International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
Automation of Belt Conveyor System
Sanjeev Kumar Patti
Final Year M.Tech (CAID) Student
Department of Electrical & Electronics Engineering
The NIE, Mysuru-08
(Autonomous Institute under VTU, Belagavi)
Abstract - In this paper, a multi load on a multiple belt
conveyor system (BCS) is considered for implementation of
automated control system using PLC to ensure proper belt
conveyor for steady and safe operation. The closed loop
control system uses motor current as the feedback signal.
The current changes with the load and changes the control
signals for steady operation in real time. A control strategy is
implemented to control the speed of a motor-driven belt
conveyor by maintaining v/f a constant. The use of variable
frequency drive improves performance and productivity.
Index Terms - Programmable Logic Control (PLC),
Variable Frequency Drive (VFD), Belt Conveyor System
(BCS), Ladder Diagram (LD), Human Machine Interface
(HMI)
I. INTRODUCTION
Since technology for motion control of electric drives is
available, the use of programmable logic controllers (PLCs)
with power electronics in electric machine applications is used
in the manufacturing and automation [1], [5]-[7]. This offers
advantages such as lower voltage drop when turned on with
near to unity power factor. PLC’s in automation are used to
reduce production cost and to increase quality and reliability.
To develop industrial electric drive systems, it is necessary to
use PLCs interfaced with power converters, personal
computers, and other electric equipment
Many applications of induction motors require besides the
motor control functionality, the handling of several specific
analog and digital I/O signals, to name a few: trip signals,
on/off/reverse commands etc. To make electric drive system
versatile PLC must be added to the system structure. This
paper presents a PLC-based monitoring and control system for
three-phase induction motors used in BCS. It describes the
design and implementation of the configured hardware and
software.
The test results obtained on induction motor performance
using PLC, show improved efficiency and increased accuracy
in variable-load constant-speed-controlled operation [2]. Thus,
the PLC correlates and controls the operational parameters
such as the speed set point requested by the user and monitors
the induction motor for its operation.
109
S Nagendra Prasad
Associate Professor
Department of Electrical & Electronics Engineering
The NIE, Mysuru-08
(Autonomous Institute under VTU, Belagavi)
A PLC is a microprocessor-based device, designed for
automating processes in industrial environments [1, 6-7]. It
uses a programmable memory for the internal storage of user-
orientated instructions for implementing specific functions
such as arithmetic, counting, logic, sequencing, and timing. A
PLC can be programmed to sense, activate and control
industrial equipment and therefore, incorporates a number of
I/O pins, which allow electrical signals to be interfaced. Input
devices and output devices of the process are connected to the
PLC and the control program is entered into the PLC memory
by PLC software.
A. Literature Survey:
• Maria G. Ioannides [1] has discussed the
implementation of a monitoring and control system for the
induction motor based on programmable logic controller
(PLC) technology is described. Also, the implementation
of the hardware and software for speed control and
protection with the results obtained from tests on
induction motor performance is provided. The PLC
correlates the operational parameters to the speed
requested by the user and monitors the system during
normal operation and under trip conditions. Tests of the
induction motor system driven by inverter and controlled
by PLC prove a higher accuracy in speed regulation as
compared to a conventional V/f control system. The
efficiency of PLC control is increased at high speeds up to
95% of the synchronous speed. Thus, PLC proves
themselves as a very versatile and effective tool in
industrial control of electric drives.
• D. Sowmiya [2] has discussed the implementation of
monitoring and control of a variable frequency drive
(VFD) fed three phase induction motor (IM) using
programmable logic controller (PLC) technology for a
powder compacting hydraulic press (HP) machine is
described. The PLC co-ordinate the operational
parameters such as ram down, ram dawdling, ram clasp
and ram up in HP machine, during the operation. Typical
techniques for three phases IM are commonly provided by
mechanical and electrical equipment’s, but it has many
limitations of stator insulation failures and reduces the life
and efficiency of the system. In this proposed method,
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
new control method based on the PLC has been
introduced The HP machine Solenoid valves are
controlled using PLC as per the operation cycle. The
efficiency of a PLC control is increased at variable speeds
and thus increases the power consumption. Thus, the PLC
proves as a resourceful and effective tool for controlling
industrial electric drives.
II. HARDWARE DESCRIPTION
A. Variable Frequency Drive:
Induction motors operate at fixed designed speeds and are
ideally suited to applications where a constant output speed is
required. However motor applications have some kind of
varying speed demand and this includes processes such as
moving air and liquids (fans and pumps), winding reels and
Fig. 2 VFD block diagram
Variable frequency drives applied to AC motors are by far
the most common [4]. Their basic design consists of four
elements (Fig. 2):
• Converter: The working principle of rectifier is
changing the incoming alternating current (AC)
supply to direct current (DC). Different designs are
available and these are selected according to the
performance required of the variable frequency drive.
The rectifier design will influence the extent to which
electrical harmonics are induced on the incoming
supply. It can also control the direction of power
flow.
• Intermediate circuit: The rectified DC supply is
then conditioned in the intermediate circuit, normally
by a combination of inductors and capacitors. The
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precision tools. Historically in applications requiring precise
speed control such as paper winding reels expensive direct
current (DC) motors or hydraulic couplings are used to
regulate the machine speed, whereas in other applications the
processes have been controlled by opening and closing
dampers and valves, or changing output speeds with gears,
pulleys, and similar devices whilst the motor works at constant
speed.
In the 1980's and 1990's, variable frequency drives started
appearing on the electric market offering an alternative method
of control. A variable frequency drive, also called as
adjustable speed drive. The basic working principle is to vary
the frequency and voltage to change the motor's speed and
torque output.
majority of VFDs currently in the marketplace use a
fixed-voltage DC link.
• Inverter: The inverter converts the rectified and
conditioned DC back into an AC supply of variable
frequency and voltage. This is normally achieved by
generating a high frequency pulse width modulated
signal of variable frequency and effective voltage.
Semiconductor switches are used to create the output;
different types are available, the most common being
the Insulated Gate Bipolar Transistor (IGBT).
• Control Logic: The control unit controls the whole
operation of the variable frequency drive; it monitors
and controls the rectifier using PWM technique, the
intermediate circuit and the inverter to deliver the
correct output in response to an external control
signal.
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
B. Belt Conveyor System (BCS): • For fixed speed or constant speed conveyors and
The belt is supported along its length by rotating idler conveyor systems: AC induction motors are ideal for
rolls and suspended between pulleys at either end (Fig. 3). A conveyor systems that operate continuously in one
drive pulley is powered to rotate the belt and move the direction while AC reversible motors are ideal for
materials on the belt forward. conveyors that must reverse or change directions
repeatedly.
Selection of motor For BCS Control:

Fig. 3 Cross section of belt conveyor

• For conveyors where the speed needs to controlled or
vary during operation: AC Speed Control Motors as
well as Brushless DC Motors (BLDC Motors) that
offer a wide speed control range and constant torque
regardless of load.
• For conveyors that require higher accuracy,
positioning Stepper Motor and Servo Motor are used.
Stepper motors, with their ability to product high
torque at a low speed while minimizing vibration, are
ideal for applications requiring quick positioning over
a short distance.
C. Proposed Block Diagram:
As shown in Fig. 4 PLC acts as interface between HMI
and VFD. SMPS is used to convert 3-ϕ AC to 24V DC, which
is given as input to PLC. VFD is used for smooth speed
control of conveyor belt system. System consists of Conveyor
Belt Forward. / Reverse motion and Bowl up / down motion,
which is controlled by VFD. Inputs can be given manually
using push buttons or directly through HMI.

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 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)

Fig. 4 Proposed Block Diagram

D. List of Components: For Furnace outlet

11 Motor 3 3.7 KW, 3ф
control
TABLE 1: For Furnace outlet
LIST OF COMPONENTS 12 Motor 3 3.7 KW, 3ф
control

SL. COMPONENT III. SOFTWARE DESCRIPTION

PURPOSE RATING
NO. NAME A. PLC Programming:
6A, 10A, The function of the CPU is to control the operation of
1 MCB Protection memory and I/O devices and to process data according to the
16A 3ф
To limit fluctuations 6A, 12.5A program. Each input and output connection point on a PLC has
2 Choke an address used to identify the I/O bit. The method for the
in the main supply 3ф
3 Contactor Protection 12A, 3ф direct representation of data associated with the inputs,
outputs, and memory is based on the fact that the PLC memory
Over load
4 OLR 10A, 3ф is organized into three regions: input image memory (I), output
protection
image memory (Q), and internal memory (M). Any memory
For smooth speed 0.75 KW, location is referenced directly using %I, %Q, and %M.
5 VFD
control of motor 3.7KW 3ф
To step down The programming used is the ladder diagram method. The
300VA,
6 Transformer supply voltage to PLC system provides a design environment in the form of
415/220V
24V DC software tools running on a host computer terminal which
To convert AC to allows ladder diagrams to be developed, verified, tested, and
7 SMPS DC for control 6.5A 1ф diagonised. First, the high-level program is written in ladder
circuit and PLC diagrams. Then, the ladder diagram is converted into binary
For monitoring and instruction codes so that they can be stored in random-access
8 PLC control of speed of 40 I/O’s memory (RAM) or erasable programmable read-only memory
motor (EPROM). Each successive instruction is decoded and
For conveyor belt executed by the CPU.
9 Motor 1 3.7 KW, 3ф
control
For Bowl speed 0.75 KW,
10 Motor 2
control 3ф

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 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)

Fig. 5: Flowchart for main program

The PLC program uses a cyclic scan in the main program

loop such that periodic checks are made to the input variables
(Fig. 5). The program loop starts by scanning the inputs to the
system and storing their states in fixed memory locations
(input image memory I). The ladder program is then executed
rung-by-rung.
The software regulates the speed (Fig. 6) and monitors the
constant speed control regardless of torque variation. The
inverter being the power supply for the motor executes this
while, at the same time, it is controlled by PLC’s software. The
inverter alone cannot keep the speed constant without the
control loop with feedback and PLC. From the control panel,
the operator selects the speed set point (nsp) and the
forward/backward direction of rotation.
Fig. 6: Flowchart for speed control program
Software used to write Ladder Program is CX-One Ver.
9.2, Cx Programmer of OMRON make. Ladder Program
(LD )is written for two cases as shown in Fig. 7 & 8
CASE 1: WHEN CONVEYOR BELT IS STOPPED.
CASE 2: WHEN CONVEYOR BELT IS MOVING.
B. HMI Screen Development:
Human Machine Interface (HMI) screen developed using
Cx-Designer of OMRON make is shown in below Fig. 9 to
Fig. 12. Once the HMI screen is developed user can press to
enter the exact screen through which parameters can be
changed.

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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)

Fig. 8: Ladder Diagram for Case 2

• Screen 1 displays Main Screen (Fig. 9), which
Fig. 7: Ladder Diagram for Case 1
indicates Time, Alarm , Voltage, Current, Actual
Speed, Starting settings, Conveyor control screen,
Bowl control screen, emergency stop in case
system to be shut down during critical cases.

• Screen 2 displays conveyor control screen (Fig.

10), which indicates Time, Alarm, Reference and
Actual Speed of BCS, Forward / Reverse motion
of BCS. If Conveyor button is clicked it shows the
BCS of process. Also it contains options to go to
Main Screen, Bowl Screen, settings screen and an
Emergency Stop switch.

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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
Fig. 9: HMI Screen 1

Fig. 10: HMI Screen 2

• Screen 3 displays Bowl control screen (Fig. 11), which indicates Time, Alarm, Reference and Actual Speed of BCS,
Upward / Downward motion of BCS. If Bowl button is clicked it shows the BCS of process. Also it contains options
to go to Main Screen, Bowl Screen, settings screen and an Emergency Stop switch.

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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)

Fig.11: HMI Screen 3

• Screen 4 displays Start up Settings screen (Fig. 12), which can be used to enter Reference Speed value, Acceleration
time, Deceleration time. To start the main program and go to other screens directly.

Fig. 12: HMI Screen 4

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ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)

IV. RESULTS ANALYSIS AND DISCUSSIONS

The main objective of the project is to develop and
implement an automated control for a conventionally
(using gears & pulley) operating conveyor belt system
using VFD and PLC in order to increase the productivity
and accuracy. Fig. 13 & Fig. 14 show Hardware circuit.
Output of two cases is provided with Ladder diagram as
shown in Fig. 15 & Fig. 16.

Fig. 14: Front & Side View of Panel

Fig. 13: Inside View of Control Panel

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 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
Fig. 15: Output for Case 1

Fig. 16: Output for Case 2

• System is monitored continuously; the fault

CONCLUSION
Successful experimental results were obtained from the
previously described scheme indicating that the PLC can be
used in automated conveyor belt systems.
The monitoring control system of the induction motor
driven by inverter and controlled by PLC proves its high
accuracy in speed regulation at constant-speed-variable-load
operation.
Each rung of the program is executed and it will
energise the respective valves when the desired input is
true. Initially when the supply is on, the VFD will start and
the belt motor will be driven through the VFD.
The efficiency obtained by using PLC control is
increased as compared to the open-loop configuration of
the induction motor fed by an inverter.
HIGHLIGHTS OF IMPLEMENTATION:
• The system is running successfully through newly
automated system.
• The high accuracy and high productivity rate is
achieved.
• Frequent maintenance is not required.
occurrence if any can be cleared immediately
without any delay.
• Since there is no human interference it leads to
improved accuracy and productivity.
• Overall System efficiency is improved after
automation.
Thus, the PLC has proved to be a versatile and
efficient control and monitoring tool in industrial electric
drives applications.
REFERENCES
[1] Maria G. Ioannides “Design and Implementation of PLC-Based
Monitoring Control System for Induction Motor” in Proc. IEEE
Transactions on Energy Conversion, VOL. 19, NO. 3, Sep 2004.
[2] D. Sowmiya “Monitoring and Control of a PLC Based VFD Fed Three
Phase Induction Motor for Powder Compacting Press Machine” in
Proceedings of 7th International Conference on Intelligent Systems and
Control (ISCO 2013)
[3] Yusong Pang, Handbook on “Intelligent Belt Conveyor Monitoring and
Control”.
[4] B.Jayant Baliga, “Power Semiconductor Devices for Variable Frequency
Drives”, Invited Paper in IEEE, Vol. 82 No. 8, Aug 1994.

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ISSN: 0976-1353 Volume 23 Issue 6 –OCTOBER 2016 (SPECIAL ISSUE)
[5] Victor L. Kitts, William K. Stees, P.E, “The Application of Medium
Voltage VFD on Underground Mine Belt Conveyor System”, IEEE,2000

[6] G. Kaplan, “Technology 1992. Industrial electronics,” IEEE Spectr., vol.

29, pp. 47–48, Jan. 1992.

[7] A. Hossain and S. M. Suyut, “Monitoring and controlling of a real

timeindustrial process using dynamic model control technology,” in
Proc.IEEE Ind. Applicat. Soc. Workshop on Dynamic Modeling Control
Applications for Industry, 1997, pp. 20–25.G. Kaplan, “Technology
1992. Industrial electronics,” IEEE Spectr., vol.29, pp. 47–48, Jan. 1992.

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