2052438.LeTienDat

HO CHI MINH UNIVERSITY OF TECHNOLOGY
OFFICE FOR INTERNATIONAL STUDY PROGRAMS
MECHATRONICS GRADUATION PROJECT

Project topic:
DESIGN OF AN AUTOMATED
CONFECTIONERY BOX WEIGHING SYSTEM
Instructor: Ph.D Tran Viet Hong
Name Student’s ID
Le Tien Dat 2052438
HCMC, 09/2024
ACKNOWLEDGEMENT
Throughout the making of this project, I have gained much knowledge and
information related to my major and I have also known how to perform a project follow
the procedure of design a mechatronics system.
I would like to express my gratefulness to Ph.D Tran Viet Hong for advising and
guiding me to finish this project through this semester. The knowledge that I have learn
gives me many experiences so that I could continue to improve myself for the future.
Throughout this project, I have researched through the documents and also applied
my knowledge to finish this report. However, this report may have some shortcomings
and limit. Therefore, I am looking forward to receive the comments and feedbacks from
the council.
Sincerely!
1
CONTENTS
ACKNOWLEDGEMENT ............................................................................................... 1
LIST OF FIGURES ......................................................................................................... 5
LIST OF TABLES .......................................................................................................... 7
CHAPTER 1. OVERVIEW............................................................................................. 8
1.1. Introduction .......................................................................................................... 8
1.1.1. Introduction to the automated weighing system ...........................................8
1.1.2. Automated weighing system classification ..................................................8
1.2. Automated weighing system ................................................................................ 9
1.3. Project topic and design scope ........................................................................... 10
CHAPTER 2. ANALYSING AND DESIGNING OPTION ........................................ 11
2.1. Weighing methods ............................................................................................. 11
2.2. Box supply simulation ....................................................................................... 12
2.3. Experiment and evaluation................................................................................. 13
2.3.1. Experimental model of automated confectionary weighing system ...........13
2.3.2. Electrical components .................................................................................14
2.3.3. Load cell error .............................................................................................14
2.3.4. Experiment result for box with weight of 0.5 kg ........................................15
2.3.5. Experiment result for box with weight of 1 kg ...........................................18
2.3.6. Experiment result for box with weight of 2 kg ...........................................21
2.3.7. Error calculation and conclusion ................................................................24
2.4. Mechanical selections ........................................................................................ 25
2.4.1. Select conveyor ...........................................................................................25
2.4.2. Select conveyor frame ................................................................................27
2.4.3. Select conveyor rollers ...............................................................................28
2.4.4. Select transmission for conveyor ................................................................28
2.5. Electronic selections .......................................................................................... 30
2.5.1. Motor selection ...........................................................................................30
2.5.2. Load cell selection ......................................................................................31
2.5.3. Placing the load cell method .......................................................................34
2.5.4. Controller selection .....................................................................................34
2
2.5.5. Photoelectric Sensor selection ....................................................................36
2.5.6. HMI selection .............................................................................................37
CHAPTER 3. MECHANICAL DESIGN...................................................................... 40
3.1. Input parameters and preliminary calculations .................................................. 40
3.1.1. Input parameters .........................................................................................40
3.1.2. Preliminary calculations .............................................................................40
3.2. Select the roller diameter ................................................................................... 43
3.3. Determine the tension on the belt at individual points ...................................... 45
3.3.1. Consider segment 1-2 .................................................................................46
3.3.4. Check the durability of the belt ..................................................................48
3.4. Analyze and calculate the conveyor transmission parts .................................... 48
3.4.1. Motor selection ...........................................................................................48
3.4.2. Check the durability of the belt during start-up ..........................................49
3.4.3. Belt drive selection .....................................................................................50
3.5. Shaft calculation ................................................................................................. 52
3.5.1. Calculate the reactions at the supports........................................................52
3.5.2. Calculate shaft diameter .............................................................................53
3.5.3. Shaft testing ................................................................................................54
3.6. Summary specification of the mechanical design .............................................. 57
3.6.1. Specification of the belt conveyor ..............................................................57
3.6.2. Specification of motor ................................................................................58
3.6.3. Specification of belt drive ...........................................................................58
3.7. 3D model of the mechanical design ................................................................... 58
3.7.1 Conveyor design ..........................................................................................58
3.7.3 Load cell cluster design ...............................................................................59
CHAPTER 4. ELECTRICAL DESIGN ........................................................................ 60
4.1. Components in the electrical system .................................................................. 60
4.2. Select electrical parts ......................................................................................... 60
4.2.1. Circuit breaker selection .............................................................................60
3
4.2.2. Wire selection .............................................................................................61
4.3. Power circuit design ........................................................................................... 63
4.4. Control circuit design ......................................................................................... 63
4.4.1. Design load cell and amplifier circuits .......................................................63
4.4.2. PLC wiring diagram....................................................................................66
CHAPTER 5. OPERATION, HMI INTERFACE PROGRAMMING ......................... 67
5.1. Operation requirement ....................................................................................... 67
5.2. HMI interface ..................................................................................................... 67
5.3. PLC connection .................................................................................................. 68
5.3.1. Declaration tag for PLC ..............................................................................68
5.3.2. Declaration process tag for HMI ................................................................68
5.4. Flowchart............................................................................................................ 69
5.4.1. Main program flowchart .............................................................................69
5.4.2. Weighing flowchart ....................................................................................71
CHAPTER 6. RESULT AND FUTURE DEVELOPMENT ........................................ 73
6.1. Result.................................................................................................................. 73
6.2. Limitation and improvement .............................................................................. 73
6.2.1. Mechanical manufacturing .........................................................................73
6.2.2. Electrical components .................................................................................73
6.2.3. Programming ..............................................................................................73
6.3. Conclusion and future development .................................................................. 73
6.3.1 Conclusion ...................................................................................................73
6.3.2. Future development ....................................................................................74
REFERENCE ................................................................................................................ 75
4
LIST OF FIGURES
Figure 1.1. Automated weighing system ....................................................................8
Figure 1.2. Intech’s confectionery automatic weighing system ................................. 9
Figure 2.1. EDEM simulation ...................................................................................12
Figure 2.2. Load cell placement ................................................................................13
Figure 2.3. Actuator block ........................................................................................14
Figure 2.4. Electrical components .............................................................................14
Figure 2.5. 0.5 kg box measure result chart ..............................................................17
Figure 2.6. 1 kg box measure result chart .................................................................20
Figure 2.7. 2 kg box measure result chart .................................................................23
Figure 2.8. PVC rubber belt conveyor ......................................................................25
Figure 2.9. Roller Conveyors ....................................................................................26
Figure 2.10. Belt drive ..............................................................................................29
Figure 2.11. Chain drive............................................................................................29
Figure 2.12. Load cell ...............................................................................................32
Figure 2.13. SIMATIC HMI MTP2200 .................................................................... 39
Figure 3.1. Principle diagram of conveyor ...............................................................40
Figure 3.2. Table 3.10 of [2] .....................................................................................41
Figure 3.3. Cross-section area of material on the belt ..............................................42
Figure 3.4. Table 3.5 of [2] .......................................................................................43
Figure 3.5. Table 3.4 of [2] .......................................................................................44
Figure 3.6. Table 4.3 of [2] .......................................................................................44
Figure 3.7. Force calculation diagram ......................................................................45
Figure 3.8. 3D model of the mechanical design .......................................................58
Figure 3.9. Load cell cluster design .......................................................................... 59
Figure 4.1. Control cluster diagram ..........................................................................60
Figure 4.2. MCB LS BKN-b 3P 16A ........................................................................61
Figure 4.3. MCB Schneider EZ9F34216 16A ..........................................................61
Figure 4.4. IEC standard Conductor Cross-sectional ................................................62
Figure 4.5. Power circuit of AC motor .....................................................................63
Figure 4.6. Load cell .................................................................................................63
5
Figure 4.7. Wiring diagram between load cell and amplifier ...................................65
Figure 4.8. PLC wiring diagram ............................................................................... 66
Figure 5.1. HMI interface..........................................................................................67
Figure 5.2. Main Program .........................................................................................70
Figure 5.3. Data filter flowchart ................................................................................72
6
LIST OF TABLES
Table 1.1. Intech’s confectionery automatic weighing system spec ......................... 10
Table 2.1. Setting for transportation module ............................................................12
Table 2.2. Load cell error ..........................................................................................15
Table 2.3. 0.5 kg box measure result ........................................................................15
Table 2.4. Average motion values of 0.5 kg box ......................................................18
Table 2.5. 1 kg box measure result ...........................................................................18
Table 2.6. Average motion values of 1 kg box .........................................................21
Table 2.7. 2 kg box measure result ...........................................................................21
Table 2.8. Average motion values of 2 kg box comparation ....................................24
Table 2.9. Motion value and static value of 0.5 kg box comparison ........................24
Table 2.10. Motion values and static values of 1 kg box comparation .....................24
Table 2.11. Motion values and static values of 2 kg box comparation .....................24
Table 2.12. Average error of all box types ...............................................................25
Table 2.13. Motor comparison ..................................................................................31
Table 2.14. Load cell description ..............................................................................33
Table 2.15. Technical Specifications ........................................................................33
Table 2.16. Types of PLC S7-1200...........................................................................35
Table 2.17. PLC SIMATIC S7-1200’s Sign board ...................................................36
Table 2.18. SIMATIC HMI MTP2200 spec ............................................................. 39
Table 3.1. Technical specifications of V-Belt type B ...............................................50
Table 3.2. V-belt information....................................................................................51
Table 3.3. Specification of the belt conveyor ...........................................................57
Table 3.4. Specification of motor ..............................................................................58
Table 3.5. Specification of belt drive ........................................................................ 58
Table 4.1. Load cell specification .............................................................................64
Table 4.2. Load cell amplifier specification ............................................................. 64
Table 5.1. Input declaration for PLC ........................................................................68
Table 5.2. Declaration process tag for HMI..............................................................68
7
CHAPTER 1. OVERVIEW
1.1. Introduction
1.1.1. Introduction to the automated weighing system
A automated weighing system is an automated system used in industrial settings to
check the weight of products as they pass through a production line. The main purpose
of a automated weighing system is to ensure that the weight of the product falls within
a specified range of tolerance. It automatically rejects items that are underweight or
overweight.
Figure 1.1. Automated weighing system
1.1.2. Automated weighing system classification

Automated weighing system are classified based on various criteria such as their
application, operational features, and design. Below are common classifications:
− By Application
+ In-Motion: These weigh products while they move along a conveyor belt,
without stopping the production process. They are ideal for high-speed
production lines, often found in food, pharmaceutical, and packaging industries.
+ Static: In this type, products are weighed when stationary. These are slower and
less common in automated environments, often used for batch processes or
smaller operations.
− By Product Handling
+ Single-lane: Designed for handling one product at a time, typically used for
streamlined, high-speed production lines.
8
+ Multi-lane: Used for handling multiple products at once across multiple lanes.
This is useful in industries that deal with small, lightweight items such as snacks
or pharmaceuticals.
− By Reject Mechanism
+ Pusher-Type: Use a physical pusher arm to remove rejected items from the
line.
+ Air-Jet: Blow lightweight items off the line using a burst of air.
+ Swing Gate: Direct items that are out of tolerance into a reject bin via a gate or
arm.
+ Drop-Through: Often used for small or lightweight products, this mechanism
allows rejected items to fall through the line.
− By Design Features
+ Belt-Type: Products are weighed as they move on a belt conveyor. These are
the most common type and work well for medium to large-sized products.
+ Rotary: Used for very high-speed production lines, typically in packaging or
beverage industries. They rotate products through a weighing mechanism.
+ Table-Top: Compact, often portable units used for smaller-scale operations or
testing environments.
1.2. Automated weighing system

