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International Research Jo urnal of Engineering and Technology (I Volume: 05 Issue: 05 | May

International Research Jo urnal of Engineering and Technology (I

Volume: 05 Issue: 05 | May 20 18

www.irjet.net

RJET)

e-ISSN: 2395-0056

p-ISSN: 2395-0072

PLC Based Inspectio n, Packaging and Storing of M aterials

Neeraj Kumar Maurya 1 , Md.

Allauddin Khan 2 , Harshit Prakash Singh 3 , Shivendra Kaura 4

1 Bachelor of Technology, Electrical & El lectronics Department, G L Bajaj Institute of Tech nology & Management, UP, India

2 Bachelor of Technology, Electrical & El lectronics Department, G L Bajaj Institute of Tech nology & Management, UP, India

3 Bachelor of Technology, Electrical & E lectronics Department, G L Bajaj Institute of Tech nology & Management, UP, India 4 Assistant Professor, Electrical & Electro nics Department, G L Bajaj Institute of Technolo gy & Management, UP, India

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Abstract This Paper comprises of Ins spection, Packing

and Automated Storage and of any y manufactured

manufactures in place of their

quality assurance system, their packag ing system and warehousing system. Using this applicat ion process time

minimum human

interaction. This system may have higher i nitial cost, but its

advantages are far more beneficial. Packin g that is sound, in line with the warehouse layout, which al so optimizes the

the freight cost. leads to reduced

cost per package. This system examines t he manufactured component as per specifications, sorts o ut the ineligible components, then it packs them in the s hipping box. The entire system is controlled by Progr ammable Logic Controller (PLC). This system helps you t o understand the whole working of a real system which is cu rrently employed in the industry.

and accuracy can be optimized due to

component. Whenever a company components, they can substitute this system

utilization of space available and lowers Minimization of manpower requirements

Key Words: Automation, PLC, programming, Sensors, Motors etc…

Ladder

logic

1. INTRODUCTION

This system comprises a miniature mod el of process of reception, put-away, storage, retrie val, packaging,

and inventory

counting.

This system is distributed in several se ctions:-

A. Conveyor Belt 1

B. Conveyor Belt 2

C. Rolling Disc

shipment preparation, replenishment

Belt 2 C. Rolling Disc shipment preparation, replenishment Fig -1 : Pro ject Layout The term

Fig -1: Pro ject Layout

The term inspection can b e defined as the activity of

examining the products, its or materials out of which

whether they follow to des ign specifications. Inspection

has become an essential part of any manufacturing system.

nonconformities and assuring

good quality products. S teps of inspection include

mination for non-conforming on evaluation and Action (accept or reject item).

Automated inspection is def ined as the automation of one

It is the means of rejecting

components, sub-assemblies, it is made, and to determine

presentation of item, Exa features, Decision based depending on Decision

or more steps involved i n the inspection procedure. Completely automated inspe ction system in which steps of

decisions and action are Automated system operates

with high accuracy for sim ple inspection tasks such as automatic gauging of a simp le dimension on a part. With

of inspection, the error rate

the increase in complexity

presentation, examination, performed automatically.

© 2018, IRJET

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International Research Jo urnal of Engineering and Technology (I Volume: 05 Issue: 05 | May

International Research Jo urnal of Engineering and Technology (I

Volume: 05 Issue: 05 | May 20 18

www.irjet.net

RJET)

e-ISSN: 2395-0056

p-ISSN: 2395-0072

inspection. The

process of automated packaging of inspec tion passed item

during shipping to be followed.

Automated Warehousing is based on Au tomatic Storage

and Retrieval Systems (AS/RS), aut omated robotic

in a warehouse.

Solutions are tailored for industry pu rposes such as production storage, cold or deep freeze storage, distribution centers. Modern warehous e system design

main taken into

offers infinite innovative possibilities. The

systems for storing and retrieving items

tends to decreases, compared to manual

is also an advantage. For safety of item and handling certain standards have

consideration are product type, product d iversity, number of articles.

