Arrangement of Nozzle Using Smart Automation

Arrangement of Nozzle By using Smart Automation
Abstract
Recent trends in automation are characterised by geographical distribution and functional
integration. On the technical level, the goal is to easily connect devices and software
components from different vendors. Functionally, there is a need for interoperability of
control functions on different hierarchical levels ranging from field equipment to process
control, operations management and various Internet-based service applications.This
project report discusses control system platform that supports the reuse of both system
and application software. The working hypothesis is that next generation control systems
will be a combination of new information technology and the domain-specific concepts
found in process automation. The application area is industrial automation, including
both process industries (continuous and batch) and discrete manufacturing. In addition,
similar applications in other areas, such as environmental monitoring or distributed
energy production, have been kept in mind. As this report is an outcome of a research
project, the focus lies on concepts and system architectures rather than on hardware
issues. To make it more useful however, also selected new implementation technologies
have been described.The discussion starts from business and technological trends and
their implied requirements for future control systems. Then we introduce the conceptual
model of a conveyor belt control platform. Only general ideas of their implementation are
given. Based on these concepts, the application needs and middleware architectures
related to local-area distribution are analysed. Also a review of a few Ethernet-based
communication standards is included. This emphasises the role of remote monitoring,
dataacquisition, and business-level services. In terms of implementation technology,
service-oriented architectures and communication over public networks become more
important. This report also describes a prototype implementation that was developed to
clarify the suggested concepts and to evaluate some technical solutions. The final section
sums up the key findings and ists areas that would need further research.
SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 1

1. INTRODUCTION:
Automation, a Greek word means self dedicated Automation is the key to modernization
and has been conceptually understood as a way to increase efficiently and to improve
productivity. The process of having machine follow a predetermined sequence of
operationwith little or no human labor, using special equipment and devices that perform
and control manufacturingprocesses is known as automation. The goals of automation are
Integration of various aspects of manufacturing operations toreduce labor cost. The
fundamental constituents of any automated process are (1) a power source, (2) a feedback
control mechanism and (3) a programmable command.Today, technology has become an
integrated part of people's lives. It has, and continues to influence many aspects of daily
life and has allowed better social interaction, ease of transportation, the ability to indulge
in entertainment and media and has helped in the development in medicine. The creation
of many devices such as mobile phones and computers have caused many people to rely
on technology to communicate with their friends, store information such as pictures,
movies, documents, and music . The internet has become a common interface that many
devices use in order to simplify the daily life of many people. The Internet has given
people the ability to search for information, store their own information in the cloud
while also giving them better ways of managing information.

1.1 PROBLEM STATEMENT
1) The industries like bosch are facing a problem to arrange the nozzle bodies in a tray
with minimum time span and with minimum effort, so we introduce a solution of
smart automation which are a doing same work in less time with more efficiently than
the traditional system.
2) Sequence and proper storage of product. This gives the company more control of
their manufacturing process , for example, it allows them to set up conditions when
there is no person for supervision or if they are on their way , Therefore, industrial
automation can simplify many manual actions.
1.2 Objectives
Companies undertake projects in manufacturing automation and computer-integrated

manufacturing for a variety of good reasons. Some of the reasons used to justify
automation are the following:
1. To increase labor productivity.Automating a manufacturing operation usually increases
production rate and labor productivity.This means greater output per hour of labor input.
2. To reduce labor cost. Ever-increasing labor cost has been and continues to be the trend
in the world’s industrialized societies. Consequently, higher investment in automation has
become economically justifiable to replace manual operations. Machines are increasingly
being substituted for human labor to reduce unit product cost.
3. To mitigate the effects of labor shortages.There is a general shortage of labor in many
advanced nations, and this has stimulated the development of automated operations as a
substitute for labor.
4. To reduce or eliminate routine manual and clerical tasks. An argument can be put forth
that there is social value in automating operations that are routine, boring, fatiguing, and
possibly some.Automating such tasks serves a purpose of improving the general level of
working conditions.
5. To improve worker safety. By automating a given operation and transferring the
worker from active participation in the process to a supervisory role, the work is made

safer. The safety and physical well-being of the worker has become a national objective
with the enactment of the Occupational Safety and Health Act (OSHA) in 1970.This has
provided an impetus for automation.
6. To improve product quality.Automation not only results in higher production rates than
manual operations; it also performs the manufacturing process with greater uniformity
and conformity to quality specifications. Reduction of fraction defect rate is one of the
chief benefits of automation.
7. To reduce manufacturing lead time.Automation helps to reduce the elapsed time
between
customer order and product delivery, providing a competitive advantage to the
manufacturer for future orders. By reducing manufacturing lead time, the manufacturer
also reduces work-in-process inventory.
8. To accomplish processes that cannot be done manually. Certain operations cannot be
accomplished without the aid of a machine.These processes have requirements for
precision, miniaturization, or complexity of geometry, that cannot be achieved manually.
Examples include certain integrated circuit fabrication operations, rapid prototyping
processes based on computer graphics (CAD) models, and the machining of complex,
mathematically defined surfaces using computer numerical control.These processes can
only be realized by computer controlled systems.
9. To avoid the high cost of not automating. There is a significant competitive advantage
gained in automating a manufacturing plant. The advantage cannot easily be
demonstrated on a company’s project authorization form.The benefits of automation
often show up in unexpected and intangible ways, such as in improved quality, higher
sales, better labor relations, and better company image. Companies that do not automate
are likely to find themselves at a competitive disadvantage with theircustomers, their
employees, and the general public.

1.3 Methodology
1.3.1 Equipment model
Knowing the current trends in computing power, data transmission and functional
integration it is reasonable to suppose that future control systems are highly distributed.
There is a mixture of computing resources varying from intelligent field devices and
embedded controllers withlimited capabilities to high-end process controllers and
workstations. These computing nodes are connected by a wired or wireless
communication network. Obviously, there is a need to combine different types of
hardware and communication techniques. Logically however, they should all provide
homogenous computing environment to enable full exploitation of the component
paradigm.
In the following, the term control system refers to a set of hardware and software
designed and installed to serve a specific application, such as a production line in an
industrial plant. As a distinction, control products are pieces of commercial hardware,
software, services or combinations of them, provided by a manufacturer. When
appropriately put together, control products from one or more suppliers form the basis for
the customer.s application, i.e. an automation platform in our terminology.

Physical components of a control system.
The total control system domain is hierarchically decomposed into system areas each
consisting of a set of device units (control computers) and the necessary network
components (e.g. switches
and firewalls). The hardware and basic software (e.g. operating system) of a device unit,
in turn, provide the computing resources for one or more logical nodes that finally act as
the runtime environment of automation components.
In our typical scenario, a control system consists of a rather large number of computers.
The purpose of the system itself and the subsystems defined by system areas is to provide
well-defined domains for system management and protection. For example, a control

engineer can be made responsible for a given system area, such as the .wet end. section in
a paper machine control system. This makes it possible to report systemrelated events
like device faults as alarms directly to the named person and to suppress events from
other parts of the system. In addition, system areas can be used to specify the authorities
of each control engineer to make modifications.
1.3.2 Automation components

In our vision, automation components are self-contained pieces of software that can be
combined and placed for execution in the logical nodes of a control system. To make this
possible, there should be widely accepted standards for both the runtime environment and
the engineering tools used for adapting and connecting components available from
various suppliers. The following discusses, disregarding any technical details, the abstract
functionality of automation components as seen by a future application designer.
Automation components are both reactive and proactive entities, whose behaviour is
defined by their responses to external events and their internal activities. The external
component interface is modelled as input and output ports that are .wired. to each other
during design stage (Figure 16). An algorithm can be specified to process new messages
received at an input port. The proactive behaviour of a component refers to internal
algorithms that are cyclically executed. If no handler routine is attached to a port, the
incoming message is just stored for later use. As a result, the model gives the designer the
possibility to build both event-driven and cyclically running applications.
An additional way for engineers to adapt library components and to control their
behaviour
is provided by component properties. Properties can also be used to store product
information, runtime statistics, etc.

A minimal set of interaction mechanisms.
1.3.3 Interactions between automation components
This section describes the most important component interaction mechanisms and their
intended uses in a distributed environment. The material in this section is generic in the
sense that it does not make assumptions about application design or implementation. The
issues discussed include general interaction patterns, i.e. continuous data distribution,
event-based data distribution, services and notifications. The focus is on the functional
views seen by the application designer.
A number of interaction principles can be found in computer systems and automation
technology examples of the most common mechanisms. It is desirable tominimise the
number of mechanisms. Yet it is not possible to make any strict recommendation here,
since the need for communication mechanisms varies depending on design practices,
standards and technologies used. The following sections give our suggestion that is
limited to three basic mechanisms, data distribution (continuous and event driven),
content-based event notifications and request-reply services. No existing product satisfies
these requirements in full. This is discussed in section when the implementation level
mechanisms of individual middleware standards and products are described.

1.4Organisation of Disseration
The division of dissertation divided into mainly five parts. The experimental work based
on automation of arranging nozzle bodies in tray by using plc programming and conveyor
belts.
The relation between the work environment ,The automation and the workers is defined
and the future scope of automation, its implementation methods and properties of
automations,hydraulic and pneumatic systems are presented in this report.
Chapter I
This chapter is related to selection of automation methods according to need of

implementation and the problem statement,It describes the fuel properties of automation.
It presents automation demand and future scope, Concepts of a component-based control
system,Component software in automation, Methodology and Equipment model
Automation components .The Interactions between automation components is described.
Chapter II
It is related to literature review and problem formulation. Extensive literature on

automation in industries and properties of automation are reviewed. Later in this chapter
objectives and problem formulation are described. An overview of research work in the
field of automation with relation to mechanical and programming methods is presented in
the chapter.
Chapter III
This chapter describes the simulation work done in the project. The basic initial ideas,the
brainstorming sessions and actual implementation of final ideas. Collecting the results

and applying these in practice.Use standardization procedure parameters for automation,.

The chapter includes the trials for maximum automation in less time by varying various
parameters of process.
Chapter IV
This chapter deals with the experimental work using process implementation decided in
previous simulation work and the results are plotted and collected and the devices ,their
use and plant operation is listed. It also deals with the many field of application where
automation can be used.
Chapter V
This chapter deals with conclusions. Conclusions regarding automation process including
mechanical and programming and extensive research on this topic and its implementation
in industries.

2. LITERATURE REVIEW
2.1 Introduction
A large work has been done on different aspects of automation in industries. Extensive
literature on automation in industries and properties of automation are reviewed. Later in
this chapter objectives and problem formulation are described. An overview of research
work in the field of automation with relation to mechanical and programming methods is
presented in the chapter
2.1 Teemu Tommila, Juhani Hirvonen, Lauri Jaakkola, Jyrki Peltoniemi, Jukka
Peltola, Seppo Sierla & Kari Koskinen
Described Next generation of industrial automation and Concepts and architecture of a

component-based control system. This mainly includes industrial automation, control
architecture, component-based control systems, local-area distribution services,
information technology, domain-specific concepts, process automation, discrete
manufacturing, systems architecture, implementation The research report at hand is a
result of three consecutive projects sharing a common theme and the short name
.OHJAAVA.. They were carried out by VTT Industrial Systems and the Helsinki
University of Technology during 2001.2004 as a part of the .Intelligent automation
systems. technology programme (ÄLY in short) organised by the National Technology
Agency, Tekes. The following Finnish companies participated in the projects: JOT
Automation (currently part of Elektrobit Group Oyj), Vacon Oyj, Raute Precision Oy,
Vaisala Oyj and Metso AutomationThe aim of the three OHJAAVA projects was to
define functional concepts and implementation architectures for future automation
platforms. The first one started from the basic idea of reusable .automation components.
on a single computer node. The second project, called OHJAAVA-II, aimed to analyse
the required interaction mechanisms and communication models in more detail. In

addition, a number of emerging Ethernet-based distribution middleware solutions for

local area control networks was evaluated. Finally, the OHJAAVA-III project focussed
on geographically distributed applications. This scope emphasised the role of remote
monitoring, data acquisition and maintenance services in addition to basic process
control. Consequently, the possible applications of such systems go beyond traditional
industrial automation, including for example, environmental monitoring, mobile working
machines and distributed energy systems. While the Java language and related
technologies were initially the key implementation technology of the OHJAAVA
platform, the emphasis gradually shifted towards more generic functional principles.
However, a number of limited Java demonstrations were developed during the projects
for testing and clarifying the basic concepts. This report summarises the key findings of
the three projects. More detailed discussions can be found in the three master.s thesis
produced during the projects. We hope that this report gives the reader some insights to
the state-of-the-art and future directions ofdistributed control systems. We also wish to
express our gratitude to the representatives of the participating Finnish companies, as
well as to Tekes for making this work possible.Espoo, May 2005,
2.2 Gavali Amit Bhimrao, Patil Mahadev S
Studied how the present automation system comes in to existence through its various
stages. In the past, automation is done through relays and contactor logics. Since the
human intervention is more, the scope of errors was also more. But with the advent of
microprocessors & microcontrollers several new tools as PLCs (Programmable Logic
controllers) come in to use. These have reduced human intervention. Which in turn has
increased accuracy, precision and efficiency.
Automation tools:
I. Relays and contactor logic
II. Programming logic controllers (PLC)
The relay, which operates much like a solenoid, is an electromagnetic device that consists
of a coil with a soft iron core and electric contacts mounted on, but insulated from, the

moving armature or plunger. The relay allows one circuit to control another. Relay
Operation:When current is supplied to the coil, the resulting magnetic field pulls the
armature and the contacts toward the coil. The relay is in energized position when the
armature is fully seated. Contacts that were open are now closed. These contacts are
referred to as the normally open (NO) contacts. Contacts that were closed are now open.
These contacts are called the normally closed (NC) contacts. In an automated system, a
PLC controller is usually the central part of a process control system. With the execution
of a program stored in program memory, PLC continuously monitors status of the system
through signals from input devices. Based on the logic implemented in the program, PLC
determines which actions need to be executed with output instruments. Most
disadvantages of a classic control panel are too much work required in connecting wire,
Difficulty with changes or replacements, Difficulty in finding errors; requiring skillful
work force, When a problem occurs, hold-up time is indefinite, usually long.
2.3 Rahul Pawar , Dr. N. R. Bhasme
Described the application of PLC’s for Automation of Processes in Industries and stated
that Several industries utilize sequential industrial process which is respective in nature.
For such processes industries have to depend upon use of relays, stepping drum, timers
and controls, considerable difficulties experienced in reprogramming necessitated due to
change in the nature of production. Often the whole system has to be scrapped and a
redesigning is required. To overcome these problems PLC control system was
introduced. The PLC can be described as a control ladder comprising a sequence
program. PLC sequence program consists of normally open and normally closed contacts
connected in parallel or in series. It also has relay coils, which turns ON and OFF as the
state of these contacts change. In this paper, about all aspects of these powerful and
versatile tools and its applications to process automation has been discussed.This includes
Automation, Programmable Logic Controller (PLC), Programming Languages, Process
Automation. With the upcoming technologies and availability of motion control of
electric drives, the application of Programmable Logic Controllers with power electronics
in electrical machines has been introduced in the development of automation systems.

The use of PLC in automation processes increases reliability, flexibility and reduction in
production cost. Use of PLC interfaced with power converters, personal computers and
other electric equipment makes industrial electric drive systems more accurate and
efficient. PLCs have been gaining popularity on the factory floor and will probably
remain preponderant in coming years. Most of this is because of the advantages they
offer.They found out following advantages
 Cost effective for controlling complex systems.
 Flexible and can be reapplied to control other systems quickly and easily.
 Computational abilities allow more sophisticated control.
 Trouble shooting makes programming easier and reduce downtime.
 Reliable components make these likely to operate for years before failure.
2.4 ANTONIO SORIN TASU
Stated The purpose of this Programmable Logic Controller (PLC) is to command 16

relays in different sequences programmed by user. This device is appliable for controlling
and monitoring industrial processes and may be implemented in multiple domains, from
auto industry and home control applications to industrial instruments, remote sensors and
security devices. It’s also ideal for battery powered devices because it’s low power
consumption. EEPROM memory make easier the implementation of the microcontroller
on devices where permanent memory is needed to store different parameters (codes for
transmitters,motor speed,receiver frequencies). The controller can be used in small
industry in controling and monitoring industrial processes. Depending of the programmed
software, the device can 1) command a packing line 2) count the products from a
industrial process line and display the result on any kind of display, and 3) communicate
with dedicated PLC’s using digital level shifters. This includes Programmable Logic
Controller, EEPROM.

PLCs (programmable logic controllers) are the control hubs for a wide variety of
automated systems and processes. They contain multiple inputs and outputs that use
transistors and other circuitry to simulate switches and relays to control equipment. They
are programmable via software interfaced via standard computer interfaces and
proprietary languages and network options. The development of low cost computer has
brought the most recent revolution, the Programmable Logic Controller (PLC). The
advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls. PLCs have been gaining popularity on the factory floor and will
probably remain predominant for some time to come. Most of this is because of the
advantages they offer. Are flexible and can be reapplied to control other systems quickly
and easily, computational abilities allow more sophisticated control, reliable components
make these likely to operate for years before failure. This controller can command up to
16 relays on two 8 bits external ports, these outputs take values depending of the 6 inputs
(F1-F6) states. Ports X and Y states are displayed on a 16 characters, 2 lines matricial
LCD display.
The data memory is partitioned into multiple banks which contain the General Purpose
Registers and the Special Function Registers. Bits RP1 and RP0 are the bank select bits.
Each bank extends up to 7Fh (128 bytes). The lower locations of each bank are reserved
for the Special Function Registers. Above the Special Function Registers are General
Purpose Registers, implemented as static RAM. All implemented banks contain Special
Function Registers. Some frequently used Special Function Registers from one bank may
be mirrored in another bank for code reduction and quicker access.
2.5 Giorgio Figliolini and Pierluigi Rea
Described the teaching activity on the design and test of pneumatic and electro-
pneumatic systems, which is carried out at the University of Cassino in Italy, since the
academic year 1994 / 95. In particular, the design and test of a vacuum gripper and an
automatic packaging machine, are proposed as examples of components and systems

operating in on/off environment. Likewise, a proportional pressure valve and a robotic

automatic packaging are presented as examples of components and systems operating in
analogue environment for the production automation.
Pneumatic and electro-pneumatic components find several applications in the industrial
environment mainly to solve problems of product automation. Most of the applications
are in the field of the low-cost automation because the traditional pneumatic and electro-
pneumatic components are conceived to work in on/off environment. In particular, a great
development of the electro-pneumatics has been due to the development of the
electronics, which has given many other solutions in terms of sensors, controllers and
mechatronic devices. Moreover, the electro-pneumatics is not only on/off, but several
analogue components can be found, as proportional valves in pressure or flow, which can
be used to design suitable servo-systems with good static and dynamic performances.
Some books dealing with pneumatics and electropneumatics can be found in literature, as
reported in but also a research activity can be found, as in. In particular, the design of a
biped walking robot with pneumatic actuation was proposed in some electro-pneumatic
force control systems for gripper and robotic hands were proposed in , and the modeling
and experimental investigation of electropneumatic components were reported in. This
paper deals with the teaching activity on the design and test of pneumatic and electro-
pneumatic systems, which has been carried out within the course of “Regulation and
Control of Mechanical Systems” for mechanical engineers at the Faculty of Engineering
of the University of Cassino in Italy, since the academic year 1994/95. In addition,
according to the reform of the Italian University, the courses of “Fluid Automation” and
“Fluid Servo-Systems” have been conceived and activated since the academic year
2003/04 for mechanical engineers at the same Faculty, which are given at last year for
undergraduates and graduates, respectively. Moreover, although after a suitable
simplification, the contents of these courses are continuously improved and implemented
of new results, which are obtained by a strong theoretical and experimental research
activity on these topics, as reported in [7-13]. The course of “Fluid Automation” deals
with the fundamentals of the digital pneumatics and electropneumatics, since the analysis
of components, as actuators, valves and sensors, up to the design and control of automatic

systems in on/off environment. ,All this theoretical teaching activity is supported by a

consistent practical activity, which is carried out at LARM (Laboratory of Robotics and
Mechatronics) in Cassino because of suitable test-beds. Hard-wired logic systems with
pneumatic and relay technologies are designed, assembled and tested, while different
automatic cycles are obtained through suitable programming of PLCs. In particular, the
design and test of a vacuum gripper and an automatic packaging machine, are proposed
as examples of components and systems operating in on/off environment. Likewise, a
proportional pressure valve and a robotic automatic packaging are presented as examples
of components and systems operating in analogue environment of the production
automation.
2.6 Tushar Jain and Meenu
Studied Automation and Integration of Industries through Computer Vision

Systems.Computer vision is the enterprise of automating and integrating a wide range of
processes and representations used for vision perception. It includes many techniques that
are useful by themselves, such as image processing (transforming, encoding, and
transmitting images) and statistical pattern classification (statistical decision theory
applied to general patterns, visual or otherwise). Moreover, it also includes techniques for
geometric modeling and cognitive processing. The field of computer vision may be best
understood by considering different types of applications. Many of these applications
involve tasks that require either work in a hostile environment, a high rate of processing,
access and use of large databases of information, or are tedious for people to perform.
Computer vision systems are used in many and various types of environments – from
manufacturing plants, to hospital surgical suits, and to the surface of Mars. For example,
in manufacturing systems, computer vision is often used for quality control. In this
application, the computer vision system scans manufactured items for defects and
provides control signals to a robotic manipulator to remove defective parts automatically.
Current examples of medical systems being developed include: systems to diagnose skin
tumors automatically, systems to aid neurosurgeons during brain surgery, systems to

perform clinical tests automatically, etc. The field of law enforcement and security is also
an active area for computer vision system development with applications ranging from
automatic identification of fingerprints to DNA analysis. The aim of this paper is to show
some of the most important vision-related topics which can have a more or less direct
impact on the machine vision and industrial automation research fields. The paper covers
a general purpose computer or machine vision systems with its industrial applications and
this includes Computer Vis ion, Machine Vis ion, Industrial Vision System
Applications,Image Processing.Machine vision provides innovative solutions in the
direction of industrial automation. The introduction of the automation has revolutionized
the manufacturing in which complex operations have been broken down into simple step-
by-step instruction that can be repeated by a machine. In such a mechanism, the need for
the systematic assembly and inspection have been realized in different manufacturing
processes. These tasks have been usually done by the human workers, but these types of
deficiencies have made a machine vision system more attractive.. Our expectation from a
visual system is to perform the following operations: the image acquisition and analysis,
the recognition of certain features or objects within that image, and the exploitation and
imposition of environmental constraints . A plethora of industrial activities have
benefited from the application of machine vision technology on manufacturing processes.
These activities include, among others, delicate electronics component manufacturing ,
quality textile production, metal product finishing , glass manufacturing , machine parts ,
printing products and granite quality inspection, integrated circuits manufacturing and
many others. Machine vision technology improves productivity and quality management
and provides a competitive advantage to industries that employ this technology.
2.7 Niharika Thakur, Manisha Hooda
Described a Review on PLC & Its Applications in Robotics and Automation. In a

traditional industrial control system, all the control devices in the field are wired directly
to each other on how the whole system is to be operated. The main control is in the

human hands which poses a lot of drawbacks such as more wired connections are
required which may again lead to large number of mechanical faults and difficulties in
troubleshooting the errors. Due to these drawbacks the PLC based automation systems
were introduced which focused on controlling the various process control systems with
the help of software and Hardware units and this includes mainly Control Systems, PLC,
Robotics, Applications.
In essence, the programmable logic controller consists of computer hardware, which is
programmed to simulate the operation of the individual logic and sequence elements that
might be contained in a bank of relays, timers, counters, and other hard-wired
components. The PLC was introduced around 1969 largely as a result of specifications
written by the General Motors Corporation. The automotive industry had traditionally
been a large buyer and user of electromechanical relays to control transfer lines,
mechanized production lines, and other automated systems. In an effort to reduce the cost
of new relays purchased each year, GM prepared the specifications for a “programmable
logic controller” in 1968. The requirements
included:
• The device must be programmable and re-programmable.
• It must be designed to operate in an industrial environment.
• It must accept 120-V ac signals from standard pushbuttons and limit switches.
• Its outputs must be designed to switch and continuously operate loads such as motors
and relays of 2-A rating.
Programmable Logic Controller (PLC) is a digital computer used for the automation of
various electro-mechanical processes in industries. These controllers are specially
designed to survive in harsh situations and shielded from heat, cold, dust, and moisture
etc.PLC consists of a microprocessor which is programmed using the computer language.
The program is written on a computer and is downloaded to the PLC via cable. These
loaded programs are stored in non – volatile memory of the PLC. During the transition of
relay control panels to PLC, the hard wired relay logic was exchanged for the program
fed by the user. A visual programming language known as the Ladder Logic was created
to program the PLC.

2.8 A.W. ROBERTS1 , A. HARRISON
Described recent research in the area of belt conveying highlighting the research being
conducted in Australia. A review of design trends associated with long overland
conveyors is presented indicating the influence of economic and technical considerations
in the design methodology. Aspects of conveyor dynamics are discussed and research and
development work concerned with specific subjects including belt drum friction, rolling
resistance and bulk solid and conveyor belt interaction. A test rig for examining stability
between bulk solids and conveyor belts during transportation is described. Throughout
the world bulk materials handling operations perform a key function in a great number
and variety of industries. While the nature of the handling tasks and scale of operations
vary from one industry to another and, on the international scene, from one country to
another according to the industrial and economic base, the relative costs of storing and
transporting bulk materials are, in the majority of cases, quite significant. It is important,
therefore, that handling systems be designed and operated with a view to achieving
maximum efficiency and reliability.
The theme embodied in the foregoing remarks is of direct relevance to Australia in view of the
heavy dependence on bulk solids handling operations. While these operations range across the
broad spectrum of the bulk handling field, a major emphasis is on the storage, handling and
transportation of coal, mineral ores and agricultural products, notably grain, in large tonnages. An
indication of the tonnages of principal minerals produced in Australia is given in Table 1, while
Table 11 summarises the mineral exports. Export earnings from minerals and agriculture are very
substantial, with those from minerals approximating 50% and agriculture 30%. Of the various
modes of conveying bulk solids, belt conveyors are of considerable importance in view of their
widespread use and proven reliability. Although their use is largely confined to in-plant
movement of materials, their application to long distance overland transportation and to the
conveying of large tonnages is gaining considerable interest. These applications are made
possible through the development of steel cord conveyor belting with much potential seen in the
newer light weight, high strength belt materials such as those reinforced with Aramid fibres.

Despite these developments, belt conveyor systems are often designed using static type
analysis based on manufacturers' handbooks or current design standards. In general,
steady state operation is assumed and belt tensions are computed on the basis of the drive
requirements and the need to limit belt sag. High factors-of-safety of the order of 7:1 are
adopted to account for unknown dynamic effects and uncertain belt splice efficiencies.
Fortunately, this situation is changing. Over recent years, significant improvements in
conveyor belt technology have occurred and more exacting design analysis procedures
have arisen as a result of the considerable research that has taken place. There is now a
much better understanding of the dynamic behaviour of belts during starting and
stopping, as well as during operation, and this has led to resonance free designs, lower
factors-of-safety and increased reliability. In view of the importance of belt conveying to
Australia's mining and mineral processing industries, it is not surprising that the subject
of belt conveying has received considerable attention in terms of research and
development. There has been wide acceptance by industry of the advances being made
and this is reflected in the new conveyor installations particularly in regard to those
associated with long overland transportation. The following list highlights some recent
and current advances:
I. Conveyor dynamics - starting and stopping characteristics and dynamic belt stresses.
II. Transverse vibrations of conveyor belts and the associated influence of idler spacing
and troughing configurations on such vibrations.
III. Conveyor belt idler resistance taking into account belt rubber hardness, sag, troughing
configuration, idler/belt indentation and ambient operating temperature.
IV. Conveyor transition geometry.
V. Stability of bulk solid on conveyor belts during motion on horizontal and vertical
curves.
VI. Conveyor belt/drive drum friction taking into account rubber hardness, surface
roughness wrap angle.
VII. Steel cord splice design and analysis.
VIII. Conveyor belt monitoring as applied to steel cord and fabric belts
IX. Belt rip detection employing ultra sonic devices.

X. Belt tension monitoring during operation.

XI. Belt cleaning including carry back measurement and development of improved
cleaning efficiencies.
XII. Economic analysis applied to conveyor design.
A selection of research publications concerned with belt conveyor developments in

Australia are given by References. While it is beyond the scope of this paper to discuss
these developments in any detail, an overview of some salient aspects of the research. is
presented.
2.9 Aniket A Jagtap1, Shubham D Vaidya1, Akash R Samrutwar1, Rahul G

Kamadi1
and Nikhil V Bhende1
Studied In the process or manufacturing industry, raw materials need to be transported

from one manufacturing stage to another. Material handling equipment are designed such
that they facilitate easy, cheap, fast and safe loading and unloading with least human
interference. For instance, belt conveyor system can be employed for easy handling of
materials beyond human capacity in terms of weight and height. This paper discusses the
design calculations and considerations of belt conveyor system for biomass wood using 3
rolls idlers, in terms of size, length, capacity and speed, roller diameter, power and
tension, idler spacing, type of drive unit, diameter, location and arrangement of pulley,
angle and axis of rotation, control mode, intended application, product to be handled as
well as its maximum loading capacity in order ensure fast, continuous and efficient
movement of crushed biomass wood while avoiding fatalities during loading and
unloading. The successful completion of this research work has generated design data for
industrial uses in the development of an automated belt conveyor system which is fast,
safe and efficient.This mainly includes Belt conveyor system, Idler, Loading, Material

handling equipment, Unloading. Different methods such as fork lifting, use of bucket
conveyor belts, conveyors systems, crane, etc. has been identified for lifting or
transporting bulk materials or products from one place to another in the manufacturing
industries depending on the speed of handling, height of transportation, nature, quantity,
size and weight of materials to be transported. The objective of this research work is to
provide design data base for the development of a reliable and efficient belt conveyor
system that will reduce cost and enhance productivity while simultaneously reducing
dangers to workers operating them. Conveyor system is a mechanical system used in
moving materials from one place to another and finds application in most processing and
manufacturing industries. It is easier, safer, faster, more efficient and cheaper to transport
materials from one processing stage to another with the aid of material handling
equipment devoid of manual handling. Handling of materials which is an important factor
in manufacturing is an integral part of facilities design and the efficiency of material
handling equipment add to the performance level of a firm. Conveyor systems are durable
and reliable in materials transportation and warehousing. Based on different principles of
operation, there are different conveyor systems namely gravity, belt, screw, bucket,
vibrating, pneumatic/hydraulic, chain, spiral, grain conveyor systems, etc. The choice
however depends on the volume to be transported, speed of transportation, size and
weight of materials to be transported, height or distance of transportation, nature of
material, method of production employed. Material handling equipment ranges from
those that are operated manually to semiautomatic systems. Material handling involves
movement of material in a manufacturing section. It includes loading, moving and
unloading of materials from one stage of manufacturing process to another. A belt
conveyor consists of an endless and flexible belt of high strength with two end pulleys
(driver and driven) at fixed positions. supported by rollers. In this work, 3 roll idlers are
required for adequate support of materials transported and protection of the belt along its
length. Pulleys are used for providing the drive to the belt through a drive unit gear box
powered by an electric motor. It also helps in maintaining the proper tension to the belt.

The drive imparts power to one or more pulleys to move the belt and its loads. Materials
are transported over the required distance as a result of friction generated between the
roller surface and the moving belt set in motion by a rotating pulley (drive pulley). The
other pulley (driven or idler pulley) acts as a wheel around which the material rotates and
returns in a continuous process. Continuous processes are characterized by non-stop
motion of bulk or unit loads along a path without halt for loading and unloading. The
peculiarities of a belt conveyor is that it is easy and cheap to maintain, it has high loading
and unloading capacity and can transport dense materials economically and at very high
efficiency over long distance allowing relative movement of material. Belt conveyor can
also be used for diverse materials: abrasive, wet, dry, sticky or dirty material. Only a
single roller needs to be powered by driver pulley and the roller will constantly spin
causing the materials to be propelled by the driving roller. Material handling equipment
such as belt conveyors are designed to load and unload materials from one stage of
processing to another in the fastest, smoothest, most judicious, safest, and most
economical way with minimum spillage.
2.10 Mr. Memane Vijay S., Prof.N.S.Biradar
Studied existing Belt conveyor system and optimize the critical parts like Roller,
Lchannels and support, to minimize the overall weight of assembly. Paper also involves
geometrical and finite element modeling of existing design and optimized design.
Geometrical modeling was done using Catia V5R20 and finite modeling done in
ANSYS14.0. Results of Linear static, Modal and Transient analysis of existing design
and optimized design are compared to prove design is safe. In this paper we work on the
roller design and optimization.
Material handling is an important sector of industry, which is consuming a considerable
proportion of the total power supply. For instance, material handling contributes about
10% of the total maximum demand in South Africa. Belt conveyors are being employed
to form the most important parts of material handling systems because of their high
efficiency of transportation. It is significant to reduce the energy consumption or energy

cost of material handling sector. This task accordingly depends on the improvement of
the energy efficiency of belt conveyors, for they are the main energy consuming
components of material handling systems. Consequently, energy efficiency becomes one
of the development focuses of the belt conveyor technology. A belt conveyor is a typical
energy conversion system from electrical energy to mechanical energy. Its energy
efficiency can generally be improved at four levels: performance, operation, equipment,
and technology. However, the Majority of the technical literature concerning the energy
efficiency of belt conveyors focuses on the operational level And the equipment level. In
practice, the improvement of equipment efficiency of belt conveyors is achieved mainly
by introducing highly efficient equipment. The idler, belt and drive system are the main
targets. In the influences on idlers from design, assembly, lubrication, bearing seals, and
maintenance are reviewed. Energy saving idlers is proposed and tested in Energy
optimized belts are developed in by improving the structure and rubber compounds of the
belts. Energy-efficient motors and variable speed drives (VSDs) are recommended in
general, extra investment is needed for the equipment retrofitting or replacement; and the
efficiency improvement opportunities are limited to certain equipment. Operation is
another aspect for energy efficiency of belt conveyors. The operation efficiency in terms
of operational cost of belt conveyors is improved by introducing load shifting. Speed
control is recommended for energy efficiency of belt conveyor systems, even though it is
occasionally challenged. The core of speed control is to keep a constantly high amount of
material along the whole belt, which is believed to have high operation efficiency. The
theoretical analysis along with experimental validation on a VSD based conveying
system is presented in. Nowadays, the idea of speed control has been adopted by industry
and successfully applied to some practical projects. Further investigations on VSDs of
belt conveyors are carried out in. The current implementations of speed control however
concentrate mostly on lower control loops or an individual belt conveyor. It has not been
used to deal with the system constraints and the external constraints, such as time-of-use
(TOU) tariff and storage capacities, nor has it been applied to coordinate multiple
components of a conveying system. A conveyor system is a common piece of mechanical
handling equipment that moves materials from one location to another. Conveyors are

especially useful in applications involving the transportation of heavy or bulky materials.

Conveyor systems allow quick and efficient transportation for a wide variety of materials,
which make them very popular in the material handling and packaging industries. Many
kinds of conveying systems are available, and are used according to the various needs of
different industries. There are chain conveyors (floor and overhead) as well. Chain
conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed
trolleys. Conveyor systems are used widespread across a range of industries due to the
numerous benefits they provide. Conveyors are able to safely transport materials from
one level to another, which when done by human labor would be strenuous and
expensive. They can be installed almost anywhere, and are much safer than using a
forklift or other machine to move materials. They can move loads of all shapes, sizes and
weights. Also, many have advanced safety features that help prevent accidents.
Conveyors can be located in areas that cause significant problems with excessive noise
production. An example of this is the location of conveyors in some coal export terminals
in Australia, which are located across a bay from residential areas. The coal loading
conveyors can produce noise levels that become an annoyance, especially at night time
when the ambient noise levels are low. For these reasons decreasing the noise produced
by conveyors is an important topic, and producing an idler roller that lowers the noise
emission from the conveyor belt assemblies will have significant benefits to both the
workers in the factories and the community as a whole. The weight of traditional steel
idler rollers can also be a problem, particularly for wide belts which can have an
individual roller weigh in excess of 20kg. This presents an Occupational Health and
Safety (OH&S) risk, as the rollers often need to be manoeuvred into hard to reach
positions, or places with limited access.

3. Simulation Work
3.1 Raw Materials
The conveyor itself is constructed with a steel framework for durability and strength. A
set of steel beams above the car, called the crosshead, span the conveyor belt shaft from
side to side and hold the pulley for the hoist cable. A steel structure, called the sling,
extends down the sides of the car from the crosshead and cradles the floor, or platform.
The sides of a passenger conveyor belt car are usually made from steel sheet and are
trimmed on the inside with decorative paneling. The floor of the car may be tiled or
carpeted. Handrails and other interior trim may be made from stainless steel for
appearance and wearability. A suspended ceiling is usually hung below the actual top of
the car and may contain fluorescent lighting above plastic diffuser panels. The conveyor
belt controls, alarm buttons, and emergency telephone are contained behind panels in the
front of the car, next to the doors.
Steel guide rollers or guide shoes are attached to the top and bottom of the sling structure
on each side to run along the guide rails. The guide rails are also steel and are attached to
the interior walls of the conveyor shaft which runs from the top of the building to the
bottom. The emergency brake mechanism consists of two clamping faces which can be
driven together by a wedge to squeeze on the guide rail. The wedge is activated by a
screw turned by a drum attached to the emergency cable.

3.2 The Manufaturing Process
1) The conveyor cars are built at the conveyor belt manufacturer's plant using standard
metal cutting, welding, and forming techniques. If the cars will be exposed to the weather
during building construction, the interior trim may be installed after the building is
finished.
2) The rest of the conveyor belt is assembled on the building site. The building design
integrates the conveyor belt shaft from the beginning, and the shaft grows as the building
is erected. The walls of the shaft are poured concrete, and the shaft straightness and other
dimensions are carefully monitored as each floor goes up.
3) Guide rails, switch ramps, service ladders, and similar support equipment are bolted
into the shaft after the shaft walls are complete, but before the shaft is roofed.
4) While the shaft is still open at the top, a crane raises the counterweight to the top of
the building and lowers it into the shaft along its rails.
5) The crane then lifts the conveyor belt car and inserts it partly into the shaft. The guide
wheels connect the car to the guide rails, and the car is carefully lowered to the bottom of
the shaft.
6) The shaft is then roofed over, leaving a machine room above the shaft. The hoist
motor, governor, controller, and other equipment are mounted in this room, with the
motor located directly over the conveyor belt car pulley.
7) The conveyor belt and governor cables are strung and attached, the electrical
connections completed, and the controller programmed.

3.3 PLC BASAED ELEVTOR BELT
In our project Conveyor belt is controlled by PLC . We can make the hardware model
of the two floor Conveyor belt . This conveyor belt is operate by using of dc motor.
PLC is gives the command to the relay. Relay is operate the dc motor in forward
direction and reverse direction. Based on this relay operation conveyor belt is
move up and down.
BCD to seven segment circuit is used for to show the current position of conveyor
belt. CONTROL CIRCUIT is controlling the conveyor belt in upward and
Downward direction. It is also control the door close and open of the conveyor
belt It is a control by the electro-magnet relay when the two relays are energized
lift is moving upward and other two relays are energized lift is moving downward.
.PLCis an industrial microcontroller system (in more recent times we meet

processors instead of microcontrollers) where we have hardware and software
specifically adapted to industrial environment. Blocks came with typical
components, which PLC consist of, is found in the following picture. Special
attention needs to be given to input and output, because in these blocks you find
protection needed in isolating a CPU blocks from damaging influences that
industrial environment can bring to a CPU via input lines.
Delta PLC

Advantages of PLC:
 Smaller physical size than hard-wire solutions.

 Easier and faster to make changes.
 PLCs have integrated diagnostics and override functions.
 Diagnostics are centrally available.
 Applications can be immediately documented.
 Applications can be duplicated faster and less expensively.
3.4 Basic Requirements
In PLC programming in order to create or change a program, the following

items are needed:
-PLC, -Programming Device, -Programming Software, -Connector Cable
3.5 For planning of our project work it is divided into two parts:
1. Making the control circuit for conveyor belt

2. Making the hardware model of conveyor belt
3.6 Full description of planning of our project work:
1.Making the control circuit for conveyor belt-For control the conveyor belt system
through PLC we can making the control circuit.
2.Making the hardware model of conveyor belt- For the making of conveyor
belt hardware model we are using the cast iron material same for nozzle tray
which is easy to construct and good in durability material For conveyor belt door
we are use dc motor to control the speed of conveyor belt

4.MATERIAL AND METHOD USED IN PROJECT:
As material of our project we are using the different component follows
COMPONENT:
1.AC MOTORs
2. Elevator Belt
3.CONVEYOR Belt
4.VACCUM LIFTING ARM
5. .PROXIMITY SENSOR
6.DAMPER
7.TRAY
4.1Workng of each Component
1.AC motor
An AC motor is an electric motor driven by an alternating current (AC). The AC motor
commonly consists of two basic parts, an outside stator having coils supplied with
alternating current to produce a rotating magnetic field, and an inside rotor attached to the
output shaft producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.
Less common, AC linear motors operate on similar principles as rotating motors but have
their stationary and moving parts arranged in a straight line configuration, producing
linear motion instead of rotation.

Operating principles
The two main types of AC motors are induction motors and synchronous motors. The
induction motor (or asynchronous motor) always relies on a small difference in speed
between the stator rotating magnetic field and the rotor shaft speed called slip to induce
rotor current in the rotor AC winding. As a result, the induction motor cannot produce
torque near synchronous speed where induction (or slip) is irrelevant or ceases to exist. In
contrast, the synchronous motor does not rely on slip-induction for operation and uses
either permanent magnets, salient poles (having projecting magnetic poles), or an
independently excited rotor winding. The synchronous motor produces its rated torque at
exactly synchronous speed. The brushless wound-rotor doubly fed synchronous motor
system has an independently excited rotor winding that does not rely on the principles of
slip-induction of current. The brushless wound-rotor doubly fed motor is a synchronous
motor that can function exactly at the supply frequency or sub to super multiple of the
supply frequency.
Other types of motors include eddy current motors, and AC and DC mechanically
commutated machines in which speed is dependent on voltage and winding connection.
Working of A.C.Motor
In an AC motor, there's a ring of electromagnets arranged around the outside (making up

the stator), which are designed to produce a rotating magnetic field. Inside the stator,
there's a solid metal axle, a loop of wire, a coil, a squirrel cage made of metal bars and
interconnections (like the rotating cages people sometimes get to amuse pet mice), or
some other freely rotating metal part that can conduct electricity. Unlike in a DC motor,
where you send power to the inner rotor, in an AC motor you send power to the outer
coils that make up the stator. The coils are energized in pairs, in sequence, producing a
magnetic field that rotates around the outside of the motor.

How does this rotating field make the motor move? Remember that the rotor, suspended
inside the magnetic field, is an electrical conductor. The magnetic field is constantly
changing (because it's rotating) so, according to the laws of electromagnetism (Faraday's
law, to be precise), the magnetic field produces (or induces, to use Faraday's own term)
an electric current inside the rotor. If the conductor is a ring or a wire, the current flows
around it in a loop. If the conductor is simply a solid piece of metal, eddy currents swirl
around it instead. Either way, the induced current produces its own magnetic field and,
according to another law of electromagnetism (Lenz's law) tries to stop whatever it is that
causes it—the rotating magnetic field—by rotating as well. (You can think of the rotor
frantically trying to "catch up" with the rotating magnetic field in an effort to eliminate
the difference in motion between them.) Electromagnetic induction is the key to why a
motor like this spins—and that's why it's called an induction motor.
Fig.:- A.C. Motor

2.Elevator Belt
A bucket elevator consists of a series of uniformly fed buckets mounted on an endless

chain or belt which operates over head and foot wheels. The buckets are used to elevate
(usually vertically) pulverized, granular, or lumpy materials. The material is received at
the boot, raised and then discharged by passing over the head wheel at the top, into a
discharge chute. Generally this mechanism is enclosed in a casing, especially the head
and foot sections. Some elevators are self-supporting, but more often they are supported
by, or at least braced against a structural steel frame. Inclined elevators, which are seldom
enclosed, are popular for handling.
Which type of bucket and bucket elevator was selected? An inclined twin chain bucket
elevator was selected for this project. The angle of inclination was 45° from the vertical.
And the selected bucket was Deep type bucket. The front edge of buckets is sheared off
at an angle of 65making them deep. Charge and Discharge of Buckets: (Scooping charge
and centrifugal discharge)The material is either scooped up by the buckets in the elevator
boot or is fed directly into the buckets. So, spaced buckets of belt-and-chain elevator was
selected which works on the principle of scooping material. Centrifugal discharge type
bucket elevator was selected. In centrifugal-discharge bucket elevators, the material to be
elevated is dug out of the boot and discharged by centrifugal force developed when the
bucket is taken around the head pulley (or sprocket) and falls directly into the discharge
spout of the upper casing. Before reaching the pulley, the buckets moves uniformly along
a rectangular path.

Fig.:- .Elevator Belt.
3.conveyor Belt
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to
belt conveyor). A belt conveyor system is one of many types of conveyor systems. A belt
conveyor system consists of two or more pulleys (sometimes referred to as drums), with
an endless loop of carrying medium the conveyor belt that rotates about them. One or
both of the pulleys are powered, moving the belt and the material on the belt forward.
The powered pulley is called the drive pulley while the unpowered pulley is called the
idler pulley. There are two main industrial classes of belt conveyors; Those in general
material handling such as those moving boxes along inside a factory and bulk material
handling such as those used to transport large volumes.
The belt consists of one or more layers of material. It is common for belts to have three
layers: a top cover, a carcass and a bottom cover. The purpose of the carcass is to provide

linear strength and shape. The carcass is often a woven or metal fabric having a warp &
weft. The warp refers to longitudinal cords whose characteristics of resistance and
elasticity define the running properties of the belt. The weft represents the whole set of
transversal cables allowing to the belt specific resistance against cuts, tears and impacts
and at the same time high flexibility. The most common carcass materials are steel,
polyester, nylon, cotton and aramid (a class of synthetic fiber that includes Kevlar) . The
covers are usually various rubber or plastic compounds specified by use of the belt.
Conveyor Belt

4. VACCUM LIFTING ARM
Components of Pneumatic arm
4.1 Pneumatic Cylinder:
Double acting cylinder is considered to be has handactuator in any pneumatic systems.

Double acting cylinders are expensive more than acting cylinders single; purpose double
acting cylinders are superior to the single important measure acting cylinders by any
other. Are double acting cylinders faster and stronger. In industrial applications, single
acting cylinders also used are possible yew, when speed and purpose forces importing are
double acting cylinder are employed. Applications include opening and closing doors,
taking things off conveyor belts and putting things one to conveyor belts
4.2 Direction Control Valve
In 5/2 way direction (management) control valve, from the name itself has 5 ports equally
speed and 2 flow positions. It can be used to isolate and simultaneously bypass has
passage way for the fluid which for example should retract golden extend has acting
cylinder double. There variety of ways to are gaunt this actuated valve. In solenoid valve
is commonly used, has rise can be manually golden twist pinch to actuate the valve, the
year golden internal external hydraulic golden pneumatic pilot to move the shaft inside,
sometimes with has return spring one the other end so it will go original back to its
positions when press is gone, yet has combination of any of above mention

4.3 GRIPPER:
Gripper is a device which involves parallel or angular motion of surface. It is provided

with the jaws to pick and place the objects. The air is provided to produce the grasping
force. Gripper is capable of lifting very small object as well as large objects like engine
blocks of vehicles.
Fig:- Pneumatic lifting arm

5. .PROXIMITY SENSOR
A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. A proximity sensor often emits an electromagnetic field or a beam of
electromagnetic radiation (infrared, for instance), and looks for changes in the field or
return signal. The object being sensed is often referred to as the proximity sensor's target.
Different proximity sensor targets demand different sensors. For example, a capacitive
proximity sensor or photoelectric sensor might be suitable for a plastic target; an
inductive proximity sensor always requires a metal target.
Proximity sensors can have a high reliability and long functional life because of the
absence of mechanical parts and lack of physical contact between the sensor and the
sensed object.
5.1 Inductive proximity sensor (proximity switch)

An inductive proximity sensor is a non-contact electronic proximity sensor. It is used for
positioning and detection of metal objects. The sensing range of an inductive switch is
dependent on the type of metal being detected. Ferrous metals, such as iron and steel,
allow for a longer sensing range, while nonferrous metals, such as aluminum and copper,
may reduce the sensing range by up to 60 percent.
Since the output of an inductive sensor has two possible states, an inductive sensor is
sometimes referred to as an inductive proximity switch.
The sensor consists of an induction loop or detector coil. Most often this is physically a
number of turns of insulated magnet wire wound around a high magnetic permeability
core, such as a ferrite ceramic rod or coil form, and the winding may or may not have a
feedback tap some number of turns from one end of the total winding. It is connected to a
capacitance to form a tuned frequency oscillator tank circuit. In conjunction with a
voltage or current gain device like a transistor or operational amplifier, this forms a tuned
frequency oscillator. When power is applied, the resulting oscillation is a high frequency
alternating electric current in the coil that has a constantly changing magnetic field able
to induces eddy currents in proximal (target) conductors. The closer the target is and the
greater its conductivity (metals are good conductors, for example), the greater the

induced eddy currents are and the more effect their resulting opposing magnetic fields
have on the magnitude and frequency of the oscillation. Its magnitude is reduced as the
load is increased in a non-magnetic conductor like aluminum because the induced field in
the target opposes the source induction field, lowering net inductive impedance and
therefore simultaneously tuning the oscillation frequency higher. But that magnitude is
less affected if the target is a highly magnetically permeable material, like iron, as that
high permeability increases the coil inductance, lowering the frequency of oscillation.
A change in oscillation magnitude may be detected with a simple amplitude modulation
detector like a diode that passes the peak voltage value to a small filter to produce a
reflective DC voltage value, while a frequency change may be detected by one of several
kinds frequency discriminator circuits, like a phase lock loop detector, to see in what
direction and how much the frequency shifts. Either the magnitude change or the amount
of frequency change can serve to defined a proximity distance at which the sensors go
from on to off, or vice versa.
Fig:- Inductive proximity sensor

6.Damper
Shock absorbers, more properly called dampers, are mounted alongside (or inside) the
springs . A shock absorbers job is to provide resistance to the movement of the spring.
Technically speaking, it does this by taking some of the energy that is being used to
compress the spring and turning it into heat. So whether the tray is bouncing up or down
from a bump on the roller, that motion is held in check by the shock absorber, and once
again some of the kinetic energy released by the spring is changed into heat by the shock
absorber. This conversion of energy keeps the tray body from bouncing more than once
or twice, providing a controlled movement and helping to keep the tray body safely in
contact with the ground.
Fig:-Spring mass damper

7.Tray
This tray is used to place the nozzle in form of proper arrangements for the further
operation. Here we have design the tray of size in length of 210mm and breadth of 94
mm. In this tray to place the nozzle bodies We have provided the the rubber socket of
exact size of nozzle. In this rubber hole the nozzle bodies are get easily placed and the
tray with this nozzle bodies are send for further operation.

Fig.:-Tray with Nozzle
5.ADVAVTAGES & DISADVANTAGES OF AUTOMATION
5.1Automation Advantages
 Reduction in production time – having a machine that is automated definitely

speeds up the production time since no thinking is needed by the machine, there is
better repeatability, and less human error.
 Increase in accuracy and repeatability – when an automated machine is
programmed to perform a task over and over again, the accuracy and repeatability
compared to an employee is far greater.
 Less human error – no one is perfect, and we are all prone to making mistakes.
Which is why a machine that performs repeated tasks is less likely to make
mistakes than an employee.
 Less employee costs – by adding automated machines to an operation, means less
employees are needed to get the job done. It also indicates less safety issues,
which leads to financial savings. With having less employees, there are numerous
costs that are diminished or reduced such as payroll, benefits, sick days, etcetera.
 Increased safety – having automated machines means having less employees who
perform tasks that can be dangerous and prone to injury, which can make the
work environment safer.
 Higher volume production – investing in automated equipment creates a valuable
resource for large production volumes, which in turn, will increase profitability.
 Reduce Waste - Robots are so accurate that the amount of raw material used can
be reduced, decreasing costs on waste.

 Improved Quality and Reliability - Automation is precise and repeatable. It

ensures the product is manufactured with the same specifications and process
every time. Repairs are few and far between.
 Better Floor Space Utilization - By decreasing a footprint of a work area by
automating parts of your production line, you can utilize the floor space for other
operations and make the process flow more efficient.
5.2Automation Disadvantages
 Less versatility – by having a machine that can perform a certain task limits to the
flexibility and variety of tasks that an employee could do.
 More pollution – different types of machines operate using motor which may
require gases or chemicals in order to operate. This can cause an increase in
pollution in the workplace.
 Large initial investment – automated machines can be one of the most costly
operating costs for a company. With automated machines running anywhere
between thousands and millions of dollars depending on the type and degree of
automation.
 Increase in unemployment – by increasing the amount of automation, there are
less employees required causing high unemployment rates.
 Unpredictable costs – there can be several unpredictable costs that may exceed
the actual cost saved by the automation itself. Some of these costs could include
research and development costs of automating a process, preventative
maintenance costs, and the cost of training employees to operate automated
machines.
 Require maintenance and training: another disadvantage of automated machines
is that they require high maintenance and for proper usage of the machines
workers are required to go through intense training and should learn how to
properly use the machine for high quality results. Having a god training to the
workers assures a good functionality for the machine.

5.CONCLUSION
The good automation and process control is very necessary in the industries.
Rapid production changes and attainment of good production with minimal
waste is really challenging. From this project work, during the time period we
have made this project model and this is for arranging the nozzles in a tray
provided, and It work easily with PLC. It’s applications are mostly in regular
industrial work.We have been able to provide automation in this process and
continuing the work.

6. REFERENCES
1)PLC Based Industrial Automation System GavaliAmitBhimrao,

PatilMahadevS.Departmen of Electronics and Telecommunication Rajarambapu Institute
of Technology Rajaramnagar, Islampur, Sangli, India.
2) A review of automation in manufacturing illustrated by a case study on mixed-mode

hot forging Colin S. Harrison Mechanical and Electrical Engineering, School of
Engineering, Glasgow Caledonian University, Cowcaddens Road, Glasgow G4 0BA,
UK.
3) Application of PLC’s for Automation of Processes in Industries Rahul Pawar, Dr. N.

R. Bhasme.M.E. Student, Department of Electrical Engineering, Government
Engineering College, Aurangabad-05 Associate Prof., Department of Electrical
Engineering, Government Engineering College, Aurangabad-05.
4) Development of a Pneumatically Driven Cell for Low Cost Automation Antonio

Carlos Valdiero, Ivan Jr.Mantovani, Andrei Fiegenbaum, Giovani P. B. Dambroz, and
Luiz A. Rasia Exact Sciences and Engineering Department, Regional University of
Northwestern Rio Grande do Sul State (UNIJUI), Av. Rudi Franke 540, P.O. Box 121,
Panambi, RS, Brazil
5) Design and Test of Pneumatic Systems for Production Automation Giorgio Figliolini
and Pierluigi Rea LARM - Laboratory of Robotics and Mechatronics DiMSAT,
University of CassinoG. Di Biasio, 43 - 03043 Cassino, ITALY.

6) PROGRAMMABLE LOGIC CONTROLLER.

ANTONIO SORIN TASU Department of Physics, Ovidius University, Constanţa,
900527, Romania
7) Programmable Logic Controller (PLC) in Automation Mallikarjun G. Hudedmani,

Umayal R M, Shiva Kumar Kabberalli, Raghavendra Hittalamani Department of
Electrical and Electronics Engineering, KLE Institute of Technology, Opposite to
Airport, Gokul, Hubballi , Karnataka, India
8)A Review Paper on PLC & Its Applications in Robotics and Automation Niharika
Thakur, ManishaHoodaDept. of ECE, ManavRachna University, Haryana, India
9) Automation and Integration of Industries through Computer Vision Systems Tushar

Jain and Meenu Department of Mechanical Engineering, National Institute of
Technology, Kurukshetra, Haryana, INDIA.





Arrangement of Nozzle Using Smart Automation

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Arrangement of Nozzle By using Smart Automation

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 1

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1.1 PROBLEM STATEMENT

Companies undertake projects in manufacturing automation and computer-integrated

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 3

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1.3.1 Equipment model

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Physical components of a control system.

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1.3.2 Automation components

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A minimal set of interaction mechanisms.

1.3.3 Interactions between automation components

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 8

This chapter is related to selection of automation methods according to need of

It is related to literature review and problem formulation. Extensive literature on

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 9

and applying these in practice.Use standardization procedure parameters for automation,.

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 10

Described Next generation of industrial automation and Concepts and architecture of a

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 11

addition, a number of emerging Ethernet-based distribution middleware solutions for

2.2 Gavali Amit Bhimrao, Patil Mahadev S

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 12

2.3 Rahul Pawar , Dr. N. R. Bhasme

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 13

2.4 ANTONIO SORIN TASU

Stated The purpose of this Programmable Logic Controller (PLC) is to command 16

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 14

2.5 Giorgio Figliolini and Pierluigi Rea

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 15

operating in on/off environment. Likewise, a proportional pressure valve and a robotic

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 16

systems in on/off environment. ,All this theoretical teaching activity is supported by a

2.6 Tushar Jain and Meenu

Studied Automation and Integration of Industries through Computer Vision

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 17

2.7 Niharika Thakur, Manisha Hooda

Described a Review on PLC & Its Applications in Robotics and Automation. In a

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 18

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 19

2.8 A.W. ROBERTS1 , A. HARRISON

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 20

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X. Belt tension monitoring during operation.

A selection of research publications concerned with belt conveyor developments in

2.9 Aniket A Jagtap1, Shubham D Vaidya1, Akash R Samrutwar1, Rahul G

Studied In the process or manufacturing industry, raw materials need to be transported

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 22

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2.10 Mr. Memane Vijay S., Prof.N.S.Biradar

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 24

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especially useful in applications involving the transportation of heavy or bulky materials.

SANDIP INSTITUTE OF ENGINEERING AND MANAGEMENT,BE MECHANICAL Page 26

3.1 Raw Materials

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3.2 The Manufaturing Process

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3.3 PLC BASAED ELEVTOR BELT