Intech’s confectionery classification system [1]
Figure 1.2. Intech’s confectionery automatic weighing system
9
Application:
− Transport finished product from packaging area to storage area. At the same time,
classify by product line when passing through the classification cluster.
− Check the volume error of confectionery box, thereby detecting underpackaged
box, replacing the need for manual work as in the past, ensuring 100% of
confectionery boxes are checked for weight before entering. Storage - Software
that combines production operations to help store data and produce statistics to
produce production reports, providing parameters for planners to develop best-
selling product lines.
Specification:
Table 1.1. Intech’s confectionery automatic weighing system spec
Maximun package size 500x500x300, max weight 𝑚𝑚𝑎𝑥 = 20 (𝑘𝑔)

Minimum package size 300x200x200, min weight 𝑚𝑚𝑖𝑛 = 1 (𝑘𝑔)
Productivity 48000 packages/day
Sorting type Pop-up Sorter
Number of output dividing doors 4
Scale option Mettler Toledo – Germany
Error ±30 (𝑔)
Barcode scanning Automatic
Code 1D-128
Barcode reader Cognex – USA
1.3. Project topic and design scope

Objective: design confectionery automated weighing system upon request:
Productivity: 33 𝐵𝑜𝑥/𝑚𝑖𝑛
Error: ± 30𝑔
Weight range: 1 𝑘𝑔 ~ 20 𝑘𝑔
Box’s size:
− Minimum size: 300x200x200 𝑚𝑚
− Maximum size: 500x500x300 𝑚𝑚
10
CHAPTER 2. ANALYSING AND DESIGNING OPTION
2.1. Weighing methods
Automated weighing systems are widely used in industries such as manufacturing,
agriculture, logistics, and healthcare to improve efficiency and accuracy in measuring
weights. There are several methods of automated weighing, each with its own
advantages and applications.
Static Weighing
Description: In static weighing, the object to be weighed is placed on a stationary
weighing platform. The weight is measured once the object and platform are at rest.
Applications: Ideal for applications where objects are weighed individually and do
not move during the weighing process, such as in laboratories, packaging lines, or retail
scales.
Advantages:
− High accuracy.
− Simple design and operation.
Disadvantages:
− Slower than dynamic methods since the object must be stationary.
Dynamic Weighing (In-Motion Weighing)
Description: In dynamic weighing systems, objects are weighed while moving, such
as on conveyor belts. The system measures weight without stopping the object’s
movement, which is useful for continuous processes.
Applications: Used in industries like packaging, parcel sorting, and food processing,
where high-speed operations are essential.
Advantages:
− High throughput (fast processing of objects).
− Continuous measurement without interrupting the flow.
Disadvantages:
− Typically less accurate than static weighing.
− Requires advanced sensors and algorithms to compensate for motion effects.
Due to requirement of the system. Select the Dynamic Weighing method.
11
To evaluate the possibility of the Dynamic Weighing method. Set up the stimulation
of box supply and experimental model to test feasibility of the chosen conceptual.
2.2. Box supply simulation

Box supply module is a 25 degree inclined conveyor. Using Altair EDEM software
to simulate the boxes supply process.
Software simulating parameter setting for merchandise:
material: cardboard
weight: ~ 7 𝑘𝑔
Software simulating parameter setting for transportation module:
Table 2.1. Setting for transportation module
Commodities supply conveyor Commodities recive conveyor

Material Alumium, rubber Alumium, rubber
Initial velocity 1 𝑚/𝑠 1 𝑚/𝑠
Figure 2.1. EDEM simulation
With those parameters setting, the boxes are not deformed and flipped during the
supply process.
12
2.3. Experiment and evaluation
2.3.1. Experimental model of automated confectionary weighing system
The experimental model is built and proceeds to collect testing data for actual system.
The experimental model includes:
− The actuator block includes the conveyor belt, load cell assembly located under
the conveyor surface.
− The control block includes PLC and other electrical components to control input
and output signals.
The task of the model is to test the load cell's weighing value and then draw error
results during the weighing process.
Figure 2.2. Load cell placement
13
Figure 2.3. Actuator block
2.3.2. Electrical components

Electrical components include: triple circuit breaker, double circuit breaker, overload
switch, contactor, PLC power source, PLC SIMATIC S7 1200.
Figure 2.4. Electrical components
2.3.3. Load cell error

The load cell has its own error shown in the table below. Then compare the result of
the system between static state and motion state.
14
Table 2.2. Load cell error
Electronic scale Load cell Load cell error Average load cell error
(kg) (kg) (kg) (kg)
0.5 0.485 0.015
1.0 0.933 0.067 0.093
2.0 1.802 0.198
2.3.4. Experiment result for box with weight of 0.5 kg

The actual evaluation results achieved when measure 0.5 kg box at 10 different time.
Table 2.3. 0.5 kg box measure result

Time Electronic scale loadcell 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
0.1 0.5 0.485 0.118 0.109 0.103 0.119 0.108 0.103 0.110 0.109 0.107 0.111
0.2 0.5 0.485 0.154 0.103 0.103 0.144 0.102 0.105 0.103 0.103 0.104 0.144
0.3 0.5 0.485 0.183 0.103 0.104 0.153 0.103 0.104 0.103 0.103 0.103 0.153
0.4 0.5 0.485 0.193 0.104 0.105 0.154 0.105 0.106 0.104 0.104 0.104 0.151
0.5 0.5 0.485 0.173 0.105 0.137 0.155 0.108 0.139 0.128 0.105 0.105 0.154
0.6 0.5 0.485 0.157 0.137 0.166 0.158 0.130 0.163 0.149 0.137 0.137 0.158
0.7 0.5 0.485 0.153 0.166 0.192 0.163 0.158 0.191 0.166 0.166 0.166 0.173
0.8 0.5 0.485 0.178 0.192 0.202 0.193 0.190 0.200 0.192 0.192 0.192 0.193
0.9 0.5 0.485 0.228 0.202 0.216 0.208 0.215 0.214 0.199 0.216 0.202 0.208
1 0.5 0.485 0.287 0.216 0.236 0.257 0.227 0.237 0.215 0.236 0.216 0.257
1.1 0.5 0.485 0.355 0.236 0.259 0.356 0.230 0.257 0.237 0.259 0.236 0.356
1.2 0.5 0.485 0.422 0.259 0.272 0.424 0.244 0.274 0.259 0.272 0.259 0.400
1.3 0.5 0.485 0.470 0.272 0.330 0.454 0.255 0.333 0.272 0.330 0.330 0.440
1.4 0.5 0.485 0.464 0.330 0.408 0.455 0.318 0.406 0.343 0.408 0.408 0.455
1.5 0.5 0.485 0.465 0.408 0.454 0.466 0.451 0.451 0.408 0.457 0.421 0.454
1.6 0.5 0.485 0.476 0.454 0.479 0.469 0.469 0.476 0.454 0.498 0.451 0.466
1.7 0.5 0.485 0.489 0.479 0.498 0.479 0.499 0.499 0.479 0.486 0.479 0.479
1.8 0.5 0.485 0.504 0.498 0.486 0.502 0.480 0.485 0.498 0.476 0.498 0.488
1.9 0.5 0.485 0.519 0.486 0.476 0.508 0.476 0.475 0.486 0.475 0.486 0.485
2 0.5 0.485 0.519 0.476 0.475 0.499 0.475 0.474 0.476 0.481 0.476 0.483
2.1 0.5 0.485 0.485 0.475 0.481 0.483 0.481 0.480 0.475 0.483 0.475 0.482
2.2 0.5 0.485 0.408 0.481 0.483 0.481 0.479 0.481 0.481 0.481 0.478 0.474
2.3 0.5 0.485 0.341 0.483 0.474 0.483 0.478 0.475 0.474 0.474 0.475 0.468
2.4 0.5 0.485 0.290 0.474 0.440 0.474 0.468 0.471 0.440 0.440 0.471 0.391
2.5 0.5 0.485 0.253 0.440 0.394 0.440 0.392 0.430 0.394 0.394 0.430 0.387
2.6 0.5 0.485 0.250 0.394 0.343 0.394 0.347 0.387 0.343 0.343 0.387 0.343
2.7 0.5 0.485 0.261 0.343 0.302 0.343 0.303 0.343 0.302 0.302 0.343 0.303
2.8 0.5 0.485 0.253 0.302 0.273 0.302 0.271 0.302 0.273 0.273 0.302 0.271
2.9 0.5 0.485 0.233 0.273 0.259 0.273 0.254 0.273 0.259 0.259 0.271 0.254
15
3 0.5 0.485 0.189 0.259 0.256 0.259 0.252 0.259 0.257 0.256 0.259 0.252
3.1 0.5 0.485 0.158 0.256 0.242 0.251 0.240 0.257 0.242 0.242 0.256 0.251
3.2 0.5 0.485 0.145 0.242 0.230 0.242 0.226 0.242 0.230 0.230 0.242 0.242
3.3 0.5 0.485 0.148 0.230 0.226 0.236 0.224 0.236 0.226 0.226 0.236 0.236
3.4 0.5 0.485 0.162 0.226 0.223 0.227 0.221 0.227 0.223 0.223 0.227 0.227
3.5 0.5 0.485 0.173 0.223 0.189 0.223 0.188 0.223 0.223 0.173 0.223 0.223
3.6 0.5 0.485 0.174 0.189 0.171 0.171 0.175 0.189 0.189 0.174 0.171 0.171
3.7 0.5 0.485 0.166 0.171 0.166 0.167 0.168 0.171 0.171 0.171 0.167 0.166
3.8 0.5 0.485 0.129 0.166 0.167 0.166 0.169 0.167 0.167 0.166 0.166 0.167
3.9 0.5 0.485 0.095 0.167 0.165 0.167 0.164 0.164 0.165 0.165 0.164 0.165
4 0.5 0.485 0.075 0.165 0.152 0.165 0.155 0.164 0.152 0.152 0.155 0.152
4.1 0.5 0.485 0.078 0.152 0.149 0.152 0.149 0.158 0.149 0.149 0.149 0.149
4.2 0.5 0.485 0.089 0.149 0.136 0.152 0.133 0.152 0.136 0.136 0.133 0.136
4.3 0.5 0.485 0.110 0.136 0.128 0.149 0.124 0.149 0.128 0.128 0.124 0.128
4.4 0.5 0.485 0.115 0.128 0.110 0.136 0.113 0.136 0.110 0.110 0.110 0.115
4.5 0.5 0.485 0.100 0.110 0.074 0.128 0.072 0.128 0.074 0.074 0.074 0.074
4.6 0.5 0.485 0.066 0.074 0.070 0.110 0.069 0.110 0.070 0.070 0.070 0.063
4.7 0.5 0.485 0.045 0.064 0.064 0.064 0.064 0.064 0.053 0.062 0.064 0.052
4.8 0.5 0.485 0.031 0.053 0.053 0.058 0.063 0.053 0.045 0.052 0.053 0.045
16
Figure 2.5. 0.5 kg box measure result chart
17
From the chart, the load cell measures most accurate values is from 1.5 to 2.2 second
=> select the value from 1.5 to 2.2 seconds, calculate the average values of ten times
measuring.
Table 2.4. Average motion values of 0.5 kg box
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
average average average average average average average average average average
value value value value value value value value value value
0.483 0.469 0.479 0.480 0.476 0.478 0.469 0.479 0.470 0.469
2.3.5. Experiment result for box with weight of 1 kg

The actual evaluation results achieved when measure 1 kg box at 10 different time.
Table 2.5. 1 kg box measure result

Time Electronic scale Loadcell 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
0.1 1 0.933 0.157 0.123 0.166 0.160 0.124 0.158 0.147 0.148 0.156 0.166
0.2 1 0.933 0.179 0.130 0.175 0.167 0.135 0.166 0.157 0.159 0.167 0.175
0.3 1 0.933 0.194 0.158 0.192 0.167 0.160 0.175 0.167 0.166 0.175 0.192
0.4 1 0.933 0.201 0.187 0.202 0.179 0.187 0.186 0.179 0.166 0.166 0.202
0.5 1 0.933 0.167 0.212 0.166 0.191 0.212 0.194 0.187 0.175 0.167 0.166
0.6 1 0.933 0.167 0.226 0.167 0.194 0.226 0.201 0.191 0.192 0.190 0.167
0.7 1 0.933 0.191 0.240 0.190 0.201 0.240 0.270 0.240 0.234 0.192 0.190
0.8 1 0.933 0.270 0.244 0.272 0.270 0.244 0.334 0.244 0.240 0.194 0.272
0.9 1 0.933 0.334 0.255 0.330 0.334 0.255 0.418 0.255 0.255 0.255 0.330
1 1 0.933 0.418 0.318 0.408 0.418 0.318 0.480 0.334 0.318 0.330 0.408
1.1 1 0.933 0.480 0.451 0.454 0.480 0.451 0.556 0.480 0.480 0.454 0.454
1.2 1 0.933 0.556 0.669 0.498 0.556 0.669 0.674 0.556 0.556 0.553 0.498
1.3 1 0.933 0.674 0.775 0.751 0.674 0.775 0.807 0.674 0.674 0.674 0.751
1.4 1 0.933 0.807 0.841 0.857 0.807 0.841 0.859 0.775 0.807 0.775 0.857
1.5 1 0.933 0.900 0.859 0.860 0.899 0.886 0.860 0.859 0.859 0.857 0.859
1.6 1 0.933 0.918 0.883 0.886 0.918 0.892 0.883 0.886 0.886 0.888 0.883
1.7 1 0.933 0.958 0.902 0.892 0.928 0.918 0.892 0.892 0.892 0.902 0.902
1.8 1 0.933 0.959 0.924 0.918 0.929 0.980 0.918 0.918 0.918 0.924 0.924
1.9 1 0.933 0.958 0.938 0.920 0.911 0.958 0.920 0.920 0.919 0.938 0.938
2 1 0.933 0.900 0.933 0.911 0.900 0.901 0.911 0.911 0.911 0.911 0.933
2.1 1 0.933 0.790 0.911 0.901 0.790 0.874 0.901 0.901 0.901 0.901 0.790
2.2 1 0.933 0.655 0.842 0.874 0.655 0.751 0.884 0.874 0.874 0.874 0.655
2.3 1 0.933 0.500 0.714 0.751 0.588 0.655 0.751 0.714 0.751 0.751 0.588
2.4 1 0.933 0.465 0.588 0.556 0.468 0.588 0.655 0.645 0.556 0.655 0.468
2.5 1 0.933 0.392 0.468 0.479 0.416 0.468 0.488 0.598 0.480 0.588 0.440
2.6 1 0.933 0.364 0.416 0.440 0.400 0.416 0.486 0.488 0.440 0.468 0.416
2.7 1 0.933 0.333 0.400 0.416 0.393 0.400 0.480 0.486 0.400 0.416 0.400
18
2.8 1 0.933 0.302 0.393 0.383 0.378 0.383 0.440 0.450 0.390 0.400 0.390
2.9 1 0.933 0.265 0.378 0.378 0.332 0.378 0.400 0.399 0.386 0.393 0.386
3 1 0.933 0.240 0.332 0.350 0.283 0.350 0.390 0.400 0.377 0.332 0.377
3.1 1 0.933 0.226 0.283 0.293 0.232 0.293 0.377 0.390 0.350 0.283 0.350
3.2 1 0.933 0.215 0.232 0.242 0.212 0.242 0.350 0.377 0.318 0.232 0.318
3.3 1 0.933 0.215 0.199 0.199 0.211 0.199 0.293 0.350 0.293 0.199 0.293
3.4 1 0.933 0.201 0.178 0.189 0.206 0.189 0.242 0.293 0.242 0.188 0.242
3.5 1 0.933 0.196 0.181 0.181 0.205 0.181 0.199 0.242 0.199 0.181 0.199
3.6 1 0.933 0.190 0.204 0.205 0.189 0.218 0.189 0.199 0.189 0.205 0.189
3.7 1 0.933 0.166 0.218 0.211 0.168 0.205 0.181 0.189 0.181 0.211 0.181
3.8 1 0.933 0.133 0.204 0.206 0.147 0.204 0.218 0.181 0.218 0.206 0.218
3.9 1 0.933 0.112 0.189 0.113 0.139 0.204 0.205 0.218 0.205 0.147 0.205
4 1 0.933 0.120 0.168 0.130 0.133 0.189 0.199 0.205 0.199 0.143 0.199
4.1 1 0.933 0.132 0.147 0.132 0.137 0.168 0.178 0.199 0.178 0.138 0.178
4.2 1 0.933 0.144 0.139 0.143 0.138 0.147 0.147 0.178 0.147 0.132 0.168
4.3 1 0.933 0.144 0.133 0.131 0.137 0.139 0.143 0.147 0.143 0.130 0.147
4.4 1 0.933 0.127 0.137 0.111 0.127 0.133 0.139 0.139 0.139 0.127 0.139
4.5 1 0.933 0.096 0.138 0.092 0.090 0.055 0.133 0.133 0.133 0.113 0.096
4.6 1 0.933 0.055 0.107 0.045 0.046 0.035 0.055 0.055 0.055 0.107 0.055
4.7 1 0.933 0.035 0.076 0.033 0.034 0.038 0.035 0.035 0.035 0.076 0.035
4.8 1 0.933 0.038 0.060 0.034 0.033 0.035 0.038 0.038 0.038 0.060 0.038
19
Figure 2.6. 1 kg box measure result chart
20
measuring.
Table 2.6. Average motion values of 1 kg box
0.880 0.899 0.909 0.866 0.895 0.896 0.895 0.895 0.899 0.860
2.3.6. Experiment result for box with weight of 2 kg

The actual evaluation results achieved when measure 2 kg box at 10 different time.
Table 2.7. 2 kg box measure result

Time Electronic scale Loadcell 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
0.1 2 1.802 0.147 0.130 0.125 0.122 0.126 0.128 0.147 0.131 0.133 0.127
0.2 2 1.802 0.190 0.150 0.139 0.130 0.139 0.139 0.190 0.150 0.150 0.139
0.3 2 1.802 0.227 0.173 0.183 0.150 0.150 0.150 0.227 0.173 0.173 0.183
0.4 2 1.802 0.261 0.186 0.182 0.183 0.173 0.173 0.261 0.186 0.186 0.182
0.5 2 1.802 0.304 0.246 0.244 0.246 0.186 0.186 0.304 0.246 0.246 0.244
0.6 2 1.802 0.387 0.299 0.293 0.299 0.246 0.246 0.387 0.299 0.293 0.293
0.7 2 1.802 0.516 0.371 0.556 0.371 0.299 0.299 0.516 0.371 0.556 0.487
0.8 2 1.802 0.643 0.440 0.647 0.487 0.371 0.371 0.556 0.440 0.647 0.556
0.9 2 1.802 0.751 0.556 0.775 0.556 0.440 0.440 0.643 0.556 0.775 0.556
1 2 1.802 0.857 0.668 0.859 0.647 0.556 0.556 0.668 0.668 0.859 0.647
1.1 2 1.802 0.974 0.761 0.972 0.766 0.668 0.647 0.761 0.761 0.972 0.766
1.2 2 1.802 1.158 0.892 1.152 1.158 0.761 1.158 0.892 0.892 1.152 1.158
1.3 2 1.802 1.338 1.046 1.335 1.338 0.892 1.221 1.046 1.046 1.335 1.338
1.4 2 1.802 1.525 1.221 1.528 1.525 1.046 1.338 1.221 1.219 1.525 1.525
1.5 2 1.802 1.683 1.433 1.681 1.683 1.221 1.433 1.432 1.335 1.683 1.681
1.6 2 1.802 1.763 1.636 1.753 1.763 1.433 1.636 1.633 1.528 1.763 1.753
1.7 2 1.802 1.804 1.724 1.810 1.804 1.636 1.683 1.724 1.724 1.804 1.810
1.8 2 1.802 1.825 1.784 1.810 1.825 1.724 1.724 1.784 1.784 1.825 1.810
1.9 2 1.802 1.842 1.806 1.809 1.807 1.784 1.784 1.806 1.809 1.807 1.809
2 2 1.802 1.817 1.801 1.804 1.842 1.806 1.804 1.801 1.801 1.842 1.804
2.1 2 1.802 1.720 1.781 1.786 1.817 1.801 1.801 1.781 1.781 1.817 1.786
2.2 2 1.802 1.525 1.712 1.715 1.720 1.781 1.781 1.712 1.712 1.720 1.715
2.3 2 1.802 1.338 1.544 1.534 1.525 1.715 1.715 1.544 1.544 1.525 1.712
2.4 2 1.802 1.149 1.395 1.392 1.338 1.712 1.712 1.395 1.395 1.338 1.544
2.5 2 1.802 0.931 1.245 1.242 1.149 1.525 1.525 1.149 1.243 1.242 1.395
2.6 2 1.802 0.707 1.043 1.045 0.931 1.043 1.043 0.931 1.149 1.043 1.245
2.7 2 1.802 0.603 0.868 0.883 0.707 0.883 0.868 0.707 0.868 0.883 1.043
21
2.8 2 1.802 0.501 0.670 0.671 0.603 0.673 0.670 0.603 0.670 0.673 0.868
2.9 2 1.802 0.419 0.494 0.414 0.501 0.414 0.494 0.501 0.494 0.414 0.670
3 2 1.802 0.350 0.383 0.360 0.419 0.360 0.383 0.419 0.383 0.360 0.494
3.1 2 1.802 0.304 0.329 0.352 0.350 0.352 0.329 0.350 0.329 0.352 0.383
3.2 2 1.802 0.282 0.278 0.286 0.288 0.286 0.278 0.304 0.278 0.286 0.304
3.3 2 1.802 0.270 0.247 0.266 0.257 0.247 0.253 0.282 0.247 0.247 0.282
3.4 2 1.802 0.254 0.237 0.259 0.237 0.237 0.247 0.270 0.237 0.237 0.270
3.5 2 1.802 0.252 0.253 0.255 0.253 0.253 0.237 0.254 0.253 0.253 0.254
3.6 2 1.802 0.248 0.237 0.243 0.237 0.237 0.218 0.252 0.237 0.237 0.252
3.7 2 1.802 0.235 0.218 0.232 0.218 0.218 0.190 0.232 0.218 0.218 0.248
3.8 2 1.802 0.205 0.190 0.206 0.190 0.190 0.164 0.206 0.190 0.190 0.235
3.9 2 1.802 0.179 0.164 0.177 0.164 0.179 0.161 0.177 0.164 0.179 0.183
4 2 1.802 0.165 0.156 0.168 0.156 0.165 0.156 0.168 0.156 0.156 0.179
4.1 2 1.802 0.166 0.161 0.166 0.161 0.166 0.145 0.166 0.161 0.161 0.165
4.2 2 1.802 0.171 0.170 0.174 0.170 0.171 0.135 0.174 0.170 0.170 0.171
4.3 2 1.802 0.157 0.178 0.159 0.178 0.157 0.125 0.159 0.178 0.178 0.157
4.4 2 1.802 0.145 0.146 0.143 0.146 0.145 0.118 0.143 0.146 0.146 0.145
4.5 2 1.802 0.135 0.125 0.127 0.125 0.135 0.114 0.127 0.125 0.125 0.135
4.6 2 1.802 0.111 0.118 0.107 0.118 0.111 0.111 0.107 0.118 0.111 0.111
4.7 2 1.802 0.067 0.114 0.060 0.114 0.067 0.067 0.060 0.114 0.067 0.067
4.8 2 1.802 0.035 0.094 0.039 0.094 0.036 0.037 0.039 0.094 0.033 0.031
22
Figure 2.7. 2 kg box measure result chart
23
measuring.
Table 2.8. Average motion values of 2 kg box comparation
1.747 1.709 1.784 1.782 1.648 1.705 1.709 1.684 1.782 1.771
2.3.7. Error calculation and conclusion
After doing experiments on 3 types of boxes with different weights and calculate the
average value of each time measuring. Calculate the error between average motion
values and static values.
Table 2.9. Motion value and static value of 0.5 kg box comparison
Static 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Average
value error error error error error error error error error error error
0.485 0.002 0.016 0.006 0.005 0.009 0.007 0.016 0.006 0.015 0.016 0.010
Table 2.10. Motion values and static values of 1 kg box comparation
0.933 0.053 0.034 0.024 0.067 0.038 0.037 0.038 0.038 0.034 0.073 0.044
Table 2.11. Motion values and static values of 2 kg box comparation
1.802 0.055 0.093 0.018 0.020 0.154 0.097 0.093 0.118 0.020 0.031 0.070
24
Table 2.12. Average error of all box types
Average weighing Average Average weighing

Average weighing
error of 0.5 kg weighing error of error of all box
error of 1 kg box
box 2kg box types
0.010 0.044 0.070 0.041
The error of the experiment almost meets the system requirement of ± 30𝑔. The
load cell used in the experiment has accuracy of C3 class.
In conclusion, select the load cell with accuracy of C4 class will bring more accurate
result. From the experimental system, select solutions for the real system.
Detect the weighing area by photoelectric sensors.
2.4. Mechanical selections

2.4.1. Select conveyor
Belt conveyor
Figure 2.8. PVC rubber belt conveyor

Mechanical analyze:
Advantages:
− Good chemical resistance.
− Good water and steam resistance.
− PVC conveyor belts have good radiation resistance, fire resistance and anti-static
properties.
25
− Operating in many different industries, harsh environments, humid climates and
low temperatures.
− Has good resistance to grease, solvents, and abrasion.
− Resistant to tearing, stretching, and peeling.
− Easy to clean, replace, repair, and maintain when problems arise.
Disadvantages:
− Some systems are difficult to transport and do not transport large size products.
− For granular products, broken pieces, etc., they may be lost or scattered during
transportation.
− When transporting long distances and the terrain is not straight, multiple
connection systems are needed compatible with each other.
Roller Conveyors
Figure 2.9. Roller Conveyors

Mechanical analyze:
Advantage:
− Roller conveyors are known for their efficiency in moving goods quickly and
smoothly.
− Roller conveyors can handle a wide range of products, sizes, and shapes.
− Low Maintenance.
− Cost-effective.
Disadvantage:
− Gravity roller conveyors rely on gravity for movement, which means limited
control over the speed and direction of the items being transported.
− Uneven Load Distribution.
26
− Roller conveyors are generally not suitable for applications that require significant
changes in elevation.
− Not Suitable for Fragile Items.
Due to the requirements of the topic, we choose PVC rubber belt conveyor.
2.4.2. Select conveyor frame

Aluminum frame:
Advantages and Disavantages of Aluminum frame
− Advantages:
+ Shaped aluminum conveyor frame is a product line made of aluminum sheet
and has a shiny anodized surface, scratch resistance and extremely good bearing
capacity. Therefore, the product has high durability and aesthetics.
+ Because the product is made of aluminum and produced by extrusion method
with high purity, the aluminum conveyor frame has extremely high durability.
+ Good anti-static ability of aluminum conveyor frame: Aluminum has a
conductivity coefficient electricity is higher than other materials such as
stainless steel, iron... Thanks to that, it helps liberate the amount of capacitance
generated during friction, minimizing the influence of electric current and
avoiding affecting electronic product lines.
+ Aluminum frame conveyor is light in weight, easy to disassemble and move.
+ Flexibility: Aluminum frame conveyor uses shaped aluminum accessories such
as corners, sliders... so the product is highly flexible and can be reused many
times. Therefore, we can maximize cost savings.
− Disadvantages:
+ Limited load-bearing capacity, the aluminum frame of the conveyor belt can
only withstand the load weight less than 50kg.
Steel frame
Advantages and Disavantages of steel frame
− Advantage:
+ Highly durable steel conveyor frame with powder-coated surface, scratch-
resistant,
27
+ Good bearing capacity, easy to disassemble.
+ Low price compared to shaped aluminum frames.
− Disadvantages:
+ Steel is susceptible to rust, corrosion by chemicals or the impact of weather.
Aluminum frame conveyor meets the requirements of the model such as: suitability,
durability, cost and maintainability. From there, choose the option of using a shaped
aluminum frame for the project.
2.4.3. Select conveyor rollers

Aluminum roller:
− Alumium rollers are used in assembly, production, and transportation of goods in
factories. The roller uses a Alumium coating that ensures certain hardness and does
not melt when heated. Alumium-coated rollers can withstand high temperatures,
have good abrasion resistance, and are good for use in many harsh working
environments, meeting maximum usage needs at low prices.
− Alumium rollers are suitable for use as roller conveyors to convey heavy materials
at low cost. alumium roller is light but still ensures hardness supports materials as
they move on the conveyor belt. The advantage of Alumium rollers is that they are
light in weight for easy movement, good anti-corrosion rollers, good impact
resistance, especially low price to help businesses save the best costs.
Galvanized steel roller:
− Rollers made of galvanized steel are used in assembly, production, and
transportation of goods in factories.
− Bearing large loads, transporting large volumes of goods compared to aluminum
rollers.
Based on criteria such as model compatibility, roller durability, low price and easy to
maintain and repair, choose the option of using rollers from aluminum.
2.4.4. Select transmission for conveyor

Belt drive:
28
− When under load, the V-belt is pulled into the grooves of the wheel and pressed
against the wheels grooved hips. The standard modular sized V-belt provides
active engagement the pulley, entering and exiting the grooves smoothly, rolling
with minimal friction.
− V-belt are covered with a layer of wear-resistant nylon. After a short period of
operation, the surface becomes smooth with low friction loss. They eliminate
slippage, metal on metal contact, stretch and lubricate.
Figure 2.10. Belt drive
Advantages:
− The transmission of force is elastic.
− Runs smoothly and stably, withstands shock.
− Reduce load and increase lifespan.
− No need for lubrication.
− Low maintenance costs.
Chain drive
Figure 2.11. Chain drive
29
Advantage:
− Drives 2 shafts far apart (<8m).
− The force acting on the small shaft does not require chain tension.
− No slipping phenomenon like belt transmission.29
− Can be used to transmit motion to multiple axes simultaneously.
− Compact structure (compared to belt transmission).
Disadvantages:
− Due to the impact, it makes noise, so the chain transmission adapts to the
movement.
− low velocity.
− Transmission ratio is unstable.
− Complex manufacturing, assembly and maintenance.
− Although it has the same function as the belt drive, it is used when the shaft rotates
quickly.
− If using belt drive, slow rotating shaft, use chain drive.
Based on criteria such as model fit, lack of slippage, easy to adjust tension and easy
to maintain, replace and repair, choose the option of using V-belt transmission.
2.5. Electronic selections

2.5.1. Motor selection
DC motors are widely used in high-quality electric drive systems, with DC motor
power ranges from a few W to several MW. This is a versatile, flexible motor that can
meet the requirement of speed, torque, acceleration, and braking with heavy loads. DC
motors are often used mainly to meet the requirement of speed. The DC motor with an
Encoder attached is used to precisely control the speed, using the Pulse Width
Modulation - PWM method. Therefore, DC motors are commonly used in LFR.
AC motor, or Alternating Current motor, is a type of electric motor that operates on
AC electrical power. AC motors are extensively used in various industrial, commercial,
and residential applications due to their efficiency, reliability, and ability to operate with
different power supplies provided by the utility grid.
30
Servo motor can be any type of motor above combined with controller and feedback
system. Servo motor is designed to provide precise control of position, speed, and
acceleration in various applications. These motors are a type of rotary or linear actuator
and are commonly used in automation, robotics, and other systems where accurate and
controlled movement is essential.
Table 2.13. Motor comparison

Name DC motor Stepper motor Servo motor
Advantage - Simple to control. - highly efficient. - High accuracy.
- Low cost. - Lower initial cost - Fast response time.
- Varies in sizes, and maintenance - High efficiency.
rpm, torque, driver, compared to DC
speed. motors.
- Can operate over a
wide range of
speeds and power
outputs.
Disadvantage - Noise. - limited speed - High cost.
- Need maintenance. control capabilities. - Complex to setup and
- lower starting program.
torque. - Require more
- noise and sophisticated power
harmonics. supplies and voltage
regulation.
Based on evaluation criteria such as reasonable price, suitability for the model,
diverse operating methods, and ease of maintenance and repair, choose the option to use
AC motors for the project.
2.5.2. Load cell selection

A load cell is a sensor or transducer that can convert a load or force convert it into an
electrical signal. This electrical signal can be a change in voltage, current or frequency
depending on the type of load cell and the circuit used.
31
Figure 2.12. Load cell
Capacitive load cell:

Capacitive load cell: Capacitive load cell works based on the change of capacitance.
For flat capacitors, there are 2 parallel flat plates. capacitance billion proportional to the
cross-section of the pole and the dielectric constant of the dielectric between the two
poles and inversely proportional to the distance between the two poles. When the load
cell is deformed under impact, the two plates will change position relative to each other,
resulting in a change in the capacitance constant. Then the output electrical signal will
also change accordingly.
Resistive load cell:
Resistive load cells work on the principle of pressure - impedance. When there is a
load or force acting on the sensor, its impedance will change. This change in impedance
will lead to a change in the output voltage when current flows through it.
Based on needs and popularity, choose a resistive load cell for the project.
Resistive load cells work on the principle of pressure - impedance. When there is a
load or force acting on the sensor, its impedance will change. This change in impedance
will lead to a change in the output voltage when current flows through it.
Select the C4 accuracy class - this accuracy class is higher and used for scales used
for shop counter scales, filling machines, dynamic check weighing as well as platform
and belt scales which require higher accuracy.
Load cell specification
32
Table 2.14. Load cell description
P/N 72202518
Capacity (kg) 30
Resolution OIML R60 C4
Full Article Description SPS-C4-30kg-0.40B
Table 2.15. Technical Specifications
Accuracy Class Units OIML R60 C4

Output Sensitivity ( = FS ) mV/V 2.0 ± 0.2
Maximum Capacity ( Emax ) kg 30
Max. Number of Load Cell Intervals 𝑛𝐿𝐶 4000
Ratio of min. LC Verification Interval Y = Emax / vmin 15000
Combined Error %FS ≤± 0.015
Creep Error (30 minutes) %FS ≤± 0.0184
Temperature Effect on Zero (ZTC) %FS/10°C ≤± 0.012
Temperature Effect on Sensitivity (STC) %FS/10°C ≤± 0.0131
Zero Balance %FS ≤± 2.0
Safe Overload %FS 120
Ultimate Overload %FS 150
Maximum Deflection mm 5-50kg:0.6~0.7
Eccentric Loading Error %Ld/cm ± 0.002
Excitation, Recommended Voltage V 5 ~ 12
Excitation, Maximum Voltage V 18
Input Resistance Ω 406 ± 6
Output Resistance Ω 350 ± 3
Insulation Resistance (50V) MΩ ≥5000
Compensated Temperature °C -10 ~ + 40
Operating Temperature °C -35 ~ + 65
Storage Temperature °C -40 ~ + 70
33
Load Cell Weight kg ~0.25
Element Material Aluminum
Ingress Protection (acc. to EN 60529) IP65
Recommended Torque on Fixation Bolts Nm < 30kg: 6
2.5.3. Placing the load cell method

Based on the requirement of the project, choose the option to place the load cell under
the conveyor belt.
Compared to load cells placed under the foot of the conveyor belt, load cells placed
under the conveyor surface have high accuracy, are less affected by environmental
impacts and are easily connected to other devices in the production system. Connect to
data management software.
2.5.4. Controller selection

Select PLC controller S7-1200 for main control of the system.
The SIMATIC S7-1200 is a compact and versatile Programmable Logic Controller
(PLC) developed by Siemens. It is part of the SIMATIC family of automation systems
and is designed for small to medium-sized automation tasks. The S7-1200 offers various
features and capabilities suitable for a wide range of industrial applications.
Security features help protect access to both the CPU and the program drivers:
− All CPUs provide password protection against access to the PLC.
− "know-how protection" feature to protect your special blocks.
The S7-1200 provides a PROFINET port, supporting Ethernet and TCP/IP standards.
In addition, you can use expansion communication modules connected by RS485 or
RS232.
The software used to program the S7 1200 is Step7 Basic. Step7 Basic supports three
programming languages: FBD, LAD and SCL. This software is integrated into Siemens'
TIA Portal.
34
S7-1200’s module CPU
The CPU provides a PROFINET port for communication over a PROFINET network.
Communication modules are available for communication over RS232 or RS48537
networks
Different CPU models provide a variety of features and capacities that help users
create effective solutions for a variety of applications.
PLC S7-1200 has the following types:
Table 2.16. Types of PLC S7-1200
SIMATIC S7-1200 Product Description

CPU CPU1211C 1211 CPU Compact CPU 1211C, 25 KB integral
AC/DC/Rly PROGRAM/DATA MEMORY, 1MB loading
1211 CPU memory; execution times for Boolean
DC/DC/DC operations: 0.1 μs; integral I/Os: 6 digital inputs,
1211 CPU 4 digital outputs, 2 analog inputs; expandable
DC/DC/Rly with up to 3 communication modules and 1
signal board; digital input as HSC with 100kHz,
24 DC digital output can be used as PTO or
PWM with 100kHz
CPU1212C 1212 CPU Compact CPU 1212C, 25 KB integral
DC/DC/DC operations: 0.1 μs; integral I/Os: 8 digital inputs,
1212 CPU 6 digital outputs, 2 analog inputs; expandable
DC/DC/Rly with up to 3 communication modules, 2 signal
modules and 1 signal board; digital input as HSC
with 100kHz, 24 DC digital output can be used
as PTO or PWM with 100kHz
CPU1214C 1212 CPU Compact CPU 1214C, 50 KB integral
35
DC/DC/DC operations: 0.1 μs; integral I/Os: 14 digital
1212 CPU inputs, 10 digital outputs, 2 analog inputs;
DC/DC/Rly expandable with up to 3 communication
modules, 8 signal modules and 1 signal board;
digital input as HSC with 100kHz, 24 DC digital
output can be used as PTO or PWM with 100kHz
PLC SIMATIC S7-1200’s Sign board

Signal board: SB1223 DC/DC.
− Digital inputs / outputs.
− DI 2 x 24 VDC 0.5A38.
DO 2x24 VDC 0.5A.
Sign boards: SB1232AQ.
− Analog output.
− AO 1 x 12bit +/- 10VDC, 0 – 20mA.
Table 2.17. PLC SIMATIC S7-1200’s Sign board
Signal Board SB1223 2x24 VDC 2 inputs, DC 24V, IEC type 1, current
Digital/analog inputs/ 2 x sinking; 2 transistor outputs DC 24V,
24VDC 0.5A, 5W; can be used as additional
outputs HSC with up to 30 kHz
SB1232 1 analog 1 analog output, ±10V with 12 bits or 0
output to 20 mA with 11 bits
2.5.5. Photoelectric Sensor selection

A photoelectric sensor is a type of sensor that detects the presence, absence, or
distance of an object by using light. It works by emitting a beam of light (usually infrared
or visible light) from a light source and then detecting changes in the beam due to
36
reflection, interruption, or absorption by an object. Photoelectric sensors are widely used
in industrial automation, safety systems, and robotics.
Types of Photoelectric Sensors
− Through-Beam Sensors:
+ Working: The emitter and receiver are placed opposite each other. The sensor
detects an object when the light beam is interrupted.
+ Use Case: Detecting larger objects or those that completely block the beam.
− Retroreflective Sensors:
+ Working: The emitter and receiver are placed in the same housing, with a
reflector positioned on the opposite side. The sensor detects objects when the
light beam is interrupted.
+ Use Case: Used for detecting objects in packaging, conveyor systems, etc.
− Diffuse Reflective Sensors:
+ Working: The emitter and receiver are in the same unit, and the sensor detects
an object based on the reflection of light from the object's surface.
+ Use Case: Suitable for detecting objects with reflective surfaces or those
positioned at variable distances.
− Laser Photoelectric Sensors:
+ Working: These sensors use a laser light source instead of an LED. They offer
higher accuracy and are used in applications that require precise object
detection.
+ Use Case: Precision measurement, detecting small objects, or applications
requiring long detection ranges.
Based on needs and popularity, choose a Through-Beam Sensors for the project.
2.5.6. HMI selection

Human-Machine Interface (HMI): An interface that allows humans to interact with
machines, typically in an industrial or automation context. It includes displays,
touchscreens, buttons, and software that presents data and allows operators to control
processes.
Select Siemens SIMATIC HMI MTP2200 Unified Comfort.
37
The Siemens HMI Comfort series is a line of advanced Human-Machine Interface
(HMI) devices from Siemens, designed for industrial applications. These devices are
part of the Siemens SIMATIC HMI product family and are used to visualize and control
automation processes.
Features of Siemens HMI Comfort Panels:
− High-Resolution Displays: These panels feature high-resolution, color displays
that provide clear and sharp visualizations. Sizes range from 4 to 22 inches.
− Touchscreen Interface: The Comfort panels are equipped with touchscreens,
allowing operators to interact directly with the interface, making it user-friendly
and intuitive.
− Scalability: They support a wide range of applications, from small-scale machines
to complex, large-scale systems.
− Connectivity: Siemens HMI Comfort panels support various communication
protocols, including PROFINET, Ethernet, and PROFIBUS, allowing them to
integrate seamlessly with other Siemens products and third-party devices.
− Data Logging and Alarm Management: The panels come with built-in features for
data logging, alarm management, and recipe handling, which are essential for
monitoring and controlling industrial processes.
− Energy Efficiency: These panels are designed to be energy-efficient, reducing
power consumption during operation.
− Durability: Siemens HMI Comfort panels are built to withstand harsh industrial
environments, with robust construction and protection against dust, water, and
other contaminants.
38
Figure 2.13. SIMATIC HMI MTP2200
SIMATIC HMI MTP2200 specification:
Table 2.18. SIMATIC HMI MTP2200 spec
Design MTP2200 Unified Comfort

Screen size 21.5 TFT
Display width (mm) 476.1
Display height (mm) 261.1
Interface Ethernet, 2-Port-Switch RJ45
RS422/485
USB
Supply voltage (VDC) 24
Permissible voltage range (VDC) 19.2 - 28.8
Current consumption (A) 1
39
CHAPTER 3. MECHANICAL DESIGN
3.1. Input parameters and preliminary calculations
D
Figure 3.1. Principle diagram of conveyor
3.1.1. Input parameters

Length of conveyor belt 𝐿 = 2000 𝑚𝑚
Choose PVC rubber belt for conveyor belts.
Productivity: 𝑁 = 33 𝑏𝑜𝑥/𝑚𝑖𝑛
Error: ±30𝑔
Weiging range: 1000 𝑔 ~ 20000 𝑔
Box’s size:
− Minimum size: 300x200x200 mm
− Maximum size: 500x500x300 mm
3.1.2. Preliminary calculations

3.1.2.1. Width of the PVC belt
Average size of the material:
40
𝑎𝑚𝑎𝑥 + 𝑎𝑚𝑖𝑛 500 + 200
𝑎𝑡𝑏 = = = 350 (𝑚𝑚) (3.1)
2 2
Minimum width of tape:
𝐵 = 𝑎𝑡𝑏 + (2 × 100) = 350 + 200 = 550 (𝑚𝑚) (3.2)
Figure 3.2. Table 3.10 of [2]
Due to table 3.10 in page 64 of [2]. Choose the belt width 𝐵 = 650 𝑚𝑚.
With the productivity of the conveyor belt being 33 boxes per minute, we have the
calculated productivity of the conveyor belt:
𝑍 = 33 × 60 = 1980 (𝑏𝑜𝑥/ℎ) (3.3)
The distance between the components on the conveyor is 1000 mm. Speed of the
conveyor belt is:
41
𝑎 𝑎
𝑣= = ≈ 0.6 (𝑚/𝑠)
𝑡. 𝑖 3600 . 𝑖 (3.4)
𝑍
Maximum calculated mass productivity of the conveyor:
𝐺 × 𝑍 20 × 1980
𝑄= = = 39.6 (𝑇/ℎ) (3.5)
1000 1000
3.1.2.2. Cross-sectional area of material on belt surface
Figure 3.3. Cross-section area of material on the belt
Form table 2 of [3]. Choose maximum slope angle allowed when transporting
items: 𝜑 = 20°
For 𝜑 = 20° => 𝑐 = 0.9 from page 101 of [2].
0.8𝐵 × 0.4𝐵 × tan 𝜑1 (3.6)

ℎ=
2
42
𝑏×ℎ
=> 𝐹1 = 𝑐
2
0.8𝐵 × 0.4𝐵 × tan 𝜑1

=
2
= 0.16𝐵2 × tan(0.35 × 𝜑) × 𝑐
= 0.16𝐵2 × tan(0.35 × 20) × 0.9
= 7470.2 (𝑚𝑚2 )
3.2. Select the roller diameter

The load per unit length due to the cargo volume
𝑄 39.6
𝑞𝑡 = = = 18.3 (𝑘𝐺) (3.7)
3.6𝑣 3.6 × 0.6
43
From table 3.5 of [2]. Choose rubber thicknesses:
− working surface side: 𝛿1 = 3 (𝑚𝑚);
− non-working surface side: 𝛿2 = 1.5 (𝑚𝑚)
Preliminary selection of layer according to the table 3.4 in page 50 of [2]. Choose the
layer 𝑖 = 3
The weight per one meter of belt:
𝑞𝑏 = 1.1𝐵(1.23𝑖 + 𝛿1 + 𝛿2 ) (3.8)
= 1.1 × 0.65(1.23 × 3 + 3 + 1.5)
= 7.61 (𝑘𝐺/𝑚)
− Thickness of the core membrane layer: 𝛿𝑚 = 1.5 (𝑚𝑚)

− Belt thickness:
𝛿 = 𝛿1 + 𝛿2 + 1.5𝛿𝑚 (3.9)
= 3 + 1.5 + 1.5 × 1.5 = 6.75 (𝑚𝑚)
Roller diameter
44
From the belt width of 650 𝑚𝑚, choose the roller diameter to be 108 𝑚𝑚. The weight
of the rotating part of the straight roller is based on table 4.3 of [2].
The weight of the rotating part
𝐺𝑐𝑙 = 7𝐵 + 4 = 7 × 0.65 + 4 = 8.5 (𝑘𝐺) (3.10)
Roller weight per meter length in loaded arm:
𝑐
𝐺𝑐𝑙 8.5
𝑞𝑐𝑙 = = = 6.11 (𝑘𝐺/𝑚) (3.11)
𝑙𝑐𝑡 1.4
Roller weight per meter length in unloaded arm
𝑜
𝐺𝑐𝑙 9.5
𝑞𝑐𝑙 = = = 3.05 (𝑘𝐺/𝑚) (3.12)
𝑙𝑘𝑡 2.8
3.3. Determine the tension on the belt at individual points
Figure 3.7. Force calculation diagram
We divide the conveyor belt's perimeter into 4 separate segments, counted from 1 to
4. Each segment has a different form of resistance. We start from point 1, where the tape
tension is smallest.
At point 1, there is tension of the output branch of the driving drum:
𝑆1 = 𝑆𝑟𝑎
45
3.3.1. Consider segment 1-2
𝑆1 : Tension force of the traction element at the entry point of the rotating element.
𝑘𝑞 = 1.07: Coefficient of increase in tension of the traction element on the drum.
𝜔 = 0.022: Coefficient of resistance to belt movement on rollers with bearings.
Resistance force at rotating part (drum):
𝑜)
𝑊12 = (𝑞𝑏 + 𝑞𝑐𝑙 𝐿𝜔 = (7.61 + 3.05 ) × 55 × 0.022 = 13 (𝑘𝐺) (3.13)
Tensile force at point 2:
𝑆2 = 𝑆1 + 𝑊12 = 𝑆1 + 13 (𝑘𝐺) (3.14)

Resistance in section 2-3
𝑊23 = 0.07𝑆2 = 0.07(𝑆1 + 13) = 0.07𝑆1 + 0.9 (3.15)
𝑆3 = 𝑆2 + 𝑊23 (3.16)
= 𝑆1 + 13 + 0.07𝑆1 + 0.9
= 1,07𝑆1 + 13.9

The resistance force of chute on the load
The resistance force at the entry point on the load with a constant speed of the traction
unit:
46
𝑄𝑣 39.6 × 19
𝑊𝑡 = = = 21 (𝑘𝐺) (3.17)
36 36
Length from chute to load: 𝑙 = 0 (𝑚𝑚)

Resistance force of the guide wall on the load
𝑊𝑚 = 5𝑙 = 5 × 0 = 0 (3.18)
Total resistance when load enters
𝑊𝑣𝑡 = 𝑊𝑡 + 𝑊𝑚 = 0 + 21 = 21 (𝑘𝐺) (3.19)
𝜔𝑙𝑚 = 0.025: Coefficient of resistance to belt movement on rollers with bearings.

𝐿 = 2(𝑚): Transport length of belt
Resistance to belt movement is caused by the mass of loads, belts and rollers.
𝑊𝑐 = (𝑞𝑏 + 𝑞 + 𝑞𝑏𝑡 )𝐿𝜔𝑙𝑚 (3.20)
= (5.85 + 6.138 + 19.7) × 5 × 0.025
= 4 (𝑘𝐺)
𝑆4 = 𝑆3 + 𝑊𝑣𝑡 + 𝑊𝑐 (3.21)
= 1,07𝑆1 + 13.9 + 21 + 4
= 1,07𝑆1 + 38.9
𝜇 = 0.3: Coefficient of adhesion of the drum to the belt. [4]
47
𝛼 = 180°: Angle of the tape on the drum.
Use Euler's quation to consider the relationship between the tension of the input
branch and the exit branch of the transmission drum.
𝑆2 = 𝑆1 𝑒 𝜇𝛼 = 𝑆1 𝑒 0.3×180 (3.22)
Set of equations from quations (3.13), (3.15) and (3.19) and (3.20):
𝑆2 = 𝑆1 𝑒 𝜇𝛼 𝑆1 ≈ 8(𝑘𝐺) (3.23)
𝑆2 = 𝑆1 + 13 𝑆 ≈ 21 (𝑘𝐺)
{ →{ 2
𝑆3 = 1,07𝑆1 + 13.9 𝑆3 ≈ 23 (𝑘𝐺)
𝑆4 = 1,07𝑆1 + 38.9 𝑆4 ≈ 48 (𝑘𝐺)
3.3.4. Check the durability of the belt

The number of fabric layers of the tape is determined by the formula: 𝑖 = 3
𝑆𝑚𝑎𝑥 𝑛𝑜 40 × 95
𝑖=3≥ = ≈ 1.06 (3.24)
𝐵𝑘𝜌 65 × 55
Satisfies the durability condition of the belt. Choose the number belt layers of 3.
3.4. Analyze and calculate the conveyor transmission parts

3.4.1. Motor selection
𝑊0 = 40: Traction force.
𝑉𝑡 = 0.6 (𝑚/𝑠): speed.
𝜂𝑔𝑡 = 0.94: efficiency of the gear box
𝜂 = 0.96: Belt drive efficiency.
Power to drive shaft:
𝑊0 𝑣 40 × 0.6
𝑁0 = = = 0.25 (𝐾𝑤) (3.25)
102𝜂𝑡 102 × 0.94
48
Motor power:
𝑁0 0.25
𝑁= = × 1.8 = 0.468 (𝐾𝑤) (3.26)
𝜂 0.96
Select the motor DB60-01330A6-A with the power of 0.6 (𝐾𝑤) and speed of 3000
(𝑟𝑝𝑚).
3.4.2. Check the durability of the belt during start-up

𝑁𝑑𝑚 = 0.6 (𝐾𝑤): Rated power of the motor.
𝜂 = 0.96: Belt drive efficiency.
𝑘𝑚 = 1.3: ratio coefficient between the starting torque and the rated torque of the
motor.
Force when starting motor:
102𝑁𝑑𝑚 𝜂𝑘𝑚 (3.27)

𝑆𝑘𝑑 =
𝑉
102 × 0.6 × 0.96 × 1.3

=
19
≈ 4 (𝑘𝐺)
𝑘𝑐 = 55 (𝑘𝐺/𝑚): Durability limit of the reinforced membrane layer in the belt.

𝑘𝑛 = 0.75: Belt connection durability coefficient.
𝑘𝑑 = 1 − 0.03𝑖 = 1 − 0.03 × 3 = 0.91 : Uneven working coefficient of the
reinforced membrane layer in the belt.
Check the durability of the belt during start-up (number of layers of membrane
required in the belt).
1.5𝑆𝑘𝑑 (3.28)
𝑖𝑘 =
𝑘𝑐 𝐵𝑘𝑛 𝑘𝑑
49
1.5 × 4
=
55 × 0.65 × 0.75 × 0.91
≈ 0.25 ≤ 3
Sastified condition of the belt durability.
3.4.3. Belt drive selection

According to specification data of V-Belt
𝑛1 = 1300 (𝑟𝑝𝑚) and 𝑃1 = 0.6 (𝑘𝑊), based on Figure 4.1 [5] , select normal V-
Belt with cross section type B
Table 3.1. Technical specifications of V-Belt type B
𝑏𝑡 𝑏 ℎ 𝑦0 A 𝑑1 𝐿
(𝑚𝑚) (𝑚𝑚) (𝑚𝑚) (𝑚𝑚) (𝑚𝑚2 ) (𝑚𝑚) (𝑚𝑚)
14 17 10.5 4 138 140 ÷ 280 800÷6300
Diameter of driven pulley: 𝑑𝑑𝑟𝑖𝑣𝑒𝑛 = 108 (𝑚𝑚)

Slipping coefficient: 𝐾 = 0.98 ÷ 0.99
Choose the transmission ratio of driving part is
𝑢=2 (3.29)
Calculate the diameter of driving pulley
𝐷𝑑𝑟𝑖𝑣𝑒𝑛 108
𝐷𝑑𝑟𝑖𝑣𝑖𝑛𝑔 = = = 54 (𝑚𝑚) (3.30)
𝑢 2
Based on table 4.14 [5], select the ratio 𝑎/𝑑𝐷𝑟𝑖𝑣𝑒𝑛 = 0.85.

According to that, calculate the preliminary value of center distance:
50
𝑎 = 0.85𝑑𝐷𝑟𝑖𝑣𝑒𝑛 = 0.85 × 108 = 92 (𝑚𝑚) (3.31)
Maximum center distance based on condition:
𝑎𝑚𝑎𝑥 = 2(𝑑1 + 𝑑2 ) = 2 × (54 + 108) = 498 (𝑚𝑚) (3.32)
Minimum center distance based on condition:
𝑎𝑚𝑖𝑛 = 0.55(𝑑1 + 𝑑2 ) + ℎ (3.33)
= 0.55(27 + 108) + 10.5
= 99.6 (𝑚𝑚)
Satisfied 𝑎𝑚𝑖𝑛 ≤ 𝑎 ≤ 𝑎𝑚𝑎𝑥

Calculation of belt length
𝜋(𝑑1 + 𝑑2 ) (𝑑2 − 𝑑1 )2 (3.34)

𝐿 = 2𝑎 + +
2 4𝑎
𝜋 × (54 + 108) (108 − 54)2

= 2 × 92 + +
2 4 × 92
= 460 (𝑚𝑚)
Table 3.2. V-belt information
V-Belt 𝑯 𝒉𝟎 𝒕 𝒆 𝝋 𝒃𝟏
type (mm) (mm) (mm) (mm) (degree) (mm)
B 16 4.2 19 12.5 34 17.2
Width of pulleys:
51
𝐵 = (𝑧 − 1)𝑡 + 2𝑒 = (1 − 1) × 19 + 2 × 12.5 = 25 (𝑚𝑚) (3.35)
Outer diameter of driving pulley is
𝑑𝑎1 = 𝑑1 + 2ℎ0 = 54 + 2 × 4.2 = 62.4 (𝑚𝑚) (3.36)
Outer diamter of driven pulley is
𝑑𝑎2 = 𝑑2 + 2ℎ0 = 108 + 2 × 4.2 = 116.4 (𝑚𝑚) (3.37)
3.5. Shaft calculation

3.5.1. Calculate the reactions at the supports
The calculation results in a beam with one movable support and one fixed support.
The moving bearing is the connection between the output shaft of the gear box and the
input shaft of the drum. The fixed bearing is located in the socket of the tang shaft.
The resultant tension of the belt:
𝑅 = 𝑆𝑚𝑎𝑥 + 𝑆𝑚𝑖𝑛 = 𝑆4 + 𝑆1 = 46.540 + 8.5 = 55.04 (𝑘𝐺) (3.38)
Load acts on the hub at points C and D:
1 55.04
𝑅𝐶 = 𝑅𝐷 = 𝑅= = 27.52 (𝑘𝐺) (3.39)
2 2
Reactions at points A and B:
27.52 × 700 + 27.52 × 200

𝑅𝐴 = 𝑅𝐵 = = 27.52 (𝑘𝐺) (3.40)
900
Bending moment D and C:
52
𝑀𝐶 = 𝑀𝐷 = 200 × 27.52 = 5504 (𝑘𝐺. 𝑚𝑚) (3.41)
Torque acting on the drum shaft:
𝑀𝑥 = 𝑖𝑀𝑑𝑚 = 8.6 × 97.45 = 838.07 (𝑘𝐺. 𝑚𝑚) (3.42)
Equivalent moment acting on the shaft:
(3.43)
𝑀𝑡𝑑 = √𝑀𝑥 2 + 𝑀𝑦 2
= √55042 + 838.07 2
= 5567 (𝑘𝐺. 𝑚𝑚)
= 54593.62 (𝑁. 𝑚𝑚)
3.5.2. Calculate shaft diameter

Choose the drum shaft material is 45X steel:
𝜎𝑐ℎ = 430 (𝑁/𝑚𝑚2 )
𝜎𝑏 = 610 (𝑁/𝑚𝑚2 )
𝜎−1 = 250(𝑁/𝑚𝑚2 )
[𝑛] = 1.6: Safety factor.
𝑘 = 2: Stress concentration coefficient.
Allowable bending stress for symmetrical cycle:
𝜎−1 250
[𝜎 ] = = = 78 (𝑁/𝑚𝑚2 ) (3.44)
[𝑛]𝑘 1.6 × 2
At the point of maximum moment:
53
3 𝑀𝑡𝑑 3 54593.62
𝑑=√ =√ = 19.1 (𝑚𝑚) (3.45)
0.1[𝜎] 0.1 × 78
Choose d equal to 20 (𝑚𝑚).
3.5.3. Shaft testing

3.5.3.1. The safety factor only considers normal stress
Maximum bending stress
𝑀𝑢 5504
𝜎𝑢 = 3
= = 6.88 (𝑘𝑔/𝑚𝑚2 ) (3.46)
0.1𝑑 0.1 × 203
𝐴 = 10 (𝑦𝑒𝑎𝑟𝑠): Durability of parts (TKCTM)

𝑘𝑛 = 0.75: Coefficient used in a year.
𝑘𝑛𝑔 = 0.67: Daily usage coefficient.
𝑛𝑡 = 19 (𝑟𝑝𝑚): Number of drum revolutions.
𝐶𝐷 = 0.4: The belt works in heavy mode.
Total working hours:
𝑇 = 24 × 365 × 𝐴𝑘𝑛 𝑘𝑛𝑔 (3.47)
= 24 × 365 × 10 × 0.75 × 0.67
= 44019 (ℎ)
Number of total working cycles:
𝑍0 = 60𝑇𝑛𝑡 𝐶𝐷 = 60 × 44000 × 19 × 0.4 = 20064000 (3.48)
The number of working cycles corresponds to the loads:
54
3 3
𝑍1 = 𝑍0 = × 20064000 = 12038400 (3.49)
5 5
1 1
𝑍2 = 𝑍3 = 𝑍0 = × 20064000 = 4012800 (3.50)
5 5
Equivalent number of working cycles:
𝑍𝑡𝑑 = 12038400 + 4012800 × 0.58 + 4012800 × 0,3 8 (3.51)
= 12054338.28
Working mode coefficient:
8 107
𝑘0 = √ = 0.977 (3.52)
12054338.28
Calculated fatigue limit:
𝜎−1 = 𝑘0 𝜎−1 (3.53)
= 0.977 × 250
𝑁
= 244.25 ( )
𝑚𝑚2
= 24.425 (𝑁/𝑚2 )
𝑘𝜎 = 1: Stress concentration coefficient (smooth shaft).

𝜀𝜎 = 0.7: Size factor.
55
𝛽 = 0.9: Surface quality coefficient (finished surface).
𝜎𝑚 = 0 due to the symmetrical arterial cycle.
Check the safety factor of the shaft:
𝜎−1 24,225 (3.54)

𝑛𝜎 = = = 2.091
𝑘𝜎 𝜎−1 1
𝜎 + 𝜎 7.3
𝜀𝜎 𝛽 𝑢 𝜎𝑏 𝑚 0.7 × 0.9
3.5.3.2. The safety factor only considers tangential stresses.

Torsional fatigue limit:
𝜏−1 = 0.25𝜎𝑏 = 0.25 × 610 = 152.5 (𝑁/𝑚𝑚2 ) (3.55)
Torque resistance:
𝜋𝑑 3 𝑏𝑡 (𝑑 − 𝑡 ) (3.56)
𝑊0 = −
16 2𝑑
𝜋203 12 × 4.5(20 − 4.5)2

= −
16 2 × 20
= 13.617
Amplitude of stress generated in the cross-section of the shaft:
𝑀𝑥 5.036
𝜏𝑎 = 𝜏𝑚𝑎𝑥 = = = 0.369 (𝑁/𝑚𝑚2 ) (3.57)
𝑊0 13.617
𝑘𝜏 = 1: Stress concentration coefficient (smooth shaft).

𝜀𝜏 = 0.7: Size factor.
𝛽 = 0.9: Surface quality coefficient (finished surface).
Check the safety factor of the shaft:
56
𝜏−1 15.25 (3.58)
𝑛𝜏 = = = 9.880
𝑘𝜏 1
𝜏 × 1.014
𝜀𝜏 𝛽 𝛼 0.73 × 0.9
The safety factor only considers normal stress 𝑛𝜎 .

The safety factor only considers tangential stresses 𝑛𝜏 .
Allowable safety factor [𝑛] = 1.5.
Calculate shaft accuracy according to formula:
𝑛𝜎 𝑛𝜏 2.2 × 2.8 (3.59)

𝑛= = = 1,729 > 1.5
√𝑛𝜎 2 + 𝑛𝜏 2 √2.22 + 2.82
So the shaft works safely.
3.6. Summary specification of the mechanical design

3.6.1. Specification of the belt conveyor
Table 3.3. Specification of the belt conveyor
Specification Value
Length (𝑚𝑚) 1085
Width (𝑚𝑚) 830
Height (mm) 515
Belt width (𝑚𝑚) 650
Number of layers 3
Belt thickness (𝑚𝑚) 6.75
Roller diameter (𝑚𝑚) 108
Drum shaft diameter (𝑚𝑚) 20
Productivity (𝑏𝑜𝑥/ℎ) 1980
57
3.6.2. Specification of motor
Table 3.4. Specification of motor
Name DB60-01330A6-A
Power (𝑘𝑤) 0.6
Rated speed (𝑟𝑝𝑚) 3000
Torque (𝑁. 𝑚) 1.91
Rated current (𝐴) 4.8
3.6.3. Specification of belt drive
Table 3.5. Specification of belt drive
Specification Symbol Unit Value

Type - - V-Belt
Cross-section - - 𝐵
The number of belts z 1
Driving pulley diameter 𝑑𝑑𝑟𝑖𝑣𝑒 𝑚𝑚 54
Driven pulley diameter 𝑑𝑑𝑟𝑖𝑣𝑒𝑛 𝑚𝑚 108
Center distance a 𝑚𝑚 470
3.7. 3D model of the mechanical design

3.7.1 Conveyor design
Figure 3.8. 3D model of the mechanical design
58
3.7.3 Load cell cluster design
Figure 3.9. Load cell cluster design
59
CHAPTER 4. ELECTRICAL DESIGN
4.1. Components in the electrical system
Control cluster
Sensor Data
Power Supply
Low – Voltage Photoelectric PLC 1214C

Ampilfier
Power Source sensor DC/DC/DC
Power Source Motor Loadcell
Figure 4.1. Control cluster diagram
In this cluster there are components:

− Load cell cluster and signal amplifier.
− Photoelectric sensors.
− PLC controls digital and analog signals.
4.2. Select electrical parts

4.2.1. Circuit breaker selection
The DB60-01330A6-A motor have power of 0.6W and rated current 𝐼𝑑𝑚 = 4.8(𝐴).
The circuit breaker current is calculated by the formula:
𝐼𝑐𝑏 = 3𝐼𝑑𝑚 = 3 × 4.8 = 14.4 (𝐴) (4.1)
From the calculated result, select the MCB LS BKN-b 3P 16A triple circuit breaker
and MCB Schneider EZ9F34216 16A double circuit breaker.
60
Figure 4.2. MCB LS BKN-b 3P 16A
Figure 4.3. MCB Schneider EZ9F34216 16A
4.2.2. Wire selection

The rated current of the motor is 4.8 A. from table of IEC standard, select the
Conductor Cross-sectional Area is 1 (𝑚𝑚). [6]
61
Figure 4.4. IEC standard Conductor Cross-sectional
62
4.3. Power circuit design
Figure 4.5. Power circuit of AC motor
4.4. Control circuit design

4.4.1. Design load cell and amplifier circuits
The SPS Load cell (30kg) is a single point low profile load cell, designed for floor
scales, belt scales and checkweighing applications. Made from high-quality anodized
aluminum, SPS is a good choice for applications with simple structures.
Figure 4.6. Load cell
63
Load cell specification:
Table 4.1. Load cell specification
Load capacity (𝑘𝑔) 30

Output (𝑚𝑉/𝑉) 2.0 ± 0.2
Linear deviation (%) 0.05
Effect of temperature on (%RO/degree Celsius sensitivity) ≤ ± 0.0131
Temperature influence to zero point (%RO/ degree Celsius) ≤ ± 0.012
zero balance (%RO) ≤ ± 2.0
Input impedance Ω 406 ± 6
Output impedance Ω 350 ± 3
Insulation Resistance (50V) MΩ ≥ 5000
Operating voltage 5V ~ 12V
Load cell amplifier PLCVN-LCA-01A:
Table 4.2. Load cell amplifier specification
Sensitivity 2.0 𝑚𝑉/𝑉 ± 10%

Input signal 𝑚𝑉
Output signal 0~5𝑉/10𝑉&4~20𝑚𝐴
Acuracy 0.1%
Power 24 VDC
Load cell power 5~12V
Capacity Max 4 load cell 350 ohm
Coefficient 100 ppm
64
Wiring diagram between load cell and amplifier:
LOADCELL
RED WHITE BLACK GREEN YELLOW
E+ S- E- S+ SLD
LOAD CELL AMPLIFIER
24V 0V IO V0 COM
PLC S7-1200 PW0
X1 24VDC
X1 0VDC
X1 0VDC
Figure 4.7. Wiring diagram between load cell and amplifier
65
4.4.2. PLC wiring diagram
Figure 4.8. PLC wiring diagram
66
CHAPTER 5. OPERATION, HMI INTERFACE PROGRAMMING
5.1. Operation requirement
Determine the system conditions that need to be operated:
− Press START button on the HMI screen to start the system.
− Press button on the HMI screen to end the operation.
− The conveyor always runs after button START starts pressing.
− The conveyor motor operates continuously with the conveyor belt and is linked to
the same sensor load cell.
− When the workpiece reaches the weighing cluster conveyor and the weighing
sensor receives the signal, the workpiece is weighed and weighed load cell returns
mass data to PLC.
− The HMI screen will display the number of kilograms of the product just weighed.
5.2. HMI interface
Figure 5.1. HMI interface
The HMI include:

− START button to start the system.
− STOP button to stop the system.
− Weights chart display.
− Chart companion.
− The number of weights the load cell can weigh will be displayed in the value box.
67
5.3. PLC connection
5.3.1. Declaration tag for PLC
Table 5.1. Input declaration for PLC
Name Data Type Address Comment

S1 Bool %M0.0 START
S2 Bool %M0.1 STOP
Sensor detects objects entering the

B1 Bool %I0.2
conveyor
Sensor detects objects entering the
B2 Bool %I0.3
weighing surface
Sensor detects objects at the end of
B3 Bool %I0.4
weighing surface
LOADCELL_In int %IW64 Signal from load cell to PLC
Value Real %MD14 Values display
5.3.2. Declaration process tag for HMI
Table 5.2. Declaration process tag for HMI
HMI components Process tag

START button S1
STOP button S2
I/O field Value
Trend control Value
68
5.4. Flowchart
5.4.1. Main program flowchart
+ Start.
+ Press START (S1) to allow the system to operate.
+ Sensor 1 objects.
+ Load cell provides signal.
+ Weighing.
+ Values display on HMI.
69
Figure 5.2. Main Program
70
5.4.2. Weighing flowchart
+ Sensor 2 detects object at the scale surface.
+ Start collect weigh value.
+ Sensor 3 detects object at the end of scale surface.
+ Load cell stops providing signal.
+ Take the average weigh values.
+ Store the average weigh values.
71
Figure 5.3. Data filter flowchart
72
CHAPTER 6. RESULT AND FUTURE DEVELOPMENT
6.1. Result
− Build a model of automated weighing system.
− Build a simple HMI screen interface for users to interact with the tissue image.
− Select mechanical and electrical options suitable for the model.
− Calculate the design in accordance with the project's objectives.
− Test the actual results of the model.
− Deviation within ±30g according to requirements.
6.2. Limitation and improvement

6.2.1. Mechanical manufacturing
Limitations: The design is not too complex for assembling the components together.
But for some part, it takes times to assemble and separate which makes difficulty for
components replacements.
6.2.2. Electrical components

Limitations: The wring in the electrical panel is narrow. It will make the maintenance
work complex.
Improvement: Use wiring duct to wire the electrical components, use tub to label the
wires so that maintenance work can be easier.
6.2.3. Programming
Limitations: Due to the limitation of the device. The TIA portal V17 program
requires the laptop that has high performant. Otherwise, the system error will affect the
simulation, loading program to the PLC process and the result.
6.3. Conclusion and future development

6.3.1 Conclusion
The objectives completed in the project:
− Build a realistic model to automatically measure objects’ weight.
73
− Optimize the model to achieve the highest possible accuracy.
− Build a simple HMI screen interface for users to interact with the model.
− Choose a mechanical and electrical solution suitable for the model.
− Calculate the design suitable for the set project objectives.
− Verify the actual results of the model.
− Deviation within ± 30 g according to the set requirements.
6.3.2. Future development

