Automated Object sorting system using PLC

Automated Object sorting system using PLC

Automated Object sorting system using PLC

Automated Object sorting system using PLC

A Project Report on

PLC BASED AUTOMATED OBJECT SORTING SYSTEM

USING HEIGHT AS A CRITERIA

Project Report Submitted to

Shri Guru Gobind Singhji Institute of Engineering and Technology,

Vishnupuri, Nanded

For the partial fulfilment for award of the degree of

Bachelor of Technology

In the Subject of

Instrumentation Engineering

By

MINAL G. MHAISKAR (2011BIN026)

SNAIHAL S. DESHMUKH (2010BIN154)

NAMRATA N. KHANDARE (2011BIN507)

Under the Guidance of

Mr. J. G. PARKHE

Assistant Professor

Department of Instrumentation Engineering,

SGGS Institute of Engineering and Technology,

Vishnupuri,Nanded-431606 (MS).

SGGS Institute of Engineering and Technology, Nanded

CERTIFICATE

This is to certify that, the Project entitled “PLC BASED AUTOMATED OBJECT SORTING SYSTEM USING HEIGHT AS A CRITERIA” is a bonafide record of the work carried out by

MINAL G. MHAISKAR (2011BIN026)

SNAIHAL S.DESHMUKH (2010BIN154)

NAMRATA KHANDARE (2011BIN507)

Under my supervision and guidance at SGGS Institute of Engineering and Technology, Nanded for the award of the degree of Bachelor of Technology in Instrumentation Engineering.

Date: 15th May, 2015

Place: Nanded

Dr. J. G. PARKHE

Project Guide

Forwarded by:

Dr. V. G. ASUTKAR

Dr. L.M.WAGHMARE

Head of Department

Director (SGGSIE&T)

ACKNOWLEDGEMENT

Success is a magnification of diligence, perseverance, inspiration and motivation. Every nice work begins with a systematic approach towards reaching successful completion. Our work is not at all an exception.

We express our sincere gratitude to Mr. J. G. PARKHE for giving us an opportunity to carry out the project work under his guidance. We are extremely grateful for his invaluable and timely guidance given during the course of our project work. We are greatly indebted to him for his critical review of our project work at each and every level. He has been always a source of inspiration for us. We feel extremely fortunate to work under his guidance. We would like to thank Mr. J. G. PARKHE for his meticulous guidance and for making this study an interesting learning experience; for his motivation, teaching and skills have added the necessary favour to this study.

We wish to take this platform to extend our sincere thanks to all our teachers for moulding us in their special way. Last but not the least we express our gratefulness to DR. S. T. HAMDE, Project coordinator for his encouragement, staunch support and belief in our project. We express our heartfelt thanks and sincere gratitude to our Project coordinator for his valuable suggestions, encouragement and moral support given during our project work. We are also thankful to him for providing the laboratory facility whenever needed.

Date: 15th May, 2015

MINAL G. MHAISKAR

SNAIHAL S. DESHMUKH

NAMRATA N. KHANDARE

ABSTRACT

In many industrial applications there is need of sorting. Sorting can be done by using many ways like sorting of object according to their dimensions (height, length etc.), according to their colours, according to their weight, using machine vision (image processing), according to the material of an object etc. For example in Thermal Power Station electromagnetic sorting technique is used to sort ferromagnetic materials from coal.

In this project, the development of a LCA (Low Cost Automation) system to sort objects according to their height has been designed. This LCA system is controlled by Programmable Logic Controller (PLC). This project consists of two parts, first consisting of software which contains ladder logic programming which is used to program PLC that controls the whole process of the project step by step according to input data sequence. Second is the hardware part which consists of conveyors used to transport the objects, sensors used to sense the height (i.e. laser sensors) of the objects, electronic system used to sort the objects and motors to drive the conveyors

The objects are been sorted according to their respective height. The main conveyor is supported of two branches to load the distinguished object on to the respective one as separated by the electronic system and detected by the laser sensors.

In this project, SCADA is also developed. SCADA provides a user friendly environment to establish an easy communication between humans and process. SCADA shows the activation of various parts of the system, i.e. conveyors, motors, LDRs and electronic devices.

The automated object sorting system is very much useful in packaging industries, Bags and package sorting at airports, in separation of bricks in brick manufacturing process, etc.

CONTENTS

Certificate

Acknowledgement

Abstract

List of Tables ………………………………………………………………………… 3

List of Figures ………………………………………………………………………... 4

1. Automation Overview ……………………………………………………… 5

2. Programmable Logic controller System ………………………………….. 6

2.1 Introduction …………………………………………………………….... 6

2.2 The need for Programmable Logic Controllers …………………………. 6

2.3 Functional Description …………………………………………………... 7

2.4 Processor Operating Cycle ………………………………………………. 9

2.5 Program & Data Organization Inside the PLC ………………………….. 10

2.6 Micrologix 1100C ………………………………………………………..13

3. Interfacing ………………………………………………………………….. 18

3.1 Documentation ………………………………………………………….. 18

3.2 Device Specifications …………………………………………………… 20

4. PLC Programming ………………………………………………………… 26

4.1 Establish a communication between PLC and PC ……………………… 26

4.2 Writing and Download Program ………………………………………... 26

4.3 PLC Programming ……………………………………………………… 27

4.5 SCADA …………………………………………………………………..30

5. Conclusion and Scope for Future work …………………………………… 35

5.1 Results …………………………………………………………………….35

5.2 Conclusion ……………………………...………………………………... 35

5.3 Applications …………………………………………………………….... 35

5.4 Future Development ……………………………………………………... 36

References................................................................................................................... 37

List of Tables

2.1: PLC Scan Cycle.................................................................................................... 10

2.2: Output Status Table ……………………………………………………………. 11

2.3: Input Status Table …………………………………………………………….... 11

2.4: Bit Table………………………………………………………………………... 12

3.1: Documentation of Devices …………………………………………………….. 18

List of Figures

2.1: PLC Architecture ……………………………………………….……………... 7

2.2: PLC Scan Cycle ………………………………………………….……………. 9

2.3: Micrologix 1100.....……………………………………………………………. 14

3.1: Photocopy of the Hardware Setup ……………………………………………. 19

3.2: Photocopy of the Interfacing Panel ...………………………………………… 19

3.3: LDR Circuit ………………………………….……………………………….. 20

3.3: Comparator IC ………………………………….…………………………….. 21

3.4: PLC interfacing with conveyor motor...............................................................23

3.5: DPDT Interfacing with pusher motor....………………………………………24

3.6: 12 volt Power Supply Circuit ………………………………………………… 24

4.3: System Configuration of SCADA.................................................................... .30

4.4: Channel Window …………………………………………..………………… 34

4.5: Tag Database …………………………..………………………………….….. 35

4.6: Graphic Display ……………………………………..…………….…………. 33

4.7: Mimic …............................................................................................................ 34

Chapter 1

AUTOMATION OVERVIEW

The primary goal of the control engineering is to distill and apply knowledge about how to control process so that resulting control system will reliably safely achieve high performance. Over recent years, PLC has emerged as practical alternative to classical control schemes when one is interested in controlling certain time varying, non-linear process.

Automation is one of flourishing field in today’s world and it has become the backbone of control engineering. PLC and DCS are the most efficient and widely used tools in industrial automation. With the rapid development in technology, the more focus is on selection of application oriented Controllers and tools. For using digital I/O’s it becomes easy and efficient to use PLC.

Process control is the process of recognizing the status of system, process the information according to rules and actuate the control element in order to achieve the control variable to its approximate value.

The oldest method in process control was manual control in which all actions and decisions were taken by human but considering errors of method, this method was followed by hard wired logic control. Logic gate was one step advancement in this method.

As circuit became larger complexity of logic gate went on increasing so Microcontroller came into picture followed by PLC, DCS programming. Control of field signals is done using these devices as per signals coming from devices and complexity of process.

Programmable Logic Controller is type of Control Logix controller and product of Allen Bradely in lab which is used for our project.

The Object sorting system uses the PLC of Allen Bradely Micrologix 1100 for the purpose of Automation. This automation technique is been accomplished using an Interfacing Panel which is consisting of relays and electronic circuits.

Chapter 2

PROGRAMMABLE LOGIC CONTROLLER SYSTEM

2.1 Introduction

According to National Electrical Manufacturers Association,

A Programmable controller is a digitally operated electronic system, designed for use in industrial environment, which uses a programmable memory for the internal storage of user oriented instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control, through digital or analog inputs and outputs, various types of machines or processes.

PLC was developed as a replacement for large amounts of relays.

2.2 The need for Programmable Logic Controllers

i) Equipment will be located on the plant floor.

ii) More than one “cell” or “subsystem”

iii) Highly distributed I/O s

iv) Local operator interface desired

v) Third party interfacing required

vi) Large discrete content or good mix of discrete and analog control with small amount complex batch, blending or multivariable analog control.

vii) Cost differential is an issue

2.3 Functional description

Figure 2.1: PLC Architecture

I)Central Processing Unit (CPU)

The central processing unit (CPU) is the brain of the PLC. CPU performs the tasks necessary to fulfill the PLC functions. Among these tasks is scanning of input and output image tables, execute user written ladder program, execute and peripherals device communication, along with special functions like data handling and self diagnostics.

II)Power Supply

The power supply may be integral or separately mounted. It always provides the isolation necessary to protect solid-state components from most high voltage line spikes.

III)I/O Modules

To interface external world with the PLC, I/O modules are used. Inputs are defined as real world signals giving the controller real time status of process variables. These signals can be analog or digital, low or high frequency, maintained or momentary. Typically they are presented to PLC as a varying voltage, current or resistance value. Signals from RTDs and thermocouple are common examples of analog input signals. Few flow meters and strain gauges provide variable frequency signals, while pushbuttons, limit switches, pressure switches, temperature switches or even electromechanical relay contacts are familiar examples of digital contact closure type.

IV)Memory Unit

The memory unit provides an interface between PLC and the user during program development, start up and troubleshooting.

Programming units vary from small Hand Held Terminal (HHT) to desktop stand alone intelligent CRT based units, These units come complete with documentation, reproduction, I/O status and online and offline production facility. Programming units are liaison between what the engineer desires to occur during the control sequence. With offline programming the user can write a control program by the programming unit, then take the unit to PLC in the field and load PLC with new program, all without removing the PLC.

V)Peripheral Devices

Peripheral devices are grouped into several categories: programming aids, I/O enhancements and computer interface devices are the most common.

Programming aids provide documentation and program recording capabilities. Optional aids include variety of resources that range from color graphics CRTs to equipment or support programs that can give the operator specific access to processor parameters. The I/O enhancement group includes all types of modules, from dry contact modules to intelligent I/O to remote I/O capabilities. The computer interface device group is rapidly expanding section of programmable controller peripheral devices, These devices allow peer to peer communication, as well as network interaction with various computer systems.

Table 2.1: PLC Scan Cycle

Event

Description

Input Scan

The status of input modules is read and the Input Image table is updated with this new data.

Processor Scan

The ladder program is executed. The input image table is evaluated, ladder rungs are solved, and the output image table is updated using this new results. This information is not yet transferred to the output modules.

Output Scan

The output image table contents are transferred to the output modules.

Communications

Communication with programming devices and other network devices take place in this section of PLC scan cycle.

Processor Overload

Processor internal housekeeping functions are carried out in this section of PLC scan cycle. These actions include performing program pre-scan and updating the internal time base and the status files.

2.4 Program& Data Organization Inside the PLC

A lot of information is stored in PLC memory. The PLC memory is divided into two main files:

1. Program file

2. Data file

Processor stores system and configuration information along with user developed ladder programs in the part of memory called “Program Memory”. Processor stores the data used by the processor in conjunction with input image files and output image files in part of memory called “Data Memory”. Data files contain the information, or data used in conjunction with input and output image tables. Along with that there are many internal data storage files.

File 0, Output status file

File 0 is the default output status file. There can be only one output status file per processor. The output status file is made of single bits grouped into 16 bit words. Each bit represents the ON or OFF status of the output points. There is a one bit in the output status file for each output module point in your PLC system. The first row in Table 2.2, lists the output module address. ON state means 1 of the output status file.

Table 2.2: Output Status Table

15

14

13

12

11

10

09

08

07

06

05

04

03

02

01

00

Address

0

1

0

1

0

0

0

1

0

0

0

1

0

0

0

0

O:0.0

File 1, Input status file

File 1 is the default input status file. There can be only one input status file per processor. The input status file is made of single bits grouped into 16 bit words. Each bit represents the ON or OFF status of the input points. There is a one bit in the input status file for each input module point in your PLC system. The first row of Table 2.3, lists the input module address.

ON state means 1 of the input status file.

Table 2.3: Input Status Table

15

14

13

12

11

10

09

08

07

06

05

04

03

02

01

00

Address

0

1

0

1

0

0

0

1

0

0

0

1

0

0

0

0

I:0.0

File 2, Processor status file

File 2 is the default processor status file. There can be only one processor status file per processor. The processor status file contains extensive amount of data regarding the processor and its operation. Status file consist of following list.

1. Operating system information

2. Monitoring of hardware and software faults

3. Clearing of hardware and software faults

4. Monitoring of arithmetic flags

5. Average scan time information

6. Communication bits

7. I/O error

File 3, Bit file

File 3 is the default bit file. A bit file is used to store signal bits in a 16-bit words format. There can be many bit files for a single processor files. Each bit file will have 256 16-bit words. One 16-bit file word is one element. Table 2.4 lists the bits 0 through 15 across the top row from right to left. The row on the right of the table 2.4 lists the bit file element. Each 1 or 0 in the file is a single bit.

Table 2.4: Bit Table

15

14

13

12

11

10

09

08

07

06

05

04

03

02

01

00

Address

0

1

0

1

0

0

0

1

0

0

0

1

0

0

0

0

B3:0

0

1

0

1

0

1

0

1

0

0

0

1

1

0

0

0

B3:1

File 4, Timer file

File 4 is the default timer file. A timer file is used to store timer data. Each timer is comprised of three 16-bit words, called “Timer Element”. There can be up to 256 timer elements in each timer file. If more than those timer elements are required then we can make one more timer file whose address is greater than 10.

File 5, Counter file

File 5 is the default counter file. A counter file is used to store counter data. Each counter comprises of three 16-bit words, called “Counter Element”. There can be up to 256 counters in each counter file. If more than that counter elements are required then we can make one more counter file whose address is greater than 10.

File 6, Control file

File 6 is the default control file. A control file is used to store status information for bit shift, first in first out (FIFO) stack, last in first out (LIFO) stack, sequence instructions and certain ASCII instructions.

File 7, Integer file

File 7 is the default integer file. An integer file element is a 16 bit word representing one whole number. The integer file is used to store integers that include whole numbers. Any whole number e.g. 100, 251 or 32767. Each integer file contains 256 integer elements. Each element can store a number ranging from -32768 to 32767. Data stored in integer file can be addressed as an integer word or at the bit level.

File 8, Floating-point file

File 8 is the default floating- point file. A floating point data is comprised of two parts, an integer and an exponent. Floating point data is stored in two words element. One word is used to store the integer. The other is used to store the exponent.

2.5 MicroLogix 1100

The PLC in this project is MicroLogix 1100 PLC. A few important specifications of this PLC are listed below.

I)Features and Benefits

1. High speed I/O: 20 KHz HSC, 20 KHz PTO/PWM output.

2. Expansion to 136 I/O for greater application flexibility.

3. Six new discrete and analog expansion I/O modules to solve even more applications.

4. Full ASCII (read/write) capability.

5. Large non-volatile 6K memory.

6. Several communication options to solve applications from peer-to-peer to device level to SCADA/RTU.

7. Real time clock and memory modules.

8. Compatibility with MicroLogix and SLC 500 instruction set and RSLogix 500 software.

9. Minimum time base of timer is 1msec.

Figure 2.3: Micrologix 1100C

II)PLC Programming Software

There are various methods of PLC programming which are listed below.

1. Ladder Programming

2. Sequential Flowchart Programming

3. Structured Text Programming

4. Functional block Diagram Programming

III)Modes Of Operation

Following are modes of operation of PLCs.

1. ONLINE or RUN: Wherein a ladder is executed, online changes in contacts / coils are permitted, but ladders can’t be inserted / deleted.

2. OFFLINE MORE or LADDER PROGRAMMING: Wherein execution of ladder logic is stopped. Using a SST / HHT can insert / delete ladders, and burn cartridges to save permanently.

3. TEST or SIMULATION: Wherein the operation is same as that in online mode except that all real outputs are set OFF thus simulation can be done.

4. ONE SCAN MODE: Wherein only one scan of logic is perforated with all real outputs off and after the single scan, PLC remain online mode executing any logic further.

A) General Specifications:

· Controller : Micrologix 1100C

· Total Program Memory (words) : 2.4k

· Ladder memory (words) : 2048

· V-Memory (words) : 256

· Non V-Memory (words) : 128

· Boolean execution : 4-6 ms

· Timers : 256 (0 to 255)

· Counters : 256 (0 to 255)

B) DC Input:

· Inputs / Module : 8

· Peak Voltage : 24.6 VDC

· ON voltage level : 9.5 VDC min

· OFF voltage level : 3.5 VDC max

· Input Current : 8.5mA @ 24VDC

· Min. ON Current : 3.5mA

· Max. OFF Current : 1.5mA

· Response Time (ON to OFF) : 1 to 8ms

C) DC Output:

· Outputs / Modules : 6

· Operating Voltage : 24 VDC

· Output Type : NMOS FET (Open Drain)

D) AC Input:

· Inputs / Module : 2

· Input Voltage range : 80 to 132 VAC

· AC Frequency : 47-63 Hz

· ON voltage level : 75 VAC min

· OFF voltage level : 20 VAC max

· Min. ON Current : 5mA

· Max. OFF Current : 2mA

· ON to OFF Response Time : 10 to 50ms

· OFF to ON Response Time : 8 to 30ms

E) AC Output:

· Outputs / Module : 2

· Operating Voltage : 24 to 140 VAC

· Output Type : SSR (Triac with zero crossover)

· ON to OFF Response Time : 0.5ms (1/2 Half Cycle)

· OFF to ON Response Time : 0.5ms (1/2 Half Cycle)

F) Data Files:

· O0 – OUTPUT

· I1 – INPUT

· S2 – STATUS

· B3 – BINARY

· T4 – TIMER

· C5 – COUNTER

· R6 – CONTROL

· N7 – INTEGER

· F8 – FLOAT

G) Force Files:

· O0 – OUTPUT

· I1 – INPUT

H) Program Files:

· SYS0

· SYS1

· LAD2

Chapter 3

INTERFACING

3.1 Documentation

The Table 3.1 shows the Documentation of Input and Output Devices.

Table 3.1: Documentation of Devices

INPUTS

Sr. No.

Input

Type

Address

1.

START

Digital

I:0/4

2.

LDR 1

Digital

I:0/0

3.

LDR 3

Digital

I:0/2

4.

STOP

Digital

I:0/1

OUTPUTS

Sr. No.

Output

Type

Address

1.

Motor 1

Digital

O:0/0

2.

Motor 2

Digital

O:0/2

3.

Motor 3

Digital

O:0/4

4.

Driver 1

Digital

O:0/1

5.

Driver 2

Digital

O:0/3

Figure 3.1: Photocopy of the Hardware Setup

3.2 Devices Specifications

· Light Dependent Resistor (LDR)

Object detection circuit includes LDR as sensor, Wheatstone bridge, differential amplifier, Darlington pair etc. Light from laser is made to fall on LDR in absence of object. Hence LDR is used here as position sensor. As light falls on LDR, its resistance decreases. Since LDR is connected in a comparator circuit, due to change in LDR resistance causes change in voltage of voltage divider circuit which is given to Operational Amplifier for comparing. Output from comparator circuit is given to transistor to switch relay.

