Project on

Automated Height Based Box Sorting System

Using PLC

Submitted in partial fulfillment of the requirement of Last Year

Instrumentation Engineering
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802 )
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

under the guidance of

Ms. Pradnya Gokhale

Department of Instrumentation Engineering

Vidya Prasarak Mandal, Thane’s
Maharshi Parshuram College of Engineering
University of Mumbai
2019 - 2020
 Project on

Automated Height Based Box Sorting System

Using PLC

Submitted in partial fulfillment of the requirement of Last Year

Instrumentation Engineering

by
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

under the guidance of

Ms. Pradnya Gokhale

Department of Instrumentation Engineering

Vidya Prasarak Mandal, Thