INDUSTRIAL TRAINING REPORT

ON
AUTOMATIC STORAGE AND RETRIEVAL SYSTEM

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
in
ELECTRONICS AND COMMUNICATION ENGINEERING

SUBMITTED BY:

RAKSHA
(UNIV. ROLL NO. 7615999)

Under the supervision of :

ER. DEVENDER SAINI(Assistant Professor)

Department of Electronics and Communication Engineering

Gurgaon Institute of Technology &Management

Bilaspur –Tauru Road, Gurgaon (Hr-122413)

(Affiliated to Maharishi Dayanand University, Rohtak)

June-2016
 CERTIFICATE

This is certified that Ms. RAKSHA carried out the training work on ‘Automatic Storage and
Retrieval System’ under my guidance. She is the sole author of this report and the work carried
out by her is novel and better than the previous work in the field of Communication
Engineering. The parameters presented in this dissertation are very useful for future works in
the field of communication engineering. She had given her best efforts in carrying out the best
results with the available resources in the existing environment.

This is also certified that the matter embodied in this dissertation has not been submitted
earlier in any institute/ university for the award of any degree or diploma to the best of my
knowledge and belief.
I also wish her best of luck for the future career in.

Supervisor: Head Of Department:

Er. Devender Saini Prof. Bijender M'dia
(Assistant Professor)
Department of Electronics and Comm. Department of Electronics and Comm.
Gurgaon Institute of Tech. & Mgmt.
 DECLARATION

I hereby certify the work which is being presented in the “TRAINING REPORT on
AUTOMATIC STORAGE RETRIEVAL SYSTEM by RAKSHA in partial fulfillment of
requirements for the award of degree B.Tech (Electronics and Communication
Engineering) has been submitted in the Department of ELECTRONICS &
COMMUNICATION ENGINEERING, Gurgaon Institute of Technology and
Management, Gurgaon (affiliated to Maharashi Dayanand University, Rohtak) is carried
out during a period from Feb 15 2016 to June 2016 under the supervision of Er Devender
Saini(Assistant Professor, Department of Electronics And Communication Engineering,
GITM, Gurgaon). The matter presented in this project has not been submitted by anyone in
any University/ Institute for the award of any Degree/ diploma.

-RAKSHA
(12-ECE-144)
(Univ. Roll No. 7615999)
 ACKNOWLEDGEMENT

It is my pleasure to acknowledge the help that I had received from different individuals during my
project completion.
My first sincere appreciation and gratitude goes to respected Mr.Kamal Thakur, the
Director of Gurgaon Institute of Technology And Management, GURGAON for the
encouragement and unstinted support given by him.
I would like to acknowledge the continuous guidance and incessant support rendered by Prof.
BIJENDER M’Dia, Head of the Department of ECE not only for this project but also in my
overall career development.
Also, it gives me immense pleasure to express my sincere and wholehearted sense of gratitude
to my esteemed Er. Devender Saini (Assistant Professor) for their invaluable and untiring
guidance and supervision throughout this session. To derive benefits of their enormous
experience, it is a matter of great privilege for me.
I am grateful to Mr. SHEKHAR ADHIKARI (Project Guide), MSIL. for his guidance,
inspiration and constructive suggestions that helped me in the preparation of this project.
I also take this opportunity to express my sincere thanks and full appreciation to
Mr.V.D.Madhusudanan (Department Manager, AutomationLab). who extended his
wholehearted cooperation; moral support and rendering ungrudging assistance whenever and
wherever need arisen. I am very thankful to him.
I want to convey my heartfelt gratitude to Mr. Anand vardhan who has helped me in the
successful completion of this project.
Moral, intellectual and very frequently required support from all the faculty members is also
hereby acknowledged.

RAKSHA
(12-ECE-144)
(Univ. Roll No. 7615999)
LIST OF FIGURES

Company fig 0.1……………………………………….3

Block diagram of production process fig 0.2………….7
Automation fig 0.3…………………………………….8
AS/RS fig 1.1...…………………………………….…12
Overview of AS/RS fig 1.2...................................…....15
Block diagram of PLC fig 2.1……..……………….....19
Relay fig 2.2.…………………………………….…....22
MCB fig 2.3…………………………………………..22
Internal parts of MCB fig 2.4…………………………23
Contactor fig 2.5………………………………………24
Transformer fig 2.6……………………………………26
VFD fig 2.7...……………………………………….....28
Rectifier fig 2.8………………………………………..29
Choke fig 2.9………………………………………….30
SMPS fig 2.10…………………………………………31
Proximity sensor fig 2.11……………………………...32
GOT fig 2.12…………………………………………..33
GOT screen fig 2.13……………………………………34
Limit switch fig 4.1…………………………………….41
Pneumatic cylinder fig 4.2……………………………...43
Hydraulic cylinder fig 4.3………………………………44
Safety Sensors fig 4.4…………………………………..45
FLR fig 4..5…………………….………………………47
GX Developer fig 4.6…..………………………………51
GT designer fig 4.7…………..…………………………52
AutoCAD fig 4.8………………………………….……58
Overview of the design fig 5.1…………………………60
Inner layout of control panel fig 5..2………….………..63
Power diagram fig 5..3…………..……………….……..65
Wiring diagram fig 5.4…………….……………………66
CONTENT

1. Abstract……………………………………………………...1
2. Introduction of company………………………………….. ..2
I. Company profile
II. Company vision and values
III. Automation

CHAPTER-1

Introduction to Project……………………………………....11-15
I. Why an ASRS
II. Types of ASRS
III. Advantage
IV. Disadvantage
V. Objective of AS/RS

CHAPTER-2

Component used…………………………………………….16-34
I. Programmable logic controller (PLC)
II. Variable frequency drive (VFD)
III. Relays
IV. Contactor
V. Miniature circuit breaker (MCB)
VI. Choke
VII. Rectifiers
VIII. Switched mode power supply (SMPS)
IX. Transformer
X. Sensors

CHAPTER-3

Methodology of the project………………………………....35-39

I. Planning
II. During installation
III. Post installation
IV. Finishing

CHAPTER-4

Hardware and software used………………………...……...40-59

Hardware used-
I. Limit switch
II. Cylinders
III. Induction Motor
IV. Solenoid
 V. Filter and regulator unit

Software used-
I. GX Developer
II. GT Designer
III. Electrical AutoCAD

CHAPTER- 5.

Project design……………………………………………..…60-70

APPENDIX………………………………………………….71-73

TESTING AND RESULT…………………………………74

Bibliography………………………………………………...75
 ABSTRACT

AS/RS systems are designed for automated storage and retrieval of parts and items in
manufacturing, distribution, retail, wholesale and institutions.

The system operate under computerized control, maintaining an inventory of stored items.

To store items, the pallet or tray is placed at an input station for the system the
information for inventor is entered into a computer terminal and the AS/RS system moves the
load to the storage area, determines a suitable location for the item, and stores the load. As
items are stored into or retrieved from the racks, the computer updates its inventory
accordingly.

Softwareused: GX Developer
GT Designer

1
 ORGANIZATION PROFILE

INTRODUCTION

THE JOURNEY OF MARUTI SUZUKI

The journey began 25 years ago with the principle of "Give" - a principle that has been
bedrock of Maruti Suzuki's approach to sustainability. Get and Grow have been the natural
outcomes over the years. Maruti Suzuki has now gone beyond its business and contributed to
the society at large, as envisioned by its founders. Maruti Suzuki has strived towards offering
high quality, latest technology and value for money products to its customers.

Suzuki motor corporation

The company started its business in the year 1909 as Suzuki loom works and then was
incorporated as Suzuki Motor Corporation in the year 1920. With headquarters at Hamamatsu,
Japan, Suzuki has steadily grown and expanded its business across geographies. Suzuki today
offers its customers a wide range of motorcycles, automobiles, outboard motors and related
products such as generators and motorized wheelchairs.

Suzuki's trademark is recognized throughout the world as a brand that offers high quality,
reliable and genuine products. Suzuki stands behind this global symbol with a determination
to maintain this confidence in the future as well, never stopping in creating such advanced
'value-packed' products.

Suzuki develops products for the new generation and changeable lifestyles, constantly
creating new technologies and applying them to products with affluent imagination. Suzuki is
continually carrying out research for the further development of four-wheel vehicles
particularly in the improvement of fuel economy and the reduction of gas emissions and
noise.

2
Vision “The leader in Indian Automobile industry, Creating
Customer delight and shareholder’s hands wealth, A
Pride of India”

Fig 0.1

3
About Maruti Suzuki –

Maruti Suzuki India Limited (MSIL, formerly known as MarutiUdyog Limited) is a

subsidiary of Suzuki Motor Corporation, Japan. Maruti Suzuki has been the leader of the
Indian car market for over two and a half decades. The company has two manufacturing
facilities located at Gurgaon and Manesar, south of New Delhi, India. Both the facilities have
a combined capability to produce over a 1.5 million (1,500,000) vehicles annually.

The Company offers 15 brands and over 150 variants ranging from people's car Maruti 800 to
the latest Life Utility Vehicle, Ertiga. The portfolio includes Maruti 800, Alto, Alto K10, A-
star, Estilo, WagonR, Ritz, Swift, Swift DZire, SX4, Omni, Eeco, Kizashi, Grand Vitara,
Gypsy and Ertiga. In an environment friendly initiative, in August 2010 Maruti Suzuki
introduced factory fitted CNG option on 5 models across vehicle segments. These include
Eeco, Alto, Estilo, Wagon R and Sx4. With this Maruti Suzuki became the first company in
India to introduce factory fitted CNG vehicles

In terms of number of cars produced and sold, the Company is the largest subsidiary of
Suzuki Motor Corporation. Cumulatively, the Company has produced over 10 million
vehicles since the roll out of its first vehicle on 14th December, 1983.

Maruti Suzuki is the only Indian Company to have crossed the 10 million sales mark since its
inception. In 2013-14, the company sold 11,55,041 vehicles including 1,01,352 units of
exports.

The Company employs over 9000 people (as on 31st March, 2012). Maruti Suzuki's sales and
service network is the largest among car manufacturers in India. The Company has been rated
first in customer satisfaction in the JD Power survey for 12 consecutive years. Besides serving
the Indian market, Maruti Suzuki also exports cars to several countries in Europe, Asia, Latin
America, Africa and Oceania.

4
Maruti Suzuki's revenue over the years:
(Rs. in million)

Year Net Sales Year Net Sales

2006-07 1,45,922 2010-11 3,58,490

2007-08 1,78,603 2011-12 3,47,059
2008-09 2,03,583 2012-13 4,26,125
2009-10 3,01,198 2013-14 4,26,448

Employees are Maruti’s greatest strength and asset. It is this underlyingphilosophy that has
molded its workforce into a team with common goals and objectives. The employee-
management relationship is therefore characterized by:

5
COMPANY VISION & VALUES

Maruti's Vision for the future is to be:

“The Leader in the Indian Automobile Industry, Creating Customer delight and
Shareholderswealth; a pride of India”.

The above vision is based on:

 LEADERSHIP: By Market Share, By Brand Equity, By Operational Practices, By

PeopleStrategy

 CUSTOMER DELIGHT: Value for Money, Quality, Service

 SHARE HOLDERS WEALTH: High Profitability & Image, As a corporate Citizen,

Ourproducts, Our People, Our Practices, Our Customer

VALUES:
The Five Values identified are:

 Customer Obsession
 Fast, Flexible & First move
 Innovation & Creativity

6
BLOCK DIAGRAMOF PRODUCTION PROCESS

Fig 0.2

7
 AUTOMATION

Fig 0.3

Automation is the use of control systems and information technologies to reduce the need
forhuman work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human
operators with machinery to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental requirements as well. Automation
plays an increasingly important role in the world economy and in daily experience.

Advantages

 Replacing human operators in tasks that involve hard physical or monotonous work.

 Replacing humans in tasks done in dangerous environments.

 Performing tasks that are beyond human capabilities size, weight, speed endurance, etc
 Economy improvement.

DISADVANTAGE

8
 Unemployment rate increases due to machines replacing humans.

 Technical Limitation. Current technology is unable to automate all the desired tasks.

 Security Threats/Vulnerability. An automated system may have limited level of

intelligence.
 Unpredictable development costs.

 High initial cost.

Automation tools
Engineers now can have numerical control over automated devices. The result has been a
rapidly expanding range of applications and human activities. One example of an industrial
control system is a programmable logic controller (PLC). PLCs are specialized hardened
computers which are frequently used to synchronize the flow of inputs from (physical)
sensors and events with the flow of outputs to actuators and events.

Types of Automation

 SEMIAUTOMATION- Automation in which a process is enhanced with less

intervention of human.

 COMPLETEAUTOMATION- Automation in which a process is enhanced

Withoutintervention of human.

Requirements of Automation

 CONTROL SYSTEM
 Pneumatics

 Speed
 Simplicity in circuitry
Less force requirement
 Less cost.
 Friendly

9
 HYDRAULICS
.

 High force requirement.

 Compactness.

 Speed has no limitation

 Precision and accuracy

 ELECTRICAL

 For compact application.

 Flexibility
 Simplicity1

10
Chapter-1

INTRODUCTION TO PROJECT

AUTOMATIC STORAGE AND RETRIEVAL SYSTEM

Fig 1.1

AS/RS systems are designed for automated storage and retrieval of parts and items in
manufacturing, distribution, retail, wholesale and institutions. They first originated in the
1960’s initially focusing on heavy pallet loads but with the evolution of the technology the
handled loads have become smaller. The system operate under computerized control,
maintaining an inventory of stored items.

Retrieval of items is accomplished by specifying the item type and quantity to be retrieved.
The computer determines where in the storage area the item can be retrieved from and
schedules the retrieval. It directs the proper automated storage and retrieval machine to the
location where the item is stored and directs the machine to deposit the item at a location
where it is to be picked up. A system of conveyors or automated guided vehicle is sometime
pare of AS/RS systems. These take loads into out of the storage area and move them to the
manufacturing floor or loading docks. To store items, the pallet or tray is placed at an input
station for the system the information for inventor is entered into a computer terminal and the
AS/RS system moves the load to the storage area, determines a suitable location for the item,
and stores the load. As items are stored into or retrieved from the racks, the computer updates
its inventory accordingly.

WHY AN AS/RS

Reasons for selecting AS/RS include –

 ANAS/RS is space efficient.

 Improved inventory management and control.
 Quick response time to locate, store and retrieve items.
 Reduced labor cost due to automation.
 Flexibility in interface with other systems like AGVS, FMS, and inspection systems such as
coordinate measuring machine.
 Helps in implementing JIT concepts by getting the right part, tools and pallets to the right
time.

TYPES OF AS/RS

Several types of AS/RS are distinguished based on certain features and applications. Some
of the important categories include:

1. Unit load ASRS.

2. Miniload ASRS.
3. Person-on-board ASRS.
4. Deep-lane ASRS.
5. Automated item retrieval system.

Unit load ASRS:

 It is used to store and retrieve loads that are palletized or sored in standard-sized
container.
 The system is system controlled.
 The S/R machines are automated and designed to handle the unit load container.
 Usually, a mechanical clamp mechanism on the S/R machines handle the load.
 The loads are generally over 200kgs per unit.
Mini load ASRS:

 This system is designed to handle small loads such as individually parts, tools, and
supplies that are contained in bins or drawers in the storage systems.
 This system is applicable where the availability of space is limited.
 Also, useful where the volume is too low for a full scaleunit load system and too high
for a manual system.
 A mini load AS/RS is generally smaller than a unit load AS/RS and is often enclosed
for security of items stored.

Person on based AS/RS:

 This system allows astorage of items in less than unit load quantities.
 Human operator rides on the carriages of the S/R machine to pick up individual items
from the bin or drawer.
 The system permits individual items to be picked directly at their storage location.
 This providesan opportunity to increase input throughput.
 The operator can select the items and place them in a module.
 It is then carried by the S/R machine to theandof the conveyor to reach the destination.

Deep-lane AS/RS:

 This is high density unit load storage system that is appropriate for storing large
quantities of stock.
 The items are stored in multi deep storage with up to 10 items in a single rack, one
load behind the next.
 Each rack is designed for flow through,with input and output on the opposite side.
 Machine is used on the entry side of the rack for input load and loads are retrieved
from other side by an S/R type machine.
 The S/R machines are similar to unit load S/R machines except that it has specialized
functions such as controlling rack entry vehicles.

Automated item retrieval system:

 Thissystemis designed for retrieval of individual items or small product cartoons.

 The items are stored in lanes rather than bins or drawer.
 When an item is retrieved from the front by use of rear-mounted pusher bar ,it is
delivered to the pickup station by pushing it from its lane and dropping onto a
conveyor.
 The supply of item in each lane is periodically replenished and thus permitting first in/
first out inventory rotation.
  After moving itself to the correct lane, the picking head activates.

Application of AS/RS:

Automatic and storage and retrieval systems are typically used in applications where:

 Thereis averyhigh volume of loads being moved into and out of storage.
 Storage density is important because of space constraints.
 No value is added in this process ( no processing, only storage and transport)
 Accuracy is critical because of potential expensive damages to the load.
Objective and scope of automatic storage and retrieval system

 Automatic storage and retrieval of the system.

 Highly space efficient.
 Quick response time, to locate, store and retrieve items.
 Reduce labor cost due to automation.
 Flexibility in interface with other systems.

Overview of ASRS ( Fig 1.2)

Chapter-2

COMPONENT USED

 Electrical components:

 Programmable logic controller (PLC)

 Variable frequency drive (VFD)
 Relays
 Contactor
 Miniature circuit breaker (MCB)
 Choke
 Rectifiers
 Switched mode power supply (SMPS)
 Transformer
 Sensors

17
PLC (Programmable logic controller):-

PLC is a digital computer used for automation of electromechanical processes. PLC

let engineers/technicians integrate all the sensors and electromechanical devices together, and
let them use a simple programming language to perform complex motion controls or
condition surveillance.

In this project, we use PLCas the heart of all devices. The whole module includes
power supply, CPU, network, and I/O module. All of module fits into a base unit,
communicating with each other by using high-speed connection protocol.

A Programmable logic controller is an industrial controller that accepts input from switches
and sensors evaluate these in accordance with a stored program and generate outputs to
control machine and process.

A programmable logic controller is an electronic device that control machines

and process. It uses programmable memory to store the instruction and execute specific
function that include ON/OFF control, timing, counting , sequencing and data handling.

18
Fig 2.1

19
Product specification:

Part number: Q06UDEHCPU

Type: Universal CPU module
Manufacturer: Mitsubishi
PLC series: Q Series
Part number: Q06UDEHCPU
Description: Universal Q CPU module, 60k step memory, 9.5 ns per instruction, Ethernet
enabled
Height (mm): 98
Depth (mm): 89.3
Width (mm): 27.4

20
RELAY

A relay is an electrically operated switch. Many relays use an electromagnet to mechanically

operate a switch, but other operating principles are also used, such as solid-state relays.
Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where several circuits
must be controlled by one signal.

Fig 2.2

A relay is electromagnetic switch operated by a relatively small operated by a relatively small

electric current that can turn on or off a much larger electric current. The heart of a relay is an
electromagnet (a coil of wire that becomes a temporary magnet when electricity flows
through it)

21
The main operation of a relay comes in places where only a low power signal can be usedto
control a circuit. It is also used in place where only one signal can be used to control a lot of
circuits.

The application of relays started during the invention of telephones.

They were also used inlong distance telegraphy.They were used to switch the signal coming
from one source to destination.
After the invention of computers they were also used to perform Boolean and other logical
operation.

22
MCB (miniature circuit breaker)

A miniature circuit breaker is an automatically operated electrical switch designed to protect

an electrical circuit from damage caused by overload or short circuit. Its basic function is to
detect a fault condition and interrupt current flow. Unlike a fuse, which operates once and
then must be replaced, a circuit breaker can be reset (either manually or automatically) to
resume normal operation. Circuit breakers are made in varying sizes, from small devices that
protect an individual household appliance up to large switchgear designed to protect high
voltage circuits feeding an entire city.

Fig 2.3

The principal of operation is simple. An MCB functions by interrupting the continuity of

electrical flow through the circuit once a fault is detected. In simple terms MCB is a switch
which automatically turns off when the current flowing through it passes the maximum
allowable limit. Generally MCB are designed to protect against over current and over
temperature faults (over heating).

There are two contacts one is fixed and the other moveable. When the current exceeds the
predefined limit a solenoid forces the movable contact to open (i.e., disconnect from the fixed
contact) and the MCB turns off thereby stopping the current to flow in the circuit. In order to
restart the flow of current the MCB is manually turned on. This mechanism is used to protect
from the faults due to over currentor over load.

To protect against fault arising due to overheat or increase in temperature bi-metallic strip is
used. MCBs are generally designed to trip within 2.5 millisecond when an over current fault
arises. In case of temperature rise or over heating it may take 2seconds to 2 minutes for the
MCB to trip.

23
The following image shows the different internal parts of an MCB with top casing removed.

Fig 2.4

24
CONTACTOR

A contactor is an electrically controlled switch used for switching a power circuit, similar
[1]
to a relay except with higher current ratings. A contactor is controlled by a circuit
which has a much lower power level than the switched circuit.

Contactors come in many forms with varying capacities and features. Unlike a circuit
breaker, a contactor is not intended to interrupt a short circuit current. Contactors range from
those having a breaking current of several amperes to thousands of amperes and 24 V DC to
many kilovolts. The physical size of contactors ranges from a device small enough to pick up
with one hand, to large devices approximately a meter (yard) on a side.

Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal
evaporators, and other electrical loads

Fig 2.5

25
TRANSFORMER:-

Fig 2.6

When two inductors are mounted together so their electromagnetic fields

interact, we have a transformer. A power supply almost invariably, contains a
transformer. A transformer generally comprises two ( or more) sets of coils (or
winding) on a single core, designed so that maximum interactionand magnetic
coupling takes place. The winding are insulated from each other and insulated
from the core. The windings may be wound on top of each other. At low
frequencies the core may be made up from thin laminated soft-iron plates
forming closed loops and designed to reduce eddy current losses. At higher
frequencies the core may be dust iron, ceramic ferrite, or air cored.

The winding used to generate the magnetic flux is called the primary
winding
(connected to AC supply). The winding in which current is induced is the
secondary winding. The input supply must be an alternating current. The input
current sets up a changing magnetic field around the input or primary winding.

26
That field sweeps the secondary and induces a current in that secondary
winding.

THE TURNS RATIO:-

The number of turns on each winding determines the output voltage from the
transformer. The output voltage from the secondary is proportional to the ratio
of the turns on the windings.
A function of the transformer is to provide an AC supply at a voltage
suitable for rectifying to produce a stated DC output. The power output from
the secondary cannot exceed the power fed into the primary. Ignoring losses , a
step-down in voltage means that an increase in current from that lower voltage
winding is possible. Similarly , a step up voltage means a decrease in the
current output. So the gauge of wire used for the secondary winding may be
different to the wire used for the primary. ( the term “gauge of wire” refers to its
cross sectional area ). There will be some energy losses in a transformer,
usually appearing as heat.

27
VFD (variable frequency drive):-
A variable frequency drive, is a type of adjustable –speed drive used in electro mechanical
drive system to control ac motor speed and torque by varying motor input frequency and
voltage.
VFD areused in applications ranging from small application to the largest of mine mill drives
and compressors. However, around 25% of the world’s electrical energy is consumed by
electric motors in industrial applications, which is especially conducive for energy saving
using VFDs in centrifugal load service,andVFDs global market penetration for all application
is still relatively small.

A variable frequency drive is device used in a drive system consisting three main subsystems;
ac motor, main drive controller assembly, and drive/operator interface.

28
 Fig 2.7

AC Motor

The AC electric motor used in a VFD system is usually three-phase induction motor. Some
type of single phase motors can be used, but three phase motors are usually preferred. Various
types of synchronous motors offer advantage in some situations, but three-phase induction
motors are suitable for most purposes and generally the most economical motor choice.

Controller

The VFD controller is a solid state power electronics conversion system consisting of three
distinct subsystems:- a rectifier bridge converter , a dc current (dc) link, and an invertor .
Most drives are AC-AC drives in that they convert AC line input into AC inverter output.
However, in some applications such as common DC bus or solar applications drives are
configured as a DC-AC drives.

29
Operator interface

The operator interface provides a means for an operator to start and stop the motor and adjust
the operating speed. Additional operator control functions might include reversing, and
switching between manual speed adjustment and automatic control from an external process
control signal.

RECTIFIER

A rectifier is an electrical device that converts alternating current ,which periodically reverses
direction , to direct current , which flows in only one direction .This process is known as
rectification.`

Types of rectifier:-

There are three basic rectifier configurations, half wave, full wave and bridge .
Here we are used full wave rectifier.

Full wave rectifier:-

Ina full wave rectifier circuit two diodes are used. One for each half of the cycle .a multiple
winding transformer is used whose secondary winding is spilt equally into halves with a
common Centre tapped connection. This configuration results in each diode conducting in
turns when its anode terminal is positive with respect to the transformer Centre point c
producing an output during both half cyclers so it is 100 % efficient.

30
 Fig 2.8

Choke

In electronics, a choke is an inductor used to block higher frequency alternating current (AC)
in an electrical circuit, while passing lower frequency or direct current (DC).
Chokeisused to improve the power factor of the circuit. When power factor is less than one,
efficiency became good.

31
 Fig 2.9

SMPS (switched mode power supply)

A switched mode power supply is an electronic power supply that incorporates a switching
regulator to convert electrical power efficiently.
DC to DC converts and DC to AC converts belong to the category of switched mode
power supplies. The various type of voltage regulators, used in linear power supplies, fall in
the category of dissipative regulator, as as they have a voltage control element usually
transistor or zener diode which dissipates power equal to the voltage difference between an
unregulated input voltage and a fixed supply voltage multiplied by the current flowing
through it. The switching regulator acts as a continuously variable power converter and hence
its efficiency is negligibly affected by the voltage difference. Hence the switching regulator is
also known as ‘non-dissipative regulator’. In a SMPS, the active device that provides
regulation is always operated in cut-off or in saturation mode.

32
 Fig 2.10

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, and looks for changes in the field or return signal. The object being sensed is often
referred to as the proximity sensors target. Different proximity sensors targets demand
different sensors .
The maximum distance that this sensor can detect is defined “ nominal range “. Some sensors
have adjustment of the nominal range or means to report a graduated detection distance.

Proximity sensors can have a high reliability and long functional life because of the absence
of mechanical parts and lack of the physical contact between sensor and sensed object

33
 Fig 2.11

Graphical Operation Terminal (GOT)

GOT, a human machine interface, so designed as to be installed on the panel surface of a

control panel or operational panel and connected to the program connector of the PLC inside
the control panel.

• GOT allows the user to monitor and change various devices on the PLC while
checking the screen.

• Screens can be created by users and installed onto the GOT.

• GT Designer2 is software which is used to design the screens, layouts, etc.

