocket of bucket conveyor. At time only one
blister is dropped. Number of blister fall inside each packet is decided by settings made on
control panel.
Bucket Conveyor
This bucket conveyor is just below the blister magazine having fixed number of bucket
whose sizes can be changed as per pack size. While moving along the blister conveyor
‘Product check sensor’ check weather exact number of blisters fell inside each bucket or not
3.2Carton Feeding
The machine is equipped with carton magazine where the carton is picked up on conveyor.
The carton magazine is equipped with a carton minimum load photocell called as ‘Minimum
carton load sensor’
Carton is moved by conveyor to the line parallel to pocket conveyor called carton line. While
being moved by carton chain rack carton is formed & prepared to receive the product.
Other photocells are fixed in the magazine they check for proper carton pick up.
3.3Carton Forming
Carton is formed while being moved along the line parallel to pocket chain.
Carton forming process is pneumatically operated. Two suction paths pick up & set the two
carton sides apart further mechanical components fold the side flaps
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The chain transport & forming conveyor are equipped with two photocells ‘Upper forming
check’ & ‘Lowe forming check’
Carton above the conveyor is guided at the top by mobile guide here an inductive sensor
called as ‘Carton guide up sensor’ is attached for this.
3.4Product Insertion
Products are inserted into the carton by pusher.
Pusher is equipped with safety device which move back the pushers guide in case the
product is harmed to be inserted.
Safety system is controlled by the sensor’ Pusher Safety Sensor’ that avoid further damages
to the machine. If blisters are not placed properly or they are not present inside pocket or
bucket pusher comes in contact
Leaflet is also inserted along with blisters inside the carton by the pusher. Mobile plate plays
important role in this process. Mobile plate catches the leaflet meanwhile pusher pushes the
fixed number of blisters inside mobile plate in such away that leaflet holding all blisters
moves inside carton.
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OPERATION SEQUENCE
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or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor
requires a metal target.
The maximum distance that this sensor can detect is defined "nominal range". Some sensors
have adjustments of the nominal range or means to report a graduated detection distance.
A continuous 50-kHz excitation square wave applied to the source (SRC) side of the sensor,
to set up the electric field in the capacitive sensor. The stimulus creates an electric field in the
sensor that partially protrudes through the overlay plastic. The capacitance-input side is
connected to the input of the capacitance-to-digital converter
4.1.2 Blister minimum/ maximum load sensor
Blister magazine is equipped with two capacitive sensor called as ‘Blister minimum load
sensor’ & ‘Blister maximum load sensor’. Blister minimum load sensor gets off if no. of
blister in magazine goes below minimum level & blister maximum load sensor takes care of
that number of blister should not go beyond predetermined limit
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circuit, a signal evaluator, and a switching amplifier. The coil of this oscillating circuit
generates a high-frequency electromagnetic alternating field. This field is emitted at the
sensing face of the sensor. If a metallic object (switching trigger) nears the sensing face,
eddy currents are generated. The resultant losses draw energy from the oscillating circuit and
reduce the oscillations. The signal evaluator behind the LC oscillating circuit converts this
information into a clear signal. The measurement of proximity, position and displacement of
objects is essential in many different applications: valve position, level detection, process
control, machine control, security, etc.
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Load configurations are also important parameters to consider. Inductive proximity sensors
may switch an AC load or a DC load. DC load configurations can be NPN or PNP. NPN is a
transistor output that switches the common or negative voltage to the load; load connected
between sensor output and positive voltage supply. PNP is a transistor output that switches
the positive voltage to the load; load connected between sensor output and voltage supply
common or negative. Wire configurations are 2-wire, 3-wire NPN, 3-wire PNP, 4-wire NPN,
and 4-wire PNP. Switch types can be normally open (NO) or normally closed (NC). Switch
specifications include whether or not the switch is normally open or normally closed. Switch
repeatability and maximum switching frequency are important parameters to consider. The
switch may be a NAMUR type switch, a specialized switch for switching a resistive load.
Requires an external amplifier.
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2). OFF: When this sensor is OFF, then either the main motor is not working properly or a
load fault had occurred in the working of the motor. Hence this clutch moves outwards.
4.2.5 Hand wheel sensor
This senor is mainly used for manual machine check. This sensor mainly operates in two
modes:
ON: When this sensor is ON, the machine works automatically.
OFF: When this sensor is OFF, the machine is working in manual mode.
receiving light. When emitted light is interrupted or reflected by the sensing object, it
changes the amount of light that arrives at the Receiver. The Receiver detects this change and
converts it to an electrical output. The light source for the majority of Photoelectric Sensors
is infrared or visible light (generally red, or green/blue for identifying colors). These Fibers
Units can be used in a variety of applications, such as detecting the presence of work pieces
and positioning
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5. Control Elements
5.1 Solenoid valve
5.1.1 Pusher Forward.
This sensor when activated is mainly used to push the blister along with the leaflet into the
carton with the help of a pusher. However when it is deactivated, the pusher returns to its
original position.
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This sensor is mainly used to push the pusher backward after the blister along with the leaflet
enters the carton.
6. ENCODER FUNCTION
Encoder is electronic device, which is responsible to step-by-step execution (on degree basis)
of entire process of IC 150.
7. INDUCTION MOTOR & DRIVE
7.1 MOTOR:
Induction motor works on the principle of magnetic effect of electric Current. There is a shaft
made up of soft iron core, which is attached to electric supply via iron brushes. The shaft is
attached surrounded by strong electro magnets. When we apply current to motor assembly
due to interaction of two electromagnets torque forces gets developed, perpendicular to shaft
of motor, this makes motor shaft to start rotating. Mechanical assembly attaches the motor
shaft to machine drive.
7.2 MOTOR DRIVE:
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In IC 150 single motor is used to drive entire machine. This is used to get perfect
synchronization of entire unit of IC 150.Drive is a complex mechanical part of machine,
which is responsible for distribution of mechanical power to the various parts of IC 150.
Drive takes input power from motor & with the help of gears & chain assembly it distributes
the power to other devices as output.
The various parts which are connected to drive assembly as follows:
1> Tucker assembly.
2> Carton conveyor.
3> Blister conveyor.
4> Leaflet assembly.
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