This system is comprises of following:-

Mechanical Structure: -

Conveyor 1

Conveyor 2

Rejection Assembly

Rolling Disc

Instrumentation Devices:-

PLC (IDAC)

Photo

8mm rang

Sensors-

3Nos(PNP,

4

w ire,

18mm

dia,

Inductive Proximity Sensor(PNP P, 3wire, 18mm dia, 3mm range, 10-30V )

Buzzer (220V)

DC Motors- 4Nos(12v, 100 rpm a nd 45 rpm)

DC Power Supply ( 12V )

Emergency Switch

Power Adapter ( 220V AC- 12V D C)

Programming:-

Programming Software: IDAC Log ic WindLDR

Ladder Diagram of Project

2. MECHANICAL STRUCTURE

the platform &

will be rotated on rollers by 12V DC mo tor. The product

which is manufactured will be placed on to the conveyor

it will undergo undergo by the

It consists of conveyor belt placed on to

platform for transportation and then inspection counting. The counting will

timer and buzzer. Other conveyor has sa me dimension as conveyor 1.

2.1 Conveyor Belt 1

Height: - 7inch,

Structure Dimensions: - 6inc h *4inch Belt Dimension: 13inch *3.8i nch *.01inch

As the material come on the belt, the belt will start moving

automatically. It means the

by the sensor and will respo nd to the belt 1 as per ladder logic. The First sensor will se nse the presence of the object only. The conveyor has m any components as well like conveyor belt, conveyor p ulley, shaft, and mechanical supports.

presence of object will sense

and mechanical supports. presence of object will sense Fig -2: Con veyor Belt 1 2.2 Rejection

Fig -2: Con veyor Belt 1

2.2 Rejection Assembly

It performs on-line/post-pr ocess inspection. It consists of rejection mechanism with 1 2V DC Motor of 30 RPM and

one proximity sensors for

Article. The motor in rej ection mechanism converts rotational movement in pris matic movement for rejection Arm. It will reject the artic le if it does not fulfill design specification of the product.

whole inspection of the Metal

specification of the product. whole inspection of the Metal Fig -3: Rejec tion Assembly 2.3 Conveyor

Fig -3: Rejec tion Assembly

2.3 Conveyor Belt 2

The dimensions of the conve yor 1 are same as conveyor 2.

placed on to the platform &

will be rotated on rollers b y 12V DC motor. The product

It consists of conveyor belt

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International Research Jo urnal of Engineering and Technology (I Volume: 05 Issue: 05 | May

International Research Jo urnal of Engineering and Technology (I

Volume: 05 Issue: 05 | May 20 18

www.irjet.net

RJET)

e-ISSN: 2395-0056

p-ISSN: 2395-0072

which is manufactured will be placed on to the conveyor platform for transportation. This belt car ries the metallic objects and will put the object upon the ro lling disc.

Height- 7inchStructure Structure Dimensions: - 6inch *4inch Belt Dimension: 13inch *3.8inch *.01inch

- 6inch *4inch Belt Dimension: 13inch *3.8inch *.01inch Fig -4: Conveyor Belt 2 2.4 Rolling Disc

Fig -4: Conveyor Belt 2

2.4 Rolling Disc

Dimension- 14inch dia

-4: Conveyor Belt 2 2.4 Rolling Disc Dimension- 14inch dia Fig -5: Rolling Disc 3. INSTRUMENTATION

Fig -5: Rolling Disc

3. INSTRUMENTATION DEVICES

industrial digital adapted for the

control of manufacturing processes, s uch as assembly

lines, or robotic devices, or any activity th hat requires high reliability control and ease of programm ing and process fault diagnosis. In this system made of har d real time IDEC

is Japanese PLC

which is used in the modern day to day in dustries.

PLC automation purpose. An IDEC PLC

A PLC or programmable controller is an computer which has been ruggedized and

controller is an computer which has been ruggedized and Fig -6: I DAC PLC 3.1 Proximity

Fig -6: I DAC PLC

3.1 Proximity Sensors

Proximity sensors are en tirely solid state electronic controls that contain no mo ving parts to wear out as do mechanical Switches. They n ecessitate no physical contact for Actuation, no cams or l inkages, have no contacts to bounce or arc and are fully e ncapsulated.

Inductive Proximity Sensor : -

Two, three, or four-wire pro ximity sensors contain a transistor oscillator and a sn ap-action amplifier. This provides exceedingly high ac curacy to a set switching point, even with very slowly approaching targets.

The sensors can drive electr omechanical relays, counters, solenoids, or electronic mo dules, and interface directly with logic systems or progr ammable controllers without additional interface circuit ry. They are available with either NPN output transist ors (current sinking) or PNP output transistors (current s ourcing).

