TILSTIC GUYS

GURU MOORTHY .

S

SENTHIL KUMAR .G

LOKESH .S

CHANDRA

MOHAN .K

THERE IS LUCK SOMETIMES IT CLICK (DON’T WAIT….)

INTRODUCTION

It is special purpose machine by using Allen Bradley plc. This is used to manufacture the clip, which is used in starter of four wheelers. The purpose of the clip is to join the copper winding and commutator In inside the starter. For this machine we designed electrical panel board by using plc, relay board, smps, mcb, transformer, pneumatic cylinder, solenoid coils, pushbutton etc… This machine consists of four pneumatic cylinders. They are Top cylinder, Bottom cylinder, Hold cylinder, Feeder cylinder. The bottom cylinder has three proximity sensors i) Top cylinder top sensor, ii) Top cylinder middle sensor, iii) Top cylinder bottom sensor. The bottom cylinder has one proximity sensor as well as hold cylinder and feeder cylinder has each separate proximity sensor. Photo guard is attached in this machine, its for safety purpose when the photo guards detects some interrupts it will stop the machine completely. This machine can be run in two modes they are auto mode and manual mode. In manual mode the operator can control this machine through the operator panel.

Allen BradleyPLC

Relay Module

Output Terminal Blocks

SolenoidsSensorsOperator

Panel

Input Terminal Blocks

BLOCK DIAGRAMS:

TERMINAL BLOCKS

PLC MCB’s SMPS

TRUNKING

TRANSFORMER

RELAY MODULE’s

TRUNKING

TRUNKINGPANEL VIEW:

TOP SOLENOI

DHOLD

FEEDER

TTS

TMS

TBSHS

FSBS

BOTTOM SOLENOI

D

E

T B H F

RSTA/M

E - EMERGECY STOPA/M - AUTO/MANUALRST - RESETT - TOP CYL PUSHBUTTONB - BOTTOM CYL PUSH BUTTONH - HOLD CYL PUSHBUTTONF - FEEDER CYL PUSHBUTTON

OPERATOR PANEL

SOFTWARE REQUIREMENTS:

• Allen Bradley PLC micrologix1100 series A

• Relay Module’s

• Mcb’s

• Switch Mode Power Supply (SMPS)

• Transformer

• Solenoid coil’s

• Read switch

• Terminal Blocks

• Push Buttons

• Photo Guard

• RS LOGIX 500

HARDWARE REQUIREMENTS:

24v (+)

SO S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14

PLC INPUT’S

I0 I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 I13 I14

INTPUT TERMINAL BLOCKS

I0 Emergency stopI1 Manual \ AutoI2 Top cylinder Up \ Down (PB)I3 Bottom cylinder Up \ Down (PB)I4 Hold cylinder ON \ OFF (PB)I5 Feeder cylinder ON \ OFF(PB)I6 ResetI7 Cycle StartI8 Top cylinder Top Read switchI9 Top cylinder Middle Read switch

I10 Top cylinder Bottom Read switchI11 Bottom Forward Read switchI12 Hold down Read switchI13 Feed Forward Read switchI14 Photo GuardI15 Spare

O0 Ram down SolenoidO1 Ram Up SolenoidO2 Bottom Cylinder UpO3 Bottom cylinder DownO4 Hold ON SolenoidO5 Feeder ON SolenoidO6 Tool Change IndicatorO7 Cycle ON LampO8 SpareO9 Home

O10 Fault LampO11 Spare

INPUT LIST

OUTPUT LIST

PLC OUPUT’S

R1 R2 R3 R4 R5 R6

RELAY OUTPUT T IO N O DL IC CH AA TN OG RE

CYCLE

ONLAMP

SPARE

SPARE

HOME

FAULT LAMP

O0 O1 O2 O3 O4 O5 O6 O7 O8 O9 O10 O11

RAM UP SOLENOID

RAM DOWN SOLENOID

BOTTOM UP SOLENOID

FEED ON SOLENOID

BOTTOM DOWN SOLENOID

HOLD ON SOLENOID

R1 R2 R3 R4 R5 R6

OUTPUT TERMINAL BLOCKS

24 V (+)

http://en.wikipedia.org/wiki/File:Kabelschuh_verschiedene_commons.jpg

ADVANTAGES

• THIS IS A SPECIAL PURPOSE MACHINE, OPERATE IN BOTH MANUAL AND AUTO MODE

• ITS VERY EFFICIENCY AND ALSO REDUCE MAN POWER

• IT PRODUCES 32CLIPS PER MINUTE

• IT SAVES TIME AND COST