EMC 311 Mechatronic

Mechatronic Project
Objective: To develop a material handling system by integrating various sensor and actuation
systems using Programmable Logic Controller or Raspberry Pi micro-controller.
Each group is required to develop a material handling system based on equipment as shown
in Figure 1, 2 and 3. Each group is given with:
1. A conveyor to transport a container that is filled with balls (see Figure 2). The conveyor
is actuated by an AC induction electric motor (see Figure 4). The motor is connected to
right relay for switching ON/OFF and to left relay for changing rotation direction (see
Figure 5 and 6). The wiring diagram is shown in Figure 7 where the solenoids of the
relays can be connected to output port of the controller using 24 VDC.
2. Two feeders with eight balls (see Figure 8) actuated with three double acting
pneumatic cylinders (see Figure 10) and a three single acting pneumatic cylinder (see
Figure 11) which are connected with pneumatic 5/2 (see Figure 16) and 3/2 directional
control valves respectively actuated with solenoid and spring return (see Figure 12 and
13).
3. Two proximity sensors (see Figure 14) to detect a metal plate on the container.
4. Two switches (see Figure 15) for operator interface.
5. A programmable logic controller (PLC) (see Figure 9) or Raspberry Pi micro-controller
with an interface circuit (see Figure 17, 18, 19, 20, 21 and 22).
Each group is encouraged to come to the laboratory in your free time to identify and learn the
components that are available in the given equipment. Snap the picture of the components
and get the component part number. Use internet to search the information of the component
or refer it to any of the lecture note.
Each group is required to design and fabricate the container to store 8 balls while traveling on
the conveyor by using recycled boxes. Add few small aluminum plates on the container so
that the container can be detected by the proximity sensors. The design of the container must
be unique and different for each group.
Based on the hardware given and the designed container, determine an operation of a
material handling system that can be performed using the available hardware.
Decompose the operation into several sequences.
Program the PLC using ladder diagram or the Raspberry Pi micro-controller using python to
follow the sequences.

There are five input devices and six output devices all together which end up with 24
connection terminals as shown in the table of device connection terminals. Refer to this table
for wiring the external devices to PLC or Raspberry Pi micro-controller. Warning: Wrongly
connecting the polarity of the Proximity Sensor will destroy the sensor! Please disconnect the
wiring each time your group finish using the equipment so that other group will learn to do the
wiring themselves.
Device Connection Terminals
Input

Output

Red Switch Negative

13 Top Left Valve Solenoid Negative

Red Switch Positive

14 Top Left Valve Solenoid Positive

Black Switch Negative

15 Bottom Left Valve Solenoid Negative

Black Switch Positive

16 Bottom Left Valve Solenoid Positive

Magnetic Sensor Negative

17 Top Right Valve Solenoid Negative

Magnetic Sensor Positive

18 Top Right Valve Solenoid Positive

Left Proximity Sensor Negative

19 Bottom Right Valve Solenoid Negative

Left Proximity Sensor Positive

20 Bottom Right Valve Solenoid Positive

Left Proximity Sensor Data

21 Right Relay Solenoid Negative

10 Right Proximity Sensor Negative

22 Right Relay Solenoid Positive

11 Right Proximity Sensor Positive

23 Left Relay Solenoid Negative

12 Right Proximity Sensor Data

24 Left Relay Solenoid Positive

The evaluation of the project will be done based on a report and a demonstration video. Each
group need to demonstrate the project in operation in a 15 minutes Youtube video. A time slot
schedule will be posted later for each group to complete the project in Automatic Control
Laboratory from 9.00am to 5.00pm.
Each group should prepare the demonstration video after completing the project and upload it
to www.youtube.com. Add narration or text to describe the work being done including
programming. Include also university name, course name, lecturer name, group member
name and group member picture. Write a report using MS Word document describing the
project which includes the address for the Youtube video and submit it before Monday
22/12/2015 using the link provided in elearning website.

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