Three sensors are used in th is system. Two photo sensors both ends of conveyor 1, b oth have same function will sense the presence of the ob ject. One Inductive proximity sensors are placed conveyo r structure. Proximity sensors will sense the metal part of a ny object & it will be generate a signal proportionally so ob ject will be stopped.

generate a signal proportionally so ob ject will be stopped. Fig -7: Proximi ty Sensor Circuit

Fig -7: Proximi ty Sensor Circuit

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Impact Factor value: 6.171

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International Research Jo urnal of Engineering and Technology (I Volume: 05 Issue: 05 | May

International Research Jo urnal of Engineering and Technology (I

Volume: 05 Issue: 05 | May 20 18

www.irjet.net

RJET)

e-ISSN: 2395-0056

p-ISSN: 2395-0072

3.2 DC Motor

Here 4 DC motors are used Conveyor 1- 1Nos Conveyor 2- 1Nos Rejection Assembly- 1Nos Rolling Disc- 1Nos

Conveyor 2- 1Nos Rejection Assembly- 1Nos Rolling Disc- 1Nos Specifications:- Fig -8: DC motor  Shaft

Specifications:-

Fig -8: DC motor

Shaft diameter: 6mm

Rated volt: 12VDC

No load Current: 0.72A

Rated Power: 10W

Rated speed: 50±5%rpm

Rated Torque : 6N.m

3.3 Buzzer

Rated speed: 50±5%rpm  Rated Torque : 6N.m 3.3 Buzzer Specifications:- Fig -9: 220V Buzzer 

Specifications:-

Fig -9: 220V Buzzer

Sound output: 121dB

Voltage input: 24VDC

Voltage tolerance: +/- 25 %

Current mA: 375mA

Alarm tones: 5

Operation Temp: –25 to +55ºC

4. LADDER LOGIC PROG RAMMING

WindLDR is the software t ool you use to create control

projects for Vision controlle rs. After you plan the control

debug, and download the PLC

control and HMI application s into the controller. You write

the Ladder Editor. The HMI

application configures the o perating panel's function. You

use the HMI Editor to creat e the Displays that are shown

Displays tell your operators your operators log in with a

password, enter set points a nd other data, and instruct the operator what to do in case of a system problem or alarm. A Display can contain both te xt and images.

on the controller's screen. what to do. You can have

the PLC application using

task, use WindLDR to write,

Input Addressing

Output Addressing

Sensor1

I0000

Motor1 Q0001

Sensor2

I0001

Motor2 Q0002

Sensor3

I0002

Motor3 Q0003

Sensor4

I0003

Motor4 Q0004

Buzzer

Q0005

Q0003 Sensor4 I0003 Motor4 Q0004 Buzzer Q0005 Fig -10: Ladder Log ic Program of Project ©

Fig -10: Ladder Log ic Program of Project

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International Research Jo urnal of Engineering and Technology (I Volume: 05 Issue: 05 | May

International Research Jo urnal of Engineering and Technology (I

Volume: 05 Issue: 05 | May 20 18

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5. RESULTS & DISCUSSIONS

RJET)

The operation of both the conveyor belt s is carried out.

The operation of sensors, actuators and al ll other electrical devices are carried out by PLC. The moto r operation their delay mechanism, counter operations sen sing unit all are carried out by PLC. It shows that the me chanical process

or manmade operation can be operated intervention and therefore reduces the

drives the whole circuitry of sensors whic h are either PNP or NPN sensors which depict the outp ut which maybe

either positive or negative on the wiring a nd operation.

without human human effort. It

6. CONCLUSIONS

automation part

can be made more effective in the industr ial scenario. The cost of production can be reduced as the h uman efforts are also reduced. It provides finest of product s with minimum of delay in its operation process. More ski lled workers are employed which improves the industr y statistics. The large quantity products demand can be co untered with the help of automation. Safety of workers a re also ensured

With the application of this project the

with the use of automation control in the kind of defects are also lowered which case of the human intervention.

industry and any is more often in

REFRENCES

Webb

Ronald A. Reis, Prentice Hall, 2003 [2] Manual of Inductive Proximity Sensor , by BCH Electric

Ltd. [3] Manual of IDEC PLC [4] Manual of 2 C/O Relay Modules, b y Connect well Industries Pvt. Ltd. [5] windsormachines

[6] “Process

by

[1] Programmable logic controllers, by

John

W.

control

instrumentation

Technology”

Curtis Johnson

.

.

e-ISSN: 2395-0056

p-ISSN: 2395-0072

© 2018, IRJET

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Impact Factor value: 6.171

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ISO 9001:2008 Certifie d Journal

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