PLC Controlled Automated Multiple Conveyor System For Sorting Process

IDL - International Digital Library Of
Technology & Research

Volume 1, Issue 7, July 2017 Available at: www.dbpublications.org
International e -Journal For Technology And Research-2017
PLC Controlled Automated Multiple

Conveyor System for Sorting Process
Rakshak T.B. Mr. Shivashankara B. S.
P.G. Student Assistant Professor
Depart ment of Mechanical Engineering , Depart ment of Mechanical Engineering
Malnad College of Eng ineering, Hassan, India Malnad Co llege of Engineering, Hassan, India
Abstract 1. Introduction
A specialized co mputer used for the control and The PLC is a device with microcontroller that
operation of manufacturing process and machinery monitors the input/output circuitry status. In the
is programmable Logic Controller (PLC). To store proposed system sensor (inputs), actuators, Motors
instructions it uses a programmab le memory. And (output). A Ladder logic program stored in the
on/off control, timing, counting, sequencing, memo ry, wh ich gives the commands to do the
arith metic, and data handling are the functions to required tasks. PLCs are armored for severe
be execute. To expand and enhance production condition (dust, moisture, heat, cold, etc) the
Programmab le Logic Controllers (PLC) is used in extensive input/output (I/O) arrangement is the
almost every aspect of industry. , a single PLC can main difference fro m other co mputers. The facility
be programmed as an efficient replacement where for the positions of complex positioning systems.
hundreds or thousands of electromechanical relays Motors, pneumatic or hydraulic cylinders, magnetic
are used in older automated systems. Sophisticated relays or solenoids, or analog outputs are operated
motion control, process control, distributive control by PLC.
systems, and complex networking are The PLC 2. Lite rature survey
Functions.
Babita Nanda, Delta plc is a basic type of plc used
PLCs provide many Benifits Co mpare to the
for small scale applications. It has 8 inputs and 6
conventional relay type of control Accuracy,
outputs. It has a 24v input slot which acts as a
reliability. Co mmun ication capabilities, faster
power source for delta plc. It also has a USB slot
response time, lower cost, and convenience to
which is used to run the program on the plc. A very
troubleshoot. The paper is based on systematic
commonly used method of programming PLCs is
conveyor controller programming by
based on the use of ladder diagrams. Writing a
programmab le logic controller using PLC offers
program is the equivalent to drawing a switching
user-friendly software and variety of expansion
circuit. The ladder diagram consists of two vertical
options. Increased more flexib ility, Durability,
lines representing the power rails. Circu its are
Maintanance.
connected as horizontal lines, that is, the rungs of
IDL - International Digital Library 1|P a ge Copyright@IDL-2017


the ladder, between these two vertical lines. In reduces the efforts of the workers by reducing the
drawing a ladder d iagram, certain conventions are time spent for material handling. The application
adopted implementing of Delta PLC for shorting of area of this machine is very wide in industries
mach ine has greatly reduced the complexity where automat ion is built [3].
involved in completing this project. Every
production unit of mass production can make use of Ganesh B.Shinde, Vishal P.Ghadage, Akshay A.
this king of system. Many more industries can be Gadhave, and Dr.D.k.Shedge In industry the
identified for the application of the system [1]. production speed should be high because the
Chitra.S, and Vijaya Raghavan, PLCs are well- demand of the product is more. But when we check
adapted to a range of automation tasks. These are weight of the object manually then it will take more
typically useful in industrial processes in time fo r checking the weight and overall speed the
manufacturing where the cost of developing and production will decrease. So by using this auto
maintaining the automation s ystem is high relative weighing control system we totally overco me this
to the total cost of the automation, and where problem.PLC will handled all the operation
changes to the system would be expected during its regarding the weight of the job. And operate the
operational life. PLCs contain input and output pneumatic cylinder according to the weight of the
devices compatible with industrial pilot devices and job. The pneumatic cylinder will remove the faulty
controls; little electrical design is required, and the job fro m the conveyor belt and pass the accurate
design problem centres on expressing the desired job successfully [4].
sequence of operations in ladder logic (or function
chart) notation. PLC applications are typically Shreeya V, Ku lkarni Swat i R, Bhosale Priyanka P,
highly customized systems so the cost of a Bandewar, G.B.Firame, Kashibai Nava In most of
packaged PLC is low co mpared to the cost of a the industries the sorting system runs by PLC
specific custom-built controller design. On the which is expensive and only can be used in large
other hand, in the case of mass -produced goods, industries. This system is less expensive as
customized control systems are economic due to microcontroller is used. The system is compact and
the lower cost of the components, which can be quick in operation so can be used in small scale
optimally chosen instead of a "generic" solution, industries, ware houses, currier services . Raspberry
and where the non-recurring engineering charges pi is used so the controlling is easy and effective.
are spread over thousands of places [2]. The response time of raspberry pi is less so image
detected and decoded in short period of time. The
Sanjay Prakash Dabadea, Rohan Prakash Chumble sorting speed is 12 box/ min i.e. 720 bo x/ hour, it is
The automatic sorting machine using conveyor belt faster than existing system [5].
is basically useful for sorting the products in the
industry specifically large scale industries where G. Sujatha, and V. Perasiriyan, The designed
mass production is carried out. The machine also conveyor sorting module can be used for different


logics that can be applied in conveyer sorting. To acts as a learning tree. Co mments that which ration
sense the object and sort the small one to Right bin, item he is going to buy [7].
Large one to middle bin and Medium one to centre
bin. To sense the object only the mediu m size Kunhimohammed.C.K, Muhammed Saifudeen
object to centre or left or right bin and if small or K. K, Sahna S, Go kul M . S and Shaeez Us man
big object is sensed stop conveyer-2 immediately Abdulla. They have developed a sorting machine
and blink Cycle on LED DO-0 at interval. Once the using PLC for auto matic colour sorting, taking in to
object is removed fro m the conveyer, stop blinking consideration three colours namely Green, Red and
and wait to accept the Object Loading again. To Black. It consumed two months to produce the
sort only Small and Medium height Object so that prototype with the expense of Rs.2000. It may
once the big object is sensed stop the conveyer. To note that the green object and the red object lying
sort the Small object 4 nos, Medium object 4 nos. in different sections of the container placed on the
and big object 4 no. to the bin and stop sensing till second conveyor belt [8].
reset button is sensed. To sort the objects in 3. Block Diagram and Flow Chart
ascending order according to the size and stop the
conveyer if the sequence is wrong [6].
Vitthal G. Chikte, Priyanka D. Ughade. They have
tried best to create a setup that will decrease human
effort and succeeded to an extent by using the low
cost automation system (LA C).Avoid risk at
hazardous places, improve accuracy, and increase
speed of production. Limitations will be there due
to the practical difficu lties in programming of the
project according to the availability of the materials
and components. The setup can be further
improved to a Sort ing system that sorts the items
based on the colour and height simultaneously.
This can be achieved using the sensors that can
emit light radiat ion of different wavelengths. In
industry it can be used for sorting of various
objects, tools, with high degree of accuracy and
quality with an automation. Operations in food
processing industries which used to be carried out
under totally hygienic conditions from the report
have gained knowledge to some extent and thus it


4.Components Required
4.1 Pro ximity Sensors
4.2 IR Sensors
4.3 PLC
4. 4 Pneumat ic actuators (Cylinders)
4.5 Conveyor Motors
6. Conveyor Belts.
Flow Chart
Fig.2 Flow Chart


4.1 Proxi mity sensors
These are used to detect metals. In the proposed

system the proximity sensors are fixed at the first
position.
Fig.3 Structure of an inducti ve proximi ty sensor Fig.5 PLC kit [13]

[13]
4.4 Pneumatic actuators (Cylinders)
4.2 IR sensors
The cylinder acts as an output devices which are
These are used to sense the Non-metals. The used to push the work samples to the conveyors
working principle is as shown in the fig.3 which are attached to the main conveyor.
Fig.6 Cylinder [13]
4.5 Conveyor Motors
Motor is an electric device which converts

Electrical energy into mechanical Energy. In the
proposed system the mechanical force is used to
move the conveyors.
Fig.4 IR Sensor [4]
4.3 Programmable l ogic controller
This is used to interface the inputs and output

Devices. The ladder logic circuit is used to Fig.7 Pulley and DC Motor in the Prototype
interface Process. (PLC) [13]
4. 6 Conveyor Belts

Fig.8 (a) Belts of Conveyor, (b) Belts of

Conveyor wi th Pulley [13].
These are used to move the work samples Fro m

initial position to final position.
5. 3D-Modelling
Fig.9 (b) Isometric View of a Model
Fig.10 Front view of a model
Fig.9 (a) Isometric View of a Model


main conveyor. Second conveyor is for Metals.
Third Conveyor is for Non-metal. The four and five
conveyor moves after filling of four wo rk samples.
6. Ladde r Logic Diagram

PROGRAM PLC_PRG
0003 VAR
0004 Stsrt AT %IX0.0: BOOL;
0005 Hold: BOOL;
0006 S1 AT %IX0.1: BOOL;
0007 Main_motor AT %QX0.0: BOOL;
0008 Inductive AT %IX0.2: BOOL;
0009 Photlectric AT %IX0.3: BOOL;
Fig.11 Top view 0010 T1: Tp;
0011 T2: TP;
0012 cylinder1_solenoid AT %QX0.1: BOOL;
0013 Cylinder2_solenoid AT %QX0.2: BOOL;
0014 Conveyor3_sensor AT %IX0.4: BOOL;
0015 C1: CTU;
0016 Conveyor5 AT %QX0.6: BOOL;
0017 T4: TP;
0018 Conveyor2_sensor AT %IX0.3: BOOL;
0019 C2: CTU;
0021 T5: TP;
0022 T6: TP;
0024 T7: TP;
0026 T3: TP;
0027 dummy1: INT;
0028 dummy2: INT;
0029 Stop AT %IX0.6: BOOL;
0030 Trigger1: F_TRIG;
Fig.12 Side view 0031 Trigger2: F_TRIG;
0032 END_VAR
The two conveyors are attached to the main
conveyor. The pro ximity sensor is attached to the
first conveyor to detect Metals. The IR Sensor is
attached to the second conveyor to detect the Non-
metals. Two sensors mentioned above acts as the
input components. The two conveyor motors and
the Pneumatic actuator (cylinder) acts as output
components. PLC is used to interface the input and
output components to get the final result. The
Ladder Logic Circuit is written to interface the
mach ine with PLC. The timer is used for the each
work samp le time requirement to co mplete the task.
The counter is used to calculate the time required to
fill the empty boxes. The First Conveyor is the


7. Proposed Actual Model Images
Fig.14 Top view of a proposed model.
Fig.15 Front View of a proposed Model
Fig.16 Side View
8. Conclusion
The developed Model sorts Metals and Non-metals

by using PLC. The Proposed Model is Economical
user friendly, Lo w cost, high accuracy, Reliable.
Fig.13 Ladder Logic Di agram


References Journal for Scientific Research & Develop ment,
Vo l. 4, Issue 04, 2016, pp.57-58.
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[8]. Mr. A kshay K. Naphade, Prof.Manish J.
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PLC Controlled Automated Multiple Conveyor System For Sorting Process

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International e -Journal For Technology And Research-2017