34
 • GOT navigation screens were prepared using design software. We can control
function like extension/retraction, check for faults, addresses, Communication
Cable (CC) links and many more operations by navigating the GOT.
Below is an example of the designed GOT screens:

Fig 2.12

35
 Main screen of got

Fig 2.13

Chapter-3

Methodology of the project

1.Planning

36
2. During installation

IS project online /offline

A

Any Design problem

any design problem during system assembly

37
 Following certification is to be given

ELECTRICAL MECHANICAL

Wiring check
Nuts and bolts
Interlock check
tightening
Fault check
Weld check
visual
incorporation

38
 NO

3. Post installation

39
4. Finishing

40
Chapter-4

Hardware and software used in project

Hardware

 Limit switch
 Cylinders
 Induction Motor
 Solenoid
 Filter and regulator unit

41
Software

 GT designer
 GXdeveloper
 AutoCAD electrical

Limit switch

In electrical engineering a limit switch is a switch operated by the motion of a machine part
or presence of an object.

Fig 4.1

42
They are used for control of a machine, as safety interlocks, or to count objects passing a
point. A limit switch is an electromechanical device that consists of an actuator mechanically
linked to a set of contacts. When an object comes into contact with the actuator, the device
operates the contacts to make or break an electrical connection.

Limit switches are used in a variety of applications and environments because of their
ruggedness, ease of installation, and reliability of operation. They can determine the presence
or absence, passing, positioning, and end of travel of an object. They were first used to define
the limit of travel of an object; hence the name "Limit Switch.

A limit switch with a roller-lever operator; this is installed on a gate on a canal lock, and
indicates the position of a gate to a control system.

Standardized limit switches are industrial control components manufactured with a variety of
operator types, including lever, roller plunger, and whisker type. Limit switches may be
directly mechanically operated by the motion of the operating lever. A reed switch may be
used to indicate proximity of a magnet mounted on some moving part. Proximity switches
operate by the disturbance of an electromagnetic field, by capacitance, or by sensing a
magnetic field.

Rarely, a final operating device such as a lamp or solenoid valve will be directly controlled
by the contacts of an industrial limit switch, but more typically the limit switch will be wired
through a control relay, a motor contactor control circuit, or as an input to a programmable
logic controller.

Miniature snap-action switch may be used for example as components of such devices as
photocopiers, computer printers, convertible tops or microwave ovens to ensure internal
components are in the correct position for operation and to prevent operation when access
doors are opened. A set of adjustable limit switches are installed on a garage door opener to
shut off the motor when the door has reached the fully raised or fully lowered position.

43
Pneumatic Cylinder

Pneumatic cylinder(s) (sometimes known as air cylinders) are mechanicaldevices which

use the power of compressed gas to produce a force in a reciprocating linear
motion.Because the operating fluid is a gas, leakage from a pneumatic cylinder will not
drip out and contaminate the surroundings, making pneumatics more desirable where
cleanliness is a requirement.

44
 fig 4.2

Hydraulic Cylinder:-

A hydraulic cylinder (also called a linear hydraulic motor) is a mechanical actuatorthat is

used to give a unidirectional force through a unidirectional stroke. It has many applications,
notably in construction equipment (engineering vehicles), manufacturing machinery, and civil
engineering.

45
 Fig 4.3

Conveyor

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 andpackaging industries. Many kinds of
conveying systems are available, and are used according to the various needs of
different industries.

PHOTOELECTRIC SENSOR

Photoelectric sensors use a beam of light to detect the presence or absence of an object. This
technology is an ideal alternative to inductive proximity sensors when you require long
sensing distances or when the item you want to sense is non-metal. Our photoelectric sensors

46
satisfy applications found in many industries, such as material handling, packaging, food
processing, and transportation. For your specialized applications that require a non-standard
connector or cable, we can customize the sensor connections.

fig 4.4

SAFETY SENSOR:

Sensors that detect the presence of operators near hazardous machines of facilitates. The
lineup includes Scanners that use laser light for detection.

Fig 4.5

Filter regulator and lubricator

47
Airleaving a compressor is hot, dirty, and wet which can damage and shorten the life of
downstream equipment, such as valves and cylinders. Before air can be used it needs to be
filtered, regulated and lubricated.

An airline filter cleans compressed air. It strains the air and traps solid particles (dust, dirt,
rust) and separates liquid (water, oil) entrained in the compressed air.
Filters are installed in the air line upstream of regulators, lubricators, directional control
valves, and air driven devices such as cylinders and air motors.

Fig 4.6

Airline filters remove contaminantsfrompneumatic systems, preventing damage to equipment

and reducing production losses due to contaminant related downtime.

48
Downtime in an industrial plant is expensive,often it is the result of a contaminated and
poorly maintained compressed air system.

Selecting the proper size of filter for any applications should be done by determining the
maximum allowable pressure drop, which can be caused by the filter. The pressure drop can
be determined by referring to flow curves provided by the manufacturer.

There are three types of filters. General purposes, oil removal and vapor removal(coalescing
removal).

General purposes are used to remove water and particles, coalescing to remove oil and vapor
removal to remove oil vapor and odor.
Pressure regulators reduce and control fluid pressure in compressed air systems.
Regulators are also frequently referred to as PRVs (pressure reducing valves). Optimally, a
pressure regulator maintains a constant output pressure regardless of variations in the input
pressure and downstream flow requirements.
In practice, output pressure is influenced to some degree by a variation in primary pressure
and flow

Solenoid

49
 “A solenoid valve is an electromechanically operated valve. The valve is controlled by an
electric current through a solenoid.
Solenoid offer fast and safe switching.

Induction motor
An induction motor or an asynchronous motor is an AC electric motor in which the
electric current in the rotor needed to produce torque is obtained by electromagnetic
induction from the magnetic field of the stator winding.

Fig 4.7

3-phase induction motor

50
An electrical motor is such an electromechanical device which converts electrical energy into
a mechanical energy
In case of 3- phase induction motor, motor does not require any starting device, it is self-
starting induction motor.

