PLC Based Object Sorting
PLC Based Object Sorting
ABSTRACT
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.
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Automated Object sorting system using PLC
CONTENTS
Certificate
Acknowledgement
Abstract
3. Interfacing ………………………………………………………………….. 18
3.1 Documentation ………………………………………………………….. 18
3.2 Device Specifications …………………………………………………… 20
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Automated Object sorting system using PLC
References................................................................................................................... 37
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List of Tables
2.1: PLC Scan Cycle.................................................................................................... 10
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List of Figures
2.1: PLC Architecture ……………………………………………….……………... 7
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Automated Object sorting system using PLC
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.
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Automated Object sorting system using PLC
Chapter 2
PROGRAMMABLE LOGIC CONTROLLER SYSTEM
2.1 Introduction
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Automated Object sorting system using 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.
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Automated Object sorting system using PLC
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.
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.
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Automated Object sorting system using PLC
0 1 0 1 0 0 0 1 0 0 0 1 0 0 0 0 O:0.0
0 1 0 1 0 0 0 1 0 0 0 1 0 0 0 0 I:0.0
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Automated Object sorting system using PLC
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
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Automated Object sorting system using PLC
The PLC in this project is MicroLogix 1100 PLC. A few important specifications of this PLC
are listed below.
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Automated Object sorting system using PLC
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
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Automated Object sorting system using PLC
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:
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)
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Automated Object sorting system using PLC
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
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Automated Object sorting system using PLC
G) Force Files:
• O0 – OUTPUT
• I1 – INPUT
H) Program Files:
• SYS0
• SYS1
• LAD2
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Automated Object sorting system using PLC
Chapter 3
INTERFACING
3.1 Documentation
The Table 3.1 shows the Documentation of Input and Output 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
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Automated Object sorting system using PLC
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.
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Automated Object sorting system using PLC
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
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Automated Object sorting system using PLC
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.
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Automated Object sorting system using PLC
Comparator IC LM324
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.
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Automated Object sorting system using PLC
Chapter 4
PLC PROGRAMMING
# 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
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Automated Object sorting system using PLC
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.
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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:
4.5.0.System Configuration :
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Automated Object sorting system using PLC
4.5.0. A) Channel
In this proper channel RS232 should be selected for communication between PLC & SCADA. Follow
the following path.
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Automated Object sorting system using PLC
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.
MAIN WINDOW:
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Automated Object sorting system using PLC
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.
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Automated Object sorting system using PLC
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.
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REFERENCES
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