Output of relay is given to PLC as input.

Output of LDR:

· When light does not fall : 13.5Kohm

· When light falls : 2Kohm

Figure 3.2: LDR Interfacing Diagram

Automated Object sorting system using PLC

Automated Object sorting system using PLC

Automated Object sorting system using PLC

Page 10 of 40

Page 10 of 40

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· DC Motor

A DC motor is used to drive the conveyor along with the rollers. The DC motor is interfaced with the PLC through a relay so as to fulfill the requirements of the motor (i.e. Voltage and Current ratings).

· DC motor voltage : 12V

· Motor torque : 2 kg-cm

· Motor RPM : 100 RPM , 10RPM

· Pusher

A Pusher is used to move the object from one conveyor to another conveyor.

· Operating Voltage : 12VDC

· Voltage : 5VDC

· DPDT

DPDT relay stands for double pole double throw relay.Relay is electromagnetic device used to separate two circuit electrically and connect them magnetically,which works at low voltage 12V or 24V.

Fig 3.3: DPD Interfacing with pusher motor

· Relay

A Relay is used to operate DC Motors, LDR’s output, operation of CD Drives.

· Operating voltage : 12VDC and 24 VDC

· Type : Electromagnetic PCB relay

· Max. Current : 7A

· Max. Voltage : 250V

· Laser

A Laser is used to supply light to the LDR when the object is to be detected.

· Voltage : 5VDC

· Wavelength : 630-680mm

· Diameter of laser case : 15mm

· Class II laser

· Conveyor Belt

Conveyor belt provide the platform for the placement of object. Conveyor belt is placed on rollers and is moved by using DC motor. Its dimensions are:

· Length : 1280mm

· Width : 150mm

Fig 3.4: PLC interfacing with conveyor motor

· Conveyor Rollers

Rollers are fitted on bearings using a shaft. It helps in moving conveyor belt.

· Diameter : 50mm

· Length : 160mm

· Bearings

Bearings are used to minimize the friction between shaft and conveyor belt. It is fitted inside the wooden socket.

· Base board

It is made up of wooden material. It provides the basement to whole assembly. All hardware components like motors, rollers and conveyor belts, etc. are mounted on the base board.

· Power Supply

The power supply circuit as shown in figure 3.5 is used to drive the CD-Drive, Motors and run the LDR comparator circuit.

Fig 3.5: 12 volt Power Supply Circuit

· Comparator IC LM324

Fig 3.6 : IC Pin Diagram

The LM324 IC is a package of four operational amplifiers (OP-AMP) that can be powered by a single-polarity supply over a very wide voltage range. The four op-amps are installed in a single 14-pin package. Here two LDR circuits are connected to two OP-AMP.

Chapter 4

PLC PROGRAMMING

4.1 Establish a communication between PLC and PC

# Go to start menu and follow following path

Configure

Start Program Rockwell Software RS Linx RS Linx Classic Drives

# configure Micrologix 1100C drive

· Configure RS232 DF1 driver

· Device name AB DF1

· Click on Auto-Configuration

· Communication Port : Com1

· Baud Rate : 19200

· Station No.: 06

· Parity : None

· Error Checking : CRC

· Stop Bit : 01

· Protocol : Full duplex

· Check RS WHO : Verification

4.2 Writing and Download Program

Start Program Rockwell Software RS Logix 500 File New

# Configure to

· Read I/O Configuration (Channel: 4-20mA & Data Format: Raw Proportional)

· Who’s who

· OK

# Choose Rung

# Save Program

# Download Program

# Check it by Running

4.2 PLC Programming

4.3 Rung Description

RUNG 0000:

This rung is used to start the entire rung

RUNG 0001:

This rung is used to latch DC motor1 i.e. to drive the main conveyor. But whenever either pusher is on then motor will stop due to cross logic.

RUNG 0002:

This rung used to start the timer for 4 seconds when LDR 1 is detected.

RUNG 0003:

This rung is used to stop the motor 1 when timer is done.

RUNG 0004:

This rung is used to start the motor 2.

RUNG 0005:

This rung is used to start the pusher 1 to push the object on sub conveyor timer will get on for 3 seconds.

RUNG 0006:

This rung is used to off the pusher 1 and reset the timer.

RUNG 0007:

This rung is used to on the timer for 4 seconds when LDR 3 will be detected.

RUNG 0008:

This rung is used to on the pusher 2 as well as timer for 3 seconds.

RUNG 0009:

This rung is used to off pusher 2 after timer is done. Also reset timer for 4 seconds.

RUNG 0010:

This rung is used to start motor3 after timer is done.

RUNG 0011:

This rung is used to end the entire process.

4.4 SCADA

SCADA is an extension of Data Logger System. It provides visual representation of online process. It is one of the plant automation processes. Its appearance is user friendly. There is many more SCADA software available in the market viz. IFix by ABB, Look Up by NI, ELLIPSE by MIT SUBISHI and WINCE by Siemens. We have used SCADA is RSView32 by Rockwell Automation.

RSView32:

It is popular SCADA available developed by Rockwell Automation. It can be studied alone without linking to PLC by using VB. It has its graphical display on which Mimics are developed. Different mimics are developed as per requirement of our project.

Steps to develop Mimics SCADA software are as follows:

4.5.0.System Configuration :

Fig 4.1 : System Configuration of SCADA

4.5.0. A) Channel

In this proper channel RS232 should be selected for communication between PLC & SCADA. Follow the following path.

Fig 4.2:Channel Window

4.5.0. B) Node

In this proper RS232 should be selected for communication between PLC & SCADA.

4.5.0. C) Scan Cycle

It is kept as default setting (Not disturbing previous setting).

4.5.0 D) Tag Database

Fig 4.3: Tag Database

4.5.1 Graphics Display

Fig 4.4:Graphics Display

4.5.1. A) Library

Different structures can be used directly from library e.g. Tank, Pipe, Control Valve, Conveyor belt as we have used in our project.

4.5.1. B) Testing and Running

MAIN WINDOW:

Fig 4.5: Mimic

Chapter 5

CONCLUSION AND SCOPE FOR FUTURE WORK

5.1 Results

The operation of the system has been accomplished and have obtained the sorting results as follows.

· When LDR1 is activated then Pusher1 is operated with start of Conveyor 2.

· When LDR3 is activated then Pusher2 is operated with start of Conveyor 3.

5.2 Conclusion

The study and development of The Automated Object Sorting system Using PLC has been performed. Thus the completion of project work brought better results and let us to study the PLC system of Allen Bradely Micrologix 1100C and also the various parts of the hardware used. Hence the approach and development of this project work offers the award of the degree of Bachelor of Technology in Instrumentation Engineering.

5.3 Applications

Manual sorting of any object consumes a lot of time and labour. Hence, PLC object sorting system finds wide application in the following industries.

1 .Brick Manufacturing Process:

In Brick manufacturing Process the quality of bricks considering their height as a parameter can be checked. If the height is more or less from the original size then the defective bricks can be sorted out.

2. Luggage sorting at Airports:

The parcels at airport which has to loaded in cargo planes can be sorted accordingly to reduced the load of the plane.

3 .Quality Checking of Solid Objects:

If the height of the solid material is taken as a criteria in quality check of that object then this system can be used effectively.

4. In Food Processing Industries:

The food packing of the food stuffs of different sizes can be sorted in such type of industries where various quantities of packed food are running on a single line.

5.4 Future Development

Following developments can be done in the system to increase the production rate as well as to minimize cost.

1. Using high quality sensor like Laser sensor we can increase the speed of the process.

2 . Objects are sorted; we can distinguish it easily by improving extra circuitry. It is also economical.

3. This system can be used to sort more than one Object in one cycle by suitably altering the hardware and software of the system.

.

REFERENCES

· Introduction to Programmable Logic Controller

Gary Dunning (Second Edition)

· Instrumentation Engineers Handbook

BelagiLiptak-Volume II

· Process Control Instrumentation Technology

C. D. Johnson (Seventh Edition)

· User manual – Allen Bradley PLC

www.ab.com

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Page 10 of 40

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