Principal of 3-phase induction motor

It may be observed that the rotor speed should not reach the synchronous speed produced by
the stator. If speed equal, there would be no relative velocity, so no EMF induction in the
motor, no, current would be flowing , therefore no torque would be generated. Difference
between rotor speed and stator speed is called the slip.

GX developer (PLC programming software)

GXDeveloper supports all MELSEC controllers from the compact PLCs of the MELSEC FX
series to the modular PLCs including MELSEC systems Q. this software shines with a
simple , intuitive interface and a short learning curve.

GX Developer supports the MELSEC instruction list (IL), MELSEC ladder diagram
(LD) and MELSC sequential function chart (SFC) languages. You can switch back and forth

51
between IL and LD at will while you are working .you can program your own function block
and a wide range of utilities are available for configuring special modules for the MELSEC
system Q. And “ configure” is the operative word here- you no longer need to program
special function modules, you just configure them.

GX simulator also enables you to simulate all your devices and applications
responses for realistic testing.

Fig 4.8

GT Designer

GT designer is a screen design software program used to create HMI screens for
the entire line of Mitsubishi electric GOTs. A user –friendly windows environment provides a
simple and recognizable interface, facilitating a fast learning curve for new users.

GT designer is equipped with a parts library, a range of touch- switches and lamps, screen
preview functionality, a GOT communication settings utility, and a project consistency check
52
function. Together, these features combine to make GT designer a platform that produces
screens that simplify the control interface between the user and the machine.

Fig 4.9

Programming language:

 A program is user developed series of instructions or commands that directs the PLC
to execute actions.

53
  A programming language provides rules for combining the instructions so that they
produce the desired action.

 The most common used programming language is ‘ladder logic ’.

 Other language occasionally used to program the PLC’s include basic, c etc.

LANGUAGES
IEC 61131-3 standard

IEC 1131-3 is the international standard for programmable controller programming

languages. The following is a list of programming languages specified by this standard:

 Ladder diagram (LD)

 Sequential Function Charts (SFC)

 Function Block Diagram (FBD)

 Structured Text (ST)

 Instruction List (IL)

One of the primary benefits of the standard is that it allows multiple languages to be used
within the same programmable controller. This allows the program developer to select the
language best suited to each particular task.

Ladder Logic

Ladder logic is the main programming method used for PLC's. As mentioned before, ladder
logic has been developed to mimic relay logic. The decision to use the relay logic diagrams

54
was a strategic one. By selecting ladder logic as the main programming method, the amount
of retraining needed for engineers and trades people was greatly reduced.

The first PLC was programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers how
to program - so this programming method has stuck and it is the most common technique for
programming in today's PLC.

Mnemonic Instruction

There are other methods to program PLCs. One of the earliest techniques involved mnemonic
instructions. These instructions can be derived directly from the ladder logic diagrams and
entered into the PLC through a simple programming terminal.

Sequential Function Charts (SFC)

SFC have been developed to accommodate the programming of more advanced systems.
These are similar to flowcharts, but much more powerful. This method is much different from
flowcharts because it does not have to follow a single path through the flowchart.

Structured Text (ST)

Programming has been developed as a more modern programming language. It is quite

similar to languages such as BASIC and Pascal.

Structured Text (ST) is a high level textual language that is a Pascal like language. It is very
flexible and intuitive for writing control algorithms.

Function Block Diagram (FBD)

FBD is another graphical programming language. The main concept is the data flow that start
from inputs and passes in block(s) and generate the output.

Ladder Logic

Ladder logic has evolved into a programming language that represents a program by a
graphical diagram based on the circuit diagrams of relay logic hardware. Ladder logic is used
55
to develop software for programmable logic controllers (PLCs) used in industrial control
applications. The name is based on the observation that programs in this language resemble
ladders, with two vertical rails and a series of horizontal rungs between them. While ladder
diagrams were once the only available notation for recording programmable controller
programs, today other forms are standardized in IEC 61131-3.

The language itself can be seen as a set of connections between logical checkers (contacts)
and actuators (coils). If a path can be traced between the left side of the rung and the output,
through asserted (true or "closed") contacts, the rung is true and the output coil storage bit is
asserted (1) or true. If no path can be traced, then the output is false (0).

Each rung of ladder language typically has one coil at the far right. Some manufacturers may
allow more than one output coil on a rung.

Rung Input : Checkers (contacts)

 —[ ]— Normally open contact, closed whenever its corresponding coil or an input

which controls it is energized. (Open contact at rest)

 —[\]— Normally closed ("not") contact, closed whenever its corresponding coil or an
input which controls it is not energized. (Closed contact at rest)

Rung Output: Actuators (coils)

 —( )— Normally inactive coil, energized whenever its rung is closed. (Inactive at rest)

 —(\)— Normally active ("not") coil, energized whenever its rung is open. (Active at
rest).

Industrial STOP/START
56
 In common industrial latching start/stop logic we have a "start" button to turn on a
motor contactor, and a "stop" button to turn off the contactor

--+----[ ]--+----[\]----( )
| start | stop run
| |
+----[ ]--+

run
-------[ ]--------------( )
run motor

For safety reasons, an Emergency-Stop and/or Stop should be hardwired in

series with the Start switch, and the relay logic should reflect this.
--[\]----[\]----+--[ ]--+---------( )
ES Stop | Start | Motor
| |
+--[ ]--+
Run

Example-

PROBLEMSTATEMENT

SPARE TYRE TRANSFER SYSTEM

 In spare tyre system we put four wheels in a car along with one as a spare tyre .These
tyres are transferred through a tyre line having two stations. One for thefour main
wheels and other for the spare wheel. The four wheels have to be transferred to station
1 andevery fifth tyre should go to the station 2. Write a ladder logic for this system in
which one station should work at a time and tyre should be transferred one by one.
After transfer of all the tyres system should get reset.

Solution

INPUTS OUTPUTS
 Sensor for sensing  Motor1-Y1
tyre - X1  Motor2-Y2

57
-

Start

Initiate a counter

Sense the tyre

Is
Tyre
prese
nt
Increment
Counter
Is
Coun
ter
<=4
Motor1 Start
Increment
Counter

Is
Coun
ter
>=5
Motor2 Start

Reset Counter

Stop

58
Why we use ladder logic:

 The ladder logic programming language is an adaption of an electrical relay wiring

diagram, also and ladder diagram.

 Ladder logic is a graphical system of symbols and terms even those not familiar with
relay wiring diagram can easily learn it.

59
AutoCAD ELECTRICAL

AutoCAD electrical is a drawing tool for designing electrical drawings.

AutoCAD electrical design software is AutoCAD for controls designers, purpose-built
to create and modify electrical control systems. It includes all the functionality of
AutoCAD plus comprehensive symbol libraries and tools for automating control
engineering tasks.
AutoCAD electrical engineering software automates common design tasks and
facilitates drafting productivity. It includes all the functionality of AutoCAD software
features such as symbol libraries, bill of material (BOM) reporting, and PLC I/O
design that make control design faster and more efficient.

Print screen of AutoCAD electrical

Fig 4.10

60
Electrical symbols for AutoCAD

This popular AutoCAD block library contains 165 electrical symbols and contains 165
symbols grouped in the following categories:

 50 electrical diagram symbols

 61 power symbols
 45 lighting symbols
 9 grounding symbols
 Installs easily into AutoCAD .

61
Chapter -5

Project design

Over view of the design:-

Fig 5.1

AS/RS systems are designed for automated storage and retrieval of parts and items in
manufacturing, distribution, retail, wholesale and institutions. They first originated in the
1960’s initially focusing on heavy pallet loads but with the evolution of the technology the
handled loads have become smaller. The systems operate under computerized control,
maintaining an inventory of stored items.

Retrieval of items is accomplished by specifying the item type and quantity to be retrieved.
The computer determines where in the storage area the item can be retrieved from and
schedules the retrieval. It directs the proper automated storage and retrieval machine to the
location where the item is stored and directs the machine to deposit the item at a location
where it is to be picked up. A system of conveyors or automated guided vehicle is sometime
pare of AS/RS systems.

These take loads into out of the storage area and move them to the manufacturing
floor or loading docks. To store items, the pallet or tray is placed at an input station for the
system the information for inventor is entered into a computer terminal and the AS/RS system
moves the load to the storage area, determines a suitable location for the item, and stores the
62
load. As items are stored into or retrieved from the racks, the computer updates its inventory
accordingly.

Some important points which is used to design the project

 Basic concept

 Concept freeze

 Detail design

 Part drawing

 Assembly drawing

 Bill of material

 Procurement

INSTALLATION

63
INSTALLATION Procedure is also important for designing process

 Installation schedule preparation

 Schedule discussion with customer

 Offline installation ( machine assembly, electrical panels preparation)

 Machine dismantle and on-site installation

 Checking and on-line trial

 Safety working

 Final trial

 Commissioning ( handover project to customer)

Description of design:

64
 Inner layout of control panel

Fig 5.2

In inner layout of control panel electrical components are situated like VFDs, relays, rectifier,
bus bar, MCB, MPCB, PLC, choke, contactor, cc-link, power supply etc.
65
CONTROL POWER DIAGRAM

66
WIRING DIAGRAM

67
SEQUENCE DIAGRAM

68
DESIGN SELECTION

69
 Following ten conditions are used to select the design.

 Two or three shifts

 Critical inventory levels

 Production flexibility is essential

 Joint storage of parts and tools

 High land cost areas

 No limit on building height

 Skilled technicians or on shaft or available

 High value parts or assemblies are used

 The number of stock keeping units in not large

 Tight existing site space in which an AS/RS installation may eliminate the need to
move

Every situation is different but these guidelines provide an overview of the sorts of
application that are best suited to AS/RS

Relay diagram

70
71
WORK DONE BY ME ON THE PROJECT

1. Preparation of the electric circuit diagrams on AutoCAD software to be put in the

machines manual

2. Preparation of control panel and junction box layout on AutoCAD software to be put
in the machine manual
3. Making of input/output list for the PLC on AutoCAD to be put in the machines
manual.
4. Helped my mentor in the PLC programing of certain aspects of the machine

5. Preparation of the got screens for fault screens display

6. Wiring of the control panel

APPENDIX

Overview of PLC coding

72
73
74
TESTING AND RESULT

75
We started our project by making power supply. That is easy for me but when I turn towards
the main circuit , there are many problems and issues related to it, which are I faced , like
component selection, which components is better than other and its feature and cost wise also,
then refer the data other materials related to its.

I had issued with better or correct result , which I desired . And also the software problems.

I also had some GOT screens issues which were resolved continuity checks performed the
GT Designer.

We started testing the circuit from the power supply.

BIBLIOGRAPHY

76
Bibliography

 Reference Books

 MSIL ALB standard book

 MSIL ALB manual standard

 OMRON sensor manuals

 KEYNEE safety sensor manual

 AutoCAD learning manual

 Q- common instruction manual

 Q- CPU basics manual

 FR- series VFD manual

 WEBSITE

 www.rittal .in
 Mitsubishi electric.co.in
 www.omron.in
 Wikipedia

77
78