Conveyor Belt PLC PROJECT

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1. INTRODUCTION 1.1

SCOPE OF PROJECT:

Today automation used in every industrial and many other application such as loading ,shifting the material in various application point and also transferring the material from one place to another another place for saving time ,cost ,labor work, and do not cause any damage to the material while shifting the material. Scient Scientific ific automa automatio tion n includ includes es integr integrati ation on of additi additiona onall functi functions ons in the soft softwa ware re PLC. PLC. In addi additi tion on to seque sequent ntial ial cont contro rol, l, moti motion on cont contro roll and and cont contro roll techno technolog logy, y, the softwar softwaree PLC also includ includes es measur measureme ement nt techno technolog logy y and other other components 1.2 INTRODUCTION ABOUT PROJECT:

In various section there is a problem of availability of space for shifting the material material or transferring transferring the material from down side to upside upside so we here use to shift the material from down to up by pneumatic cylinder. First off all the material is loaded loaded on conveyor conveyor belt that loaded loaded material moves towards the flat platform platform which situated on pneumatic cylinder. The pneumatic cylinder applying the pressure to move the material upward direction, then there is one another pneumatic cylinder which place horizontally in front of second conveyor belt .The second pneumatic cylinder push the material on second conveyor belt which pass pass the material at target point . 1.2.1INTRODUCTION 1.2.1INTRODUCTION ABOUT CONVEYOR:

The belt consists of one or more layers of material they can be made out of rubber. Many belts in general general material handling have two layers. An under layer of material to provide linear strength and shape called a carcass and an over layer called the cover. The carcass is often a cotton or plastic web or mesh. The cover is often various rubber or plastic compounds specified by use of the belt. Covers can be made from more exotic materials for unusual applications such as silicone for heat or gum rubber when traction is essential. Material flowing over the belt may be weighed in transit using a belt weighter. Belts with regularly spaced partitions, known as elevator belts, belts, are used for 1


transporting loose materials up steep inclines. Belt Conveyors are used in selfunloading bulk freighters and in live bottom trucks. Conveyor technology is also used in conveyor transport such as moving sidewalks or, escalators as well as on many many manufacturing assembly lines. Stores often have conveyor belts at the check-out counter to move shopping items. Ski areas also use conveyor belts to transport skiers up the hill. A wide variety of related conveying machines are available, different as regards principle of operation, means and direction of conveyance, including vibrating screw conveyors, pneumatic conveyors, the moving floor system, which uses reciprocating slats to move cargo, and roller conveyor system, which uses a series of powered rollers to convey boxes or pallets.Conveyors pallets.Conveyors are used as components in automated distribution and warehousing. In combination with computer controlled pallet handling equipment this allows for more efficient retail, wholesale, and manufacturing distribution. It is considered a labor saving system that allows large volumes to move rapidly through a process, allowing companies to ship or receive higher volumes with smaller storage space and with less labor expense.Rubber Conveyor Belts are commonly used to convey items with irregular bottom surfaces, small items that would fall in between rollers (e.g. a sushi conveyor bar), or bags of product that would sag between rollers. Belt conveyors are generally fairly similar in construction consisting of a metal frame with rollers at either end of a flat metal bed. The rollers allow weight to be conveyed as they reduce the amount of friction generated from the heavier loading on the belting. Belt conveyors can now be manufactured with curved sections which use tapered rollers and curved belting to convey products around a corner. These conveyor systemsare commonly used in postal sorting offices and airport baggage handling systems. Belt conveyors are the most commonly used powered conveyors because they are the most versatile and the least expensive. Product is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transp transport orted ed success successful fully. ly. These These convey conveyors ors should should use only only the highes highestt qualit quality y premium belting products, which reduces belt stretch and results re sults in less les s maintenance for tension adjustments. Belt conveyors can be used to transport product in a straight line or through changes in elevation or direction. In certain applications they can also be used for static accumulation or cartons.

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transporting loose materials up steep inclines. Belt Conveyors are used in selfunloading bulk freighters and in live bottom trucks. Conveyor technology is also used in conveyor transport such as moving sidewalks or, escalators as well as on many many manufacturing assembly lines. Stores often have conveyor belts at the check-out counter to move shopping items. Ski areas also use conveyor belts to transport skiers up the hill. A wide variety of related conveying machines are available, different as regards principle of operation, means and direction of conveyance, including vibrating screw conveyors, pneumatic conveyors, the moving floor system, which uses reciprocating slats to move cargo, and roller conveyor system, which uses a series of powered rollers to convey boxes or pallets.Conveyors pallets.Conveyors are used as components in automated distribution and warehousing. In combination with computer controlled pallet handling equipment this allows for more efficient retail, wholesale, and manufacturing distribution. It is considered a labor saving system that allows large volumes to move rapidly through a process, allowing companies to ship or receive higher volumes with smaller storage space and with less labor expense.Rubber Conveyor Belts are commonly used to convey items with irregular bottom surfaces, small items that would fall in between rollers (e.g. a sushi conveyor bar), or bags of product that would sag between rollers. Belt conveyors are generally fairly similar in construction consisting of a metal frame with rollers at either end of a flat metal bed. The rollers allow weight to be conveyed as they reduce the amount of friction generated from the heavier loading on the belting. Belt conveyors can now be manufactured with curved sections which use tapered rollers and curved belting to convey products around a corner. These conveyor systemsare commonly used in postal sorting offices and airport baggage handling systems. Belt conveyors are the most commonly used powered conveyors because they are the most versatile and the least expensive. Product is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transp transport orted ed success successful fully. ly. These These convey conveyors ors should should use only only the highes highestt qualit quality y premium belting products, which reduces belt stretch and results re sults in less les s maintenance for tension adjustments. Belt conveyors can be used to transport product in a straight line or through changes in elevation or direction. In certain applications they can also be used for static accumulation or cartons.

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1.2.2INTRODUCTION 1.2.2INTRODUCTION ABOUT WHOLE SYSTEM:

This whole system is operated by proximity sensor, motor and PLC in our project we use capacitive type of proximities sensor to sense the material at which position and it gives the signal towards the PLC .The PLC of our project depends on the number of input output module and analog signal .We select PLC in our project, because Programmable Logic Controller, popularly known as PLC is a tool. It is the imagination that limits it's scope. Currently it is abundantly used in process control and machine control. With incre increase ased d appl applic icati ation onss price pricess shal shalll come come down down and and that that will will furth further er boos boostt it's it's application.PLC basically a low current device so usually electronic faculty people can handle it or design the PLC, but coming to application, i.e. sales and marketing, most mostly ly it is uses uses in high high elec electri tricc netw networ ork k syste system, m, so a elect electri rical cal know knowle ledg dgee is essential. The PLC is user friend friendly ly digita digitally lly,, operat operating ing electro electronic nic device device that that uses uses programmable memory for internal storage of instruction that implement specific function, such as logic sequence, timing, counting to control machine and process .The PLC signal can be use for start and stop motor .Therefore we use here dcmotor that operated at 12(v)/24(v) DC supply .The voltage depend upon speed require for the process . This conventional method of conveyor control is further mobilized by use of dimmers. They were better option in the case of on off control they can be operated in full load condition also. But the main problem with them is stoppage of conveyors . the pneumatic stoppers were used which did not stop the belts completely but use to stop s top materials on it. This leads to wear and tear of the belts as well as the product also the rejection ratio is increased.Computerized conveyor belt system is used. In this the control of these belts is achieved by the use of the pc interface and plc based. These lead to better option of conveyor control in today’s industrial environment. It is very difficult for those to maintain them at constant or through variable speeds .Recently single shop conveyor belt systems are modified to become multiple type i.e instead of single conveyor multiple conveyors are used in series, parallel and speed is controlled using remote monitoring. Also the recent trend is 3


emerging towards controlling the speed of these conveyors by the use of computer technology. Conveyors are used in a broad range of industries and applications to move packaged goods, assemblies, process byproducts, or any material from one place to another. A process designer will typically look for opportunities to use the force of gravity to accomplish product movement. Electric motors are commonly used when gravity cannot be employed or when the speed of a gravitational fall needs to be controlled. Airports, mines, cement plants, distribution facilities, assembly, and food processing plants all utilize conveyors. Conveyors are typically constant torque loads, meaning the required torque to drive a conveyor is independent of speed. A fixed amount of torque is also required to overcome the frictional, or machine drag, portion of the total load. Conveyors can have nominal amounts of friction and machine inertia for which to compensate. Material flowing over the belt may be weighed in transit using a beltweigher . Belts with regularly spaced partitions, known as elevator belts, belts, are used for transporting loose materials up steep inclines. Belt Conveyors are used in selfunloading bulk freighters and in live bottom trucks. Conveyor technology is also used in conveyor transport such as moving sidewalks or escalators or escalators,, as well as on many manufacturing assembly lines. lines. Stores often have conveyor belts at the check-out counter to counter to move shopping items. Ski areas also use conveyor belts to transport skiers up the hill. So we also want to develop the material shifting technology so we use advance technology which used in market i.e.plc, pneumatic based.

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2. LIRERATURE SURVEY

The history of conveyor belts begins in the latter half of the 17th century. Since then, conveyor belts have been an inevitable part of material transportation. But it was in 1795 that conveyor belts became a popular means for conveying bulk materials. In the beginning, conveyor belts were used only for moving grain sacks to short distances. The conveyor belt system and working were quite simple in the early days. The conveyor belt system had a flat wooden bed and a belt that traveled over the wooden bed. Earlier, conveyor belts were made of leather, canvas or rubber. This primitive conveyor belt system was very popular for conveying bulky items from one place to another. In the beginning of the 20th century, the applications of conveyor belts became wider. Hymle Goddard of Logan Company was the first to receive the patent for the roller conveyor in 1908. The roller conveyor business did not prosper. A few years Later, in 1919, powered and free conveyors were used in automotive production. Thus, conveyor belts became popular tools for conveying heavy and large goods within factories. One of the turning points in the history of conveyor belts was the introduction of synthetic conveyor belts. It was introduced during the Second World War, mainly because of the scarcity of natural materials such as cotton, rubber and canvas. Since then, synthetic conveyor belts have become popular in various fields. The longest conveyor system in an Airport is the Dubai International Airport baggage handling system at 92km. It was installed by Siemens and commissioned in 2008, and has a combination of traditional belt conveyors and tray conveyors. With the increasing demand in the market, many synthetic polymers and fabrics began to be used in the manufacture of conveyor belts. Today, cotton, canvas, EPDM, leather, neoprene, nylon, polyester, polyurethane, urethane, PVC, rubber, silicone and steel are commonly used in conveyor belts. Nowadays, Industrial Mechanical the material 5


used for making a conveyor belt is determined by its application.consists of two or more, pulleys with a continuous loop of material - the conveyor belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler. There are two main industrial classes of belt conveyors; Those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport industrial and agricultural materials, such as grain, coal, ores, boxes etc. generally in outdoor locations. Generally companies providing general material handling type belt conveyors do not provide the conveyors for bulk material handling. In addition there are a number of commercial applications of belt conveyors such as those in grocery stores. 2.1 Control Scheme: -

Belt conveyors are the most commonly used powered conveyors because they are the most versatile and the least expensive. Product is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transported successfully. These conveyors should use only the highest quality premium belting products, which reduces belt stretch and results in less maintenance for tension adjustments. Belt conveyors can be used to transport product in a straight line or through changes in elevation or direction. In certain applications they can also be used for static accumulation or cartons. The main problem of this system is required to keep continuous watch on each conveyor current because of choking of transfer chute or jamming of conveyor. This will tend to interruption of coal supply to boiler.

The existing system has sensing device like zero speed sensing, receiving conveyor position sensing. It has also facility for selection to operate conveyor avoiding control system i.e. manual run mod. In some CHP there is facility of three type of selection. One is for start or stop plant with auto mode. In this mod each conveyor will operate sequentially after selecting the stream. Second which is in

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all CHP for start or stop of plant with manual mod. Third is operating the system without any protection or interlock. 2.2 Operating Principle: -

Manufacturers of conveyor belt systems offer holistic services. They will study your needs, make recommendations, design special systems, and customize your conveyor belt and systems. Many offer round-the-clock service and undertake different kinds of service as well as preventive maintenance. Experts in the field of conveyor belts, many companies share their knowledge and host content on sites that explain in depth how one must choose a conveyor belt, how to optimize efficiency, and all about maintenance, speeds, parts, safety concerns, and ergonomic design of systems.

Before starting conveyor system it is necessary to start first receiving conveyor and then start feeding conveyor i.e. operating logic is from down stream to upstream. For stopping of conveyor system the operation will be opposite i.e. from upstream to down stream. So it is necessary if any conveyor is stopped in the system all the upstream conveyor should stop automatically. The existing system takes care of this logic. This is known as conveyor sequential operation. If due to any problem the rotation of conveyor becomes slow or towards zero its necessary to stop the conveyor. This is known as zero speed protection. Existing system takes care of it and stops the

conveyor and

further stop

the

upstream

system

sequentially. 2.3 Draw Back Of Existing System: -

The main problem of this system is required to keep continuous watch on each conveyor current because of choking of transfer chute or jamming of conveyor. Many times it is required to reduce the feeding rate by adjusting feeder to reduce the current of conveyor. When current comes to normal again it is tried to

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establish the required feed rate, if it is not again establish by stopping the conveyor system the problem is identify and attended. For sensing of speed simple proxy switches are used.. As proxy switches are basically on/off switches equipped with timer, they aresystem should be operating when there is material flow. This is done by sensing via simple mechanical under material position. In our system when shaft of pneumatic cylinder goes up the lower motor stop by sensor. This reduces the fault material shifting but speed slows down of whole systems.

2.4 Limitations

The main problem of this system is required to keep continuous watch on each conveyor current because of choking of transfer chute or jamming of conveyor. Many times it is required to reduce the feeding rate by adjusting feeder to reduce the current of conveyor. When current comes to normal again it is tried to establish the required feed rate, if it is not again establish by stopping the conveyor system the problem is identify and attended. The major problem of this system when the conveyor motor power fuses blown off, it will stop the rotation of conveyor but will not stop the upstream conveyors as controller sense motor is running because the control supply does not pick up motor off relay. Because of this the logic of system fails. We already told the speed of the process slow down because continuous operation not done by this system because the material goes up take some time to shift and the shaft also takes the some time to regain it’s position. There is also problem of sensor in the field because sensor sense material position and then cylinder shaft goes up by logic developed but when shaft goes up the shaft steam also sensed by sensor and according to logic shaft not get there regain position similar thick happen in also on upper cylinder. So this creates faulty operation.

2.5 Advance technology build :

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According to market survey we think that there is all where the problem of shifting material from ground to up side because of area availability like in big malls, airport so we develop the system which operated by pneumatic, advanced plc based i.e. operated automatically and time consuming. Some sort of drawbacks or limitation already told problem of sensor can be relocated by logic and the sensor output can be hold so all related problems can be solved and slightly accurate model ca developed. I think this type of technology will never heard until so we take idea of car washing technology that developed in material shifting by use of conveyor belt.

METHODOLOGY 3.1 BLOCK DIAGRAM

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Figure3.1: Block diagram

3.2 WORKING

Our project is totally based on conveyor belt that is use to transfer the material upward and downward direction. There is use of two conveyor belt first is upper side and other is lower side and there is use of two electrically operated dcmotor and proximity sensor to sense the material location and also use the PLC for automatic on off the motor. Firstly material is loaded on first conveyor belt that is homing position by manually and we press the start push button so the material in homing position and sensor1 sense that material then the motor1 is start . so the material move forward then the material shifted on lower cylinder platform. So when the material on that plat form and the second sensor which are located perpendicular to the material that sence that material after sensation by according to the program the relay is operated and the it give signal to the solenoid valve coil. This solenoid valve having two coil that is for up, down motion for lower cylinder and forward reveres motion for upper cylinder .so the coil giving the pressure to the lower cylinder to move the cylinder shaft upward. The pressure required for this process we are taken from compressor. The cylinder shaft is operated at the pressure of 30-40 bar. So this pressure moves the material up direction. At his condition the lower i.e. motor1 should be stop because platform of lower cylinder at up position so the material fall down through the belt. When material reaches up located position there placed third sensor is sense the material and the upper motor2 start and also at that time the second relay operated by same manner that previously explain and the second valve coil is operated that giving the pressure to the upper valve and the shaft of that cylinder moves forward so the material which are located on that platform is shifted on the upper belt and move towards the target position . When the material is shifted according to program the lower cylinder shaft and upper cylinder shaft moves down and reverse respectively by applying pressure through the solenoid valve. When material reach target point that minces at last location the last sensor4 is sense that material and the mtor2 is stop, this material is shifted by manually or by robotics hand to the storing position. This continuously done by starting first motor again.

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This is total working of project by manually also we can operate this technique without using sensor by pressing the push button of the control panel.

3.3 MECHANICAL ASSEMBLY

1. conveyor belt 2. Dc gear motor 3. Sensor 4. pneumatic cylinder

Figure3.3. Conveyor, motor and sensor system

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The dc geared motor 1 is used to rotate the driver pulley of the conveyor belt. As the belt moves the material passing on the belt proceeds. The speed of the belt is maintained at certain level by the use of plc based assembly. The inductive or optical sensors are used to count number of objects passing on the belt according to that the speed is maintained and start /stop can also be contol.The main theme is to give output of the sensor to plc and output of plc is given to the dc geared motor and pneumatic cylinder for proper working .

3.4 ELECTRONIC ASSEMBLY

3.4.1...Relay board:

Figure3.4.1: Relay card

. The Relay Card has six SPDT relays, each of which is rated to handle up to 250 V AC, 1200 V·A (max. 10 A) or up to 30 V DC, 240 W (max. 8 A). Each relay draws approximately 20 mA from the +24V power supply when energized. This current draw can be reduced by approximately a factor of two by using the function call to engage the power-save mode once a relay is energized.

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Figure 3.4.1. Relay Output Circuit The purpose of this card is to convert electronic outputs or contacts to relay contacts.

This results in a practical isolation between load and driving circuit. Ideal for use with our computer interface card VM110 or infrared remote control receiver VM122. The card features high grade input and output connectors.

3.4.1.1 Specifications: eight high quality relay contacts, 5A/230Vac max relay outputs are transient suppressed using VDRs LED confirmation on each relay contact eight drive inputs to use with open collectors or regular switches features 12Vdc / 200mA power output (for VM122 supply) input power: 12Vac / 500mA (including 12V output) (VM129)

3.4.2 POWER SUPPLY DESIGN:

Power supply is the first and the most important part of our project.For our project we require +5v regulated power supply with maximum current rating 500 mA Following basic building blocks are required to generated power supply.

Step Down 230vacTransformerr

Rectifier

Filter

3 Terminal Vtg. Reg.o/p Regulator

Figure 3.4.2 Power Supply Design

Step down transformer is the first part or regulated power supply . To step down the mains 230V A.C. we require step down transformer. Following are the main characteristic of electronic transformer. I) Power transformer are usually designed to operate from source of low impedance at a single freq. 13


II) III)

IV)

It is required to construct with sufficient insulation of necessary dielectric strength. Transformer rating are expressed in volt-amp. The volt-amp of each secondary winding or windings is added for the total secondary VA. To this are added the load losses. Temperature rise of a transformer is decided on two well known factors i.e. losses on transformer and heat dissipating or cooling facility provided unit.

3.4.2.1 RECTIFIER UNIT: Rectifier unit is a ckt. Which converts A.C. into pulsating D.C. Generally semi-conducting diode is used as rectifying element due to its property of conducting current in one direction only Generally there are two types of rectifier. 1. Half wave rectifier 2. Full wave rectifier. In half wave rectifier only half cycle of mains A.C. rectified so its efficiency is very poor. So we use full wave bridge type rectifier, in which four diodes are used. In each half cycle, two diodes conduct at a time and we get maximum efficiency at o/p. Following are the main advantages and is advantages of a fullwave bridge type rectifier ckt.

3.4.2.2 ADVANTAGES : 1. The need of center tapped transformer is eliminated. 2. The o/p is twice that of center tap circuit for the same secondary voltage. 3. The PIV rating of diode is half of the center taps circuit.

3.4.2.3 DISADVANTAGES : 1. It requires four diodes. 2. As during each half cycle of A.C. input, two diodes are conducting therefore voltage drop in internal resistance of rectifying unit will be twice as compared to center tap circuit

3.4.2.4 Filter circuit : Generally a rectifier is required to produce pure D.C. supply for using at various places in the electronic circuit, However, the o/p of rectifier has pulsating character i.e. if such a D.C. is applied to electronic circuit it will produce a hum i.e. it will contain A.C. and D.C. components. The A.C. components are undesirable and must be kept away from the load. To do so a filter circuit is used which removes (or filter out) the A.C. components reaching the load. Obviously a filter circuit is installed 14


between rectifier and voltage regulator. In our project we use capacitor filter because of his low cost, small size and litile weight and good characteristic. Capacitors are connected in parallel to the rectifier o/p because it passes A.C. but does not pass at all.

3.4.2.5 Three terminal voltage regulators : A voltage regulator is a ckt. That supplies constant voltage regardless of change in load current. IC voltage regulators are versatile and relatively cheaper. The 7800 series consists of three terminal positive voltage regulators. these ICs are designed as fixed voltage regulator and with adequate heat sink, can deliver o/p current in excess of 1A. These devices do not require external component. This IC also has internal thermal overload protection and internal short circuit and current limiting protection for our project we use 7812 and 7824 voltage regulator IC.

Figure 3.4.2.1 12VPower supply design

Figure 3.4.2.2 24 Power supply design

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3.4.2.6 Design to step down transformer : The following information must be available to the designer before the commences for the design of transformer. 1. Power output 2. operating voltage. 3. Frequency Range 4. Efficiency and Regulation Size of core : Size of core is one of the first consideration in regard of core and winding configuration used. Generally following formula is used to find area or size of core. Ai =

(p1/0.87)

Where Ai = Area of cross section in sq. cm. P1 = Primary voltage In Transformer

P1 = P2

For our project we required +5V regulated output. So transformer secondary rating is 12V, 500 mA. So secondary power wattage is, P2

=

12 X 500 X 10 –3 w. =

6w.

so , Ai =

(6/0.87)

= 2.62 Generally 10% of area should be added to core accommodate all turns for low Iron losses and compact size. So, Ai = 2.88. Turns per volt Turns per volt of transformer are given by relation 10,000 Turns/volt = ------------------4.44f B Ai Here; F is the frequency in Hz B is flux density in Wb/m2 A is net area of cross section. For project for 50Hz the turns per volt for 0.91 wb/m2, Turns per volt = 50/Ai = 50/ 2.88 = 17 16


Thus for primary winding = 220 X 17 = 3800. For secondary winding = 12 X 17 = 204

3.4.2.7Rectifier design : R. M. S. Secondary voltage at secondary of transformer is 12V. So, maximum voltage Vm across Secondary is = RMS voltage *1.41 = 12* 1.41 =16.97 D.C. output voltage at rectifier o/p is Vdc = 2Vm/3.14 = 2*16.97/3.14 = 10.80 v PIV = 2 Vm = 2 X 16.97 = 34V Design of filter capacitor Formula for calculating filter capacitor is,

1 C=

----------------------------4. 3 r f RL r = ripple present at o/p of rectifier. (Which is maximum 0.1 for full wave rectifier ?) f = Frequency of mains A.C. R = I/p impedance of voltage regulator IC. 1 C = ------------------- = 1000F 4 3 0.1*50*28

3.5 COMPONENT SELECTION 3.5.1 PLC :

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Figure 3.5.1:ALLEN BRADLY PLC

RSLogix 500™ Programming Software: RSLogix 500, a Microsoft® 32-bit Windows 95® and Windows NT® programming software package, supports Allen-Bradley SLC 500 and MicroLogix families of processors. RSLogix 500 is designed to offer powerful functionality, superior diagnostics, reliable communications, and an easy to use interface. RSLogix 500 provides everything you expect in a programming software package, from consolidated project view to drag-and-drop editing. Plus, RSLogix 500 is part of the RSLogix family of products that share: •

A common user interface and feature set

•

Flexible, easy-to-use editors

•

Point-and-click I/O configuration

•

Powerful database editor

•

Diagnostic and troubleshooting tools

•

Dependable communications

Input module 18


Choose from over 60 modules to control digital, analog, and temperature signals. Numerous specialty modules from Rockwell Automation and third-party partners are also available. With this complete and varied assortment of modules we can offer you the flexibility and speed you need to configure all your control systems.