− Design objects supply conveyor belts to supply objects for the automatic weighing
system.
− Need to redesign the mechanical part to be more precise and neat.
− Need to solve the problem of anti-interference in the scale surface to measure
products more accurate.
74
REFERENCE
[1] VIET NAM INDUSTRIAL AND TECHNICAL GROUP, "intech-group.vn",

https://intechvietnam.com/giai-phap-tu-dong-hoa/day-chuyen-phan-loai-banh-
keo-tu-dong-635/.
[2] N. D. Sơn, Kỹ thuật nâng chuyển tập 2, NXB Đại học Quốc gia TP Hồ Chí Minh,
2014.
[3] Nguyễn Văn Dự , "Hướng dẫn tính toán băng tải", 2011.
[4] P. Đức, Máy vận chuyển liên tục, Nhà xuất bản Giao thông vận tải, 2019.
[5] Trịnh Chất và Lê Văn Uyển, Tính toán thiết kế hệ thống dẫn động cơ khí (Tập
1,2), NXB Giáo Dục, 2006.
[6] ieec.com.vn.
75
III
Scale : III
H
III
He Soc et Button Head Cap Scre

E BOX GSBCB
M Stainless Steel Mitsumi
C WSSA Washer M Aluminum Mitsumi
DA Motor holder Iron Wor shop
II DB A A Motor Caster cuahang attu.com

SLBNP He nut M Stainless Steel Mitsumi
Scale : DA Photoelectric sensor holder Aluminum Wor shop
BRQM DDTA P Photoelectric sensor Aluminum codienhaiau.com
II Rubber eet Rubber T Shop HCM
DA Aluminum rame Aluminum Wor shop
N M He head bolt M Stainless Steel Misumi
I ANN . He nut M Stainless Steel Misumi
Scale : DA
Con eyor belt tension
increaser
Aluminium Wor shop
I E BOX GSBCB
DA Side barrier Aluminium Wor shop
DA Spacer bar Aluminium Wor shop
E BOX GSBCB
E BOX GSBCB
S F BE Angular Ball Bearing Steel Mitsumi
DA Dri ing pulley Aluminium Wor shop
He Soc et Button Head Cap
E BOX GSBCB Stainless Steel Mitsumi
Scre M
DA Dri ing belt Rubber Wor shop
H DA Dri ing roller Aluminium Wor shop
C EG Parallel ey Stainless Steel Mitsumi
DA Dri ing roller holder Aluminium Wor shop
H
DA Dri en pulley Aluminum Wor shop
DA Loadcell holder Aluminum Wor shop
SPS C Loadcell SPS g Aluminum cantoanthinh. n
DA Scale sur ace Aluminum Wor shop
E LBOX FBL He Soc et Flat Head Scre M Stainless Steel Mitsumi
II I TECHNICAL PARAMETERS: LNTN T nut M Aluminium Mitsumi
. Dimensions: mm DA Con eyor belt Rubber Wor shop
. Producti ity: T min DA Dri en roller Aluminium Wor shop
. Ma load eight: g DA Roller holder Aluminium Wor shop
. Net eight: g No. Symbol Name Q.ty Material Notation
. Ma imum load dimensions: mm DESIGN OF AN AUTOMATED Graduation project

Func. Full name Sign Date Quantity Weight Scale
Designer L.T.Dat
MECHANICAL g :
DRAWING Sheet: Total sheet:
Instruct. T. .Hong HCMC Uni ersity o Technology

Mechatronics Engineering
Appro e. T. .Hong
POWER CIRCUIT CONTROL CIRCUIT
L1.1 L1.4
L1 /J3 J11/-X1 24VDC -X1 24VDC
L2.1
L2 /J3 H11/ -X1 0VDC -X1 0VDC
L3.1
L3 /J3
N N
N /J3
RED_1MM^2
BLK_1MM^2 L+:
BLUE_1MM^2 -HMI MTP2200 L+ M
24 VDC INPUT
RED_1MM^2
GRY_1MM^2 M:
PE:
L1.4
L2.1
L3.1
L1.1
N
2L+:
24 VDC OUTPUT
1 3 5 13 21
-F3 1 3
MOTOR OVERT LOAD SWITCH
3RV2011-0BA15 14 22 -F2 2M:
I> I> I> MCB Schneider EZ9F34216 16A 2 4

2 4 6
1M:
-S1
I0.0
1 3 5
-S2
-F1
MCB LS BKN-b 3P 16A 2 4 6
L1.5
I0.1
N1
-B1
L2.2
L3.2
L1.2
I0.2
-T1 -B2
POWER MODULE L1 N
SIMATIC PLC S7 1200 CPU 1214 DC/DC/DC
SIEMEN PM1207 I0.3
1 3 5
-K1 L+ M
RED_1.5MM^2 CONTACTOR -B3
3RT2016-1CN27 2 4 6
3L+: I0.4
BLK_1.5MM^2 BLUE_1MM^2
24 VDC INPUT
BROWN_1MM^2
3M: I0.5
GRY_1.5MM^2
I0.6
GREEN_1.5MM^2
L2.3
L3.3
L1.3
BLUE_1.5MM^2 -K1
L+
+ - Q0.0 I0.7
-X1 0VDC / C14
U1 V1 W1
COIL FOR POWER CONTACTOR
Q0.1 I1.0
Q0.2 I1.1
U1 V1 W1 PE -X1 24VDC / C14
M
-X1 L1 L2 L3 N PE -PE AC MOTOR 0.6 KW -PE
3
Q0.3 I1.2
CEE 3/N/PE~230/400 VAC, 16A, 50Hz
Q0.4 I1.3
Q0.5 I1.4
-AMPLIFIER -LOAD CELL
24 VDC OUTPUT
Q0.6 I1.5
RED
24V E+
WHITE
0V S-
Q0.7 2M
BLACK
IO E-
ANALOG INPUT
Q1.0 AI0 GREEN
V0 S+
YELLOW
COM SLD
Q1.1 AI1
DE IGN OF AN AUTOMATED Gra uation pro ect

CONFECTIONERY BO WEIGHING Y TEM
Func. Full na e ign Date uantity Weight cale
Designer L.T.Dat
ELECTRICAL 1
DRAWING heet 2 Total sheet 4
Instruct. T.V.Hong HCMC University of Technology

Approve. T.V.Hong
Main program Weighing
Weighing
Start
Sensor 2 detect object

at the scale surface
No
Press START button
Start collect weigh

Yes values
Sensor 3 detect object

at the end of scale
Conveyor operates surface
No Load cell stops

Sensor 1 detects providing signal
objects
Yes
Take the average

Load cell provides weigh value
signal
Store the average

weigh value
Weighing
Return
Values display on
HMI
End
DESIGN OF AN AUTOMATED Graduation project

Func. Full name Sign Date Quantity Weight Scale
Designer L.T.Dat
FLOW CHART
DRAWING Sheet: Total sheet:

Appro e. T. .Hong
DESIGN OF AN AUTOMATED CONFECTIONERY BOX WEIGHING
SYSTEM
Design specifications:
- Productivity: 33 box/min
- Weight range: 1kg~20kg
- Box's minimum size: 300x200x200mm
- Box's maximum size: 500x500x300mm
- Error: ±30g
ELECTRICAL MECHANICAL
SELECTI NS SELECTI NS
CEE 3/N/PE~230/400 VAC, C NVE R MECHANISM

16A, 50Hz
P WER
CEE 3/N/PE~220/380 VAC,
16A, 50Hz
BELT
C NVE R
AC motor
M T R
DC motor
S7 1200 CPU 1214 R LLER

DC/DC/DC C NVE R
S7 1200 CPU 1214
C NTR LLER
AC/DC/Rly
S7 1200 CPU 1214
DC/DC/Rly
C NCLUSI N
Capacitive load cell Electrical selection Mechanical selection

L AD CELL
Resistive load cell - CEE 3/N/PE~230/400 VAC, 16A, 50Hz power source is chosen due to
synchronous the new standard of ASIAN countries .
- AC motor is economically efficient, and commonly used for conveyors. Its
torque is not too powerful like DC motor's.
- PLC Siemen SIMATIC S7 1200 CPU 1214 DC/DC/DC is chosen due to its
- Belt conveyor is chosen for its flexibility and ability to carry large
accessibility. Its feature is enough to meet the project requirement.
Through-Beam Sensor volumes of material over long distances. its mechanism meets the
PH T ELECTRIC - Select the load cell resistive load cell for general-purpose,
requirement of the project.
SENS R cost-effective, wide-capacity applications.
Retro-Reflective Sensor - Through-Beam Sensor is chosen for its precise object detection over long
distances, such as safety barriers, perimeter monitoring, and conveyor
systems.
- HMI MTP2200 Unified Comfort is chosen for its capability.
DESIGN OF AN AUTOMATED
MTP2200 Unified Comfort CONFECTIONERY BOX WEIGHING SYSTEM
Graduation project
HMI Func.
Designer
Full name
L.T.Dat
Sign Date
SOLUTION Quantity Weight Scale
KTP700 Basic SELECTING Sheet: Total sheet:

DRAWING
Appro e. T. .Hong

2052438.LeTienDat

Uploaded by

Copyright:

Available Formats

2052438.LeTienDat

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2052438.LeTienDat

Uploaded by

Copyright:

Available Formats

HO CHI MINH UNIVERSITY OF TECHNOLOGY

OFFICE FOR INTERNATIONAL STUDY PROGRAMS

MECHATRONICS GRADUATION PROJECT

Instructor: Ph.D Tran Viet Hong

Figure 1.1. Automated weighing system

1.1.2. Automated weighing system classification

1.2. Automated weighing system

Figure 1.2. Intech’s confectionery automatic weighing system

Table 1.1. Intech’s confectionery automatic weighing system spec

Maximun package size 500x500x300, max weight 𝑚𝑚𝑎𝑥 = 20 (𝑘𝑔)

1.3. Project topic and design scope

2.2. Box supply simulation

Table 2.1. Setting for transportation module

Commodities supply conveyor Commodities recive conveyor

Figure 2.1. EDEM simulation

Figure 2.2. Load cell placement

2.3.2. Electrical components

Figure 2.4. Electrical components

2.3.3. Load cell error

2.3.4. Experiment result for box with weight of 0.5 kg

Table 2.3. 0.5 kg box measure result

Table 2.4. Average motion values of 0.5 kg box

2.3.5. Experiment result for box with weight of 1 kg

Table 2.5. 1 kg box measure result

Table 2.6. Average motion values of 1 kg box

2.3.6. Experiment result for box with weight of 2 kg

Table 2.7. 2 kg box measure result

Table 2.8. Average motion values of 2 kg box comparation

2.3.7. Error calculation and conclusion

Table 2.10. Motion values and static values of 1 kg box comparation

Table 2.11. Motion values and static values of 2 kg box comparation

Average weighing Average Average weighing

0.010 0.044 0.070 0.041

2.4. Mechanical selections

Figure 2.8. PVC rubber belt conveyor

Figure 2.9. Roller Conveyors

2.4.2. Select conveyor frame

2.4.3. Select conveyor rollers

2.4.4. Select transmission for conveyor

Figure 2.10. Belt drive

Figure 2.11. Chain drive

2.5. Electronic selections

Table 2.13. Motor comparison

2.5.2. Load cell selection

Capacitive load cell:

Table 2.15. Technical Specifications

Accuracy Class Units OIML R60 C4

2.5.3. Placing the load cell method

2.5.4. Controller selection

Table 2.16. Types of PLC S7-1200

SIMATIC S7-1200 Product Description

PLC SIMATIC S7-1200’s Sign board

Table 2.17. PLC SIMATIC S7-1200’s Sign board

2.5.5. Photoelectric Sensor selection

2.5.6. HMI selection

SIMATIC HMI MTP2200 specification:

Table 2.18. SIMATIC HMI MTP2200 spec

Design MTP2200 Unified Comfort

Figure 3.1. Principle diagram of conveyor

3.1.1. Input parameters