OUTPUT MODULE 

These modules act as link between the CPU and the output devices in the field.



Analog output module : Typical output from these modules is 4-20 mA, 0-10 V

Ex : Control Valve, Speed, Vibration 

Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC

Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control

Applications The SLC 500 provides cost-effective, reliable control in hundreds of thousands of applications around the world — everything from amusement park rides and microbreweries to pharmaceutical and food processes. The smaller size of the SLC means that you can use an SLC in applications where you can't afford the size and overhead of a traditional, full-size PLC. And its modular design offers you the flexibility to buy exactly what you need. SLC 500 controllers are ideally suited for OEM applications on the following types of machinery: •

Packaging Machinery

•

Conveyors and other Material Handling Machinery

•

Machine Tools

•

Textile Machinery 19


•

Food Products Machinery

•

Pharmaceutical Products Machine

3.5.2 PROXIMITY SENSOR :

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Figure of proximity sensor A Proximity sensor can detect objects without physical contact. A proximity sensor often emits an electromagnetic field or beam and look for changes in the field. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target. The proximity sensor is often found in bulk-handling machines, level detectors, and package detection. One advantage of capacitive proximity sensors is that they are unaffected by dust or opaque containers, allowing them to replace optical devices. Conditioning the output of a proximity sensor has always been difficult. Proximity sensor designers must confront linearity, hysteretic, excitation voltage instability, and voltage offset. A proximity sensor that measures current flow between the sensing electrode and the target provides readouts in appropriate engineering units. Usually, one side of the voltage source or oscillator connects to the sensing electrode, and the other side connects through a current-measuring circuit to the target, which generally is a metal part at earth or ground potential. Probes used with a 21


capacitive proximity sensor have either a flat disc or rectangular sensing element surrounded by a guard electrode that provides electrical isolation between the proximity sensor and its housing. The guard also ensures that the lines of electrostatic field emanating from the probe are parallel and perpendicular to the surface of the proximity sensor. In optical sensor one transmitter and receiver plate in build is located inbuilt it use the optical ray to detect the object when object in target position the ray is reflected back and received by inner plate and is operated.

Specification: 1. Switching Range:100mm 2. Switching freq.:10hz 3. Operating temp.: -14 to 158 0f 4. Measuring time:100micro sec.

3.5.3 DC MOTOR :

Figure3.8.3: 12vdc motor 22


Introduction Nr-dc-eco is high quality low cost dc geared motor. It contains brass gears and steel pinions to ensure longer life and better wear and tear properties. the gears are fixed on hardened steel spindles polished to a mirror finish. these spindles rotate between bronze plates which ensures silent running. the output shaft rotates in a sintered bushing. The whole assembly is covered with a plastic ring. all the bearings are permanently lubricated and therefore require no maintenance. The motor is screwed to the gear box from inside.

Specifications: 1. Total length: 46mm 2. Motor diameter: 36mm 3. Motor length: 25mm 4. Dc supply: 4 to 12v 5. Rpm: 100 6. Brush type: precious metal 7. Gear head diameter: 37mm 8. Gear head length: 21mm 9. output shaft: centered 10. shaft diameter: 4mm and 6mm 11. shaft length: 22mm 12. gear assembly: spur 13. torque: 0.25 to 7kg/cm

3.5.4 PNEUMATIC CYLINDER :

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Figure of pneumatic cylinder Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which produce force, often in combination with movement, and are powered by compressed gas (typically air ). To perform their function, pneumatic cylinders impart a force by converting the potential energy of compressed gas into kinetic energy. This is achieved by the compressed gas being able to expand, without external energy input, which itself occurs due to the pressure gradient established by the compressed gas being at a greater pressure than the atmospheric pressure. This air expansion forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved.

General about pneumatic cylinder: Once actuated, compressed air enters into the tube at one end of the piston and, hence, imparts force on the piston. Consequently, the piston becomes displaced (moved) by the compressed air expanding in an attempt to reach atmospheric pressure.

Fail safe mechanisms: Pneumatic systems are often found in settings where even rare and brief system failure is unacceptable. In such situations locks can sometimes serve as a safety mechanism in case of loss of air supply (or its pressure falling) and, thus, remedy or abate any damage arising in such a situation. Due to the leakage of air from input or output reduces the pressure and so the desired output.

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Pressure, radius, area and force relationships Although the diameter of the piston and the force exerted by a cylinder are related, they are not directly proportional to one another. Additionally, the typical mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the instroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas. The relationship, between force on outstroke, pressure and radius, is as follows:

This is derived from the relationship, between force, pressure and effective cross sectional area, which is: F = p A\,

With the same symbolic notation of variables as above, but also A represents the effective cross sectional area. On instroke, the same relationship between force exerted, pressure and effective cross sectional area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston less that of the piston rod. For instroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows:

Where: F represents the force exerted

25


r 1 represents the radius of the piston r 2 represents the radius of the piston rod π is pi, approximately equal to 3.14159.

Specification: 1. Model: DGS/SMS 2. Bore size: 12mm 3. Stroke: Up to 14 & 300mm 4. End cover: Aluminium 5.Barrel: Aluminium/Brass/S.S. 6.Piston: Brass/: Aluminium 7.Piston Rod: EN 8/ S. Steel 8.Pressure: Up to 12 bar 9.Temp.: 85 0c Max. 10. Medium :Air

3.5.5 SOLENOIDVALVE:

Figure3.5.5:5/3 Double acting solenoid valve

A solenoid is an electromechanical device which allows for an electrical device to control the flow of a gas or liquid. The electrical device causes a current to flow through a coil located on the solenoid valve. This current flow in turn results in a magnetic field which causes the displacement of a metal actuator .

26


The actuator is mechanically linked to a mechanical valve inside the solenoid valve. The valve then changes state, either opening or closing to allow a liquid or gas to either flow through or be blocked by the solenoid valve. A spring is used to return the actuator and valve back to their resting state when the current flow is removed.

Specification:

1. Model: ARMSS/ARMDS 2. Size: 1/4”&1/2” BSP/NPT 3. Pressure: Up to 100 Bar 4. Medium:Air 5. Coil: All std. voltage available

3.6 HARDWAER DESIGN:

3.6.1 Control Panel:

Figure of control panel

Control panel is used for manual operation. we use here material for control panel is plywood as frame. In control panel we design input and out put connection our project. Here we use for input as switches and output as 10mm LED .while designing inputs connection give +24v supply to the one terminal of all switches and respective terminal given to the input card of plc. while designing outputs connection give -24v supply to the cathodes terminal of all LED and by connecting 10kohm resister to the anode terminal of LED given to the out terminal of plc.

27


3.6.2: Frame:

Figure3.6.2: Project frame

The material use for frame is aluminum. we take the cutting plates aluminum and develop the 3m length ,0.5m breadth and 3m height frame. The two conveyor are placed on that at 1.5m first and 2.5m second conveyor belt is located. This conveyor is placed on bicycle hub so we use four hub to support the one conveyorand four for other conveyor second conveyor.the weight of frame is about 5kg.

28


3.7 SOFTWARE DESIGHN: 3.7.1 LADDER DIG:

29


30


31


32


3.7.2 Flowchart

33


4.IMPLEMENTATION 4.1 INTERFACING

Fig 4.1 Interfacing diagram

4.2COMPONENT COSTING

COMPONENT NAME

QUANTITY

COST IN RS.

TOTAL

CONVEYOR BELT

2

900

1800

7805 (+V REGULATOR)

2

15

30

SENSOR( PAIR)

4

250

1000

DC MOTOR

2

250

500

RELAY CARD

1

500

500

TRANSFORMER(3 AMP)

2

150

500

TRANSFORMER(0.5AMP)

1

100

100

RESISTOR

12

0.5

6

CAPACITOR

10

1

10

DIODES

10

0.75

7.5

PNEUMATIC CYLINDE

2

1100

2200

LED

1

30

30

SWITCHES

14

5

70

HARDWARE FRAME

1

500

500

CABELS

3

20

60

34


SOLENOID VALVE

2

800

1600

TOTAL

8913.5

Table 4.2- Component costing

35


4.3 FEATURES, LIMITATION & APPLICATION 4.3.1 FEATURES 1. Maintain ace free operation. Break downs avoided hence no production loss. 2. The pc interface shows the entire data of the process occurred hence off line

data record can be done. 3. PLC interface provides much flexibility for further enhancements. 4. Accurate quantity counted per minute is observed on PLC display. 5. DC geared motor provides the gradual speed variation of the conveyer belt

system. 6. It is best auto operated conveyer belt system. 7. The system can be enhanced for n-number of successive pareller belts. 4.3 .2 LIMITATION 1. The system with PLC requires the programming which is done by the expense

in industry only hence the maintenance of the system is difficult. 2. As the conveyor belts are used the wear and tear is prominent 3. The torque speed characteristics of DC geared motors are not up to the mark

hence system suffers.

4.3.3Application of project 

Bottle filling system



In airport for bags shifting



In chemical industries



In big malls



In pharmaceutical company



Milk chilling plant.



Domestic appliance industry. 36




Fertilizer industry



Automobiles industry



Coal mining industries



Marine industries



Cement industry



Tunnel boaring machine



Gas filling chambers



Food industry



Thermal power plant

37


5. CONCLUSION & FUTURE SCOPE

In few years ago we use simple electrically operated conveyor belt which is time consuming and several labor power is required it has several disadvantage for shifting of material from one place to other place Maintains free operation as break downs avoided hence no production loss. The pc interface show the entire data of the process occurred hence off line data record can be done. PLC interface provides much flexibility for further enhancements. The system can be enhanced for parallel belts. It is best auto operated conveyer belt system.

But today’s in industries the conveyor belt is operated by different operating system such as PLC, SCADA, DCS, and MICROCOTROER. Hence we controlling our project through PLC which is time saving process .it required less labor power, no production loss, Transport skiers up the hill, Transportation of material is done without damaging Product is conveyed directly on the belt so both regular and irregular shaped objects, large or small, light and heavy, can be transported successfully from one place to other. This report has been focused on the required conveyor control system, which will fulfill requirements smooth material shifting . The control system, which will replace the existing system, must overcome all the drawbacks of old system. This system also work on reverse manner to shift material up to down, also for shift at different height

38


BIBLIOGRAPHY  

T. Okoshi , Control techniques (1976),3rd ed.2001,/377,378,379. N.

Abramson,

Advanced

Techniques

for

conveyors

(1981),7 th

ed.2006 ,/299,300,301,302,303,304. 

Larry Wall & Randal Schwartz , Interfacing techniques (1989),5th ed.2004,/488489,490,490,492,492,493,494,495.

 •

M.A .Mazidi & J.G. Mazidi , 8051 Microcontroller and embedded systems() http:// www.plant-maintenance.com/articles/dust_suppression.pdf

•

http://www.galtech.co.uk/gsm-autodialler.php

•

http://www.emucamp.com.enhanced-wireless-gsm-trafficemulation-

•

http://www.scribd.com/doc/7029820/Gsm-Wcdma-Seamless-Network

•

http://portal.acm.org/citation.cfm?id=1598474

•

http://linkinghub.elsevier.com/retrieve/pii/S108480450900073

•

http://sciencelinks.jp/j-east/article/200510/000020051005A0295017.php

•

http://www.encyclopedia.com/doc/1G1-161290543.html

•

http://hobbyproject.com

•

VB Pro

•

Resonance Kit

•

Kile Compiler

39


CONTENTS SR.

TITLE

PAGE NO.

NO. CERTIFICATE

1.

2.

ACKNOLEDGEMENT

I

ABSTRACT

Ii

CONTENTS

Iii

ABRIVATIONS

Iv

LIST OF FIGURES

v

LIST OF TABLE

Vi

INTRODUCTION

1

1.1 Scope of project

1

1.2 Introduction about project

2

1. Introduction about Conveyor

2

1.4 Introduction about whole systems

2

LIRERATURE SURVEY

3

2.1 control scheam 2.2 Operating principle 2.3 Drawback of existing system 2.4 Limitations 2.5 advance technology build 3.

METHODOLOGY

4

3.1 Block diagram 3.2 Working

5

3.3 mechanical assembly

6

3.4 Electronic Assembly

6

3.4.1 Relay board

8

3.4.2 Power supply design

9

3.5 Component use 3.5.1 PLC

9

3.5.2 proximity sensor

9

3.5.3 Dcmotor

10

3.5.4 pneumatic cylinder

12


3.5.5 solenoid valve 3.6 Hardware Design 3.6.1Control panel

3.6.2 Frame 3.7 software design 3.7.1 ladder dig 3.7.2flowchart 4

IMPLEMENTATION

4.1Interfacing diagram 4.2 component costing 4.3 feature ,limitation &application 5

Conclusion & Future scope BIBLIOGRAPHY

13 14 15


LIST OF FIGURES. FIGURE NO. 3.1 3.3 3.4.1 3.4.2 3.4.2.1 3.4.2.2 3.5.1 3.5.2 3..5.3 3.5.4 3.5.5 3.6.1 3.6.2 4.1

TITLE Block diagram Conveyor,motor&sensor system Relay board Power supply design 12vPower supply 24vPower supply ALLEN BRADLY PLC Proximity sensor 12 dcmotor Pneumatic cylinder Solenoid valve Control panel Project frame Interfacing circuit

PAGE NO. 9 10 13 14 15 15 18 21 22 23 26 32 30 33


ABSTRACT Our project is MATERIAL SHIFTING USING PNEUMATIC PRESSURE AND CONVEYOUR BELT CONTROL BY PLC .Our aim from this project is to shift the material firstly to upper level Today automation is mostly used in many industrial and many other applications such as material load in airplane, trucks and other industrial application where fewer places is available to shift the material. The material shifting is done by pneumatic cylinder from lower position to upper position. Where height is more we can use this technology to shift the material The application of material shifting in continuous manner in short time therefore we use the latest technology like proximity sensor, motor, and PLC.

Conveyor Belt PLC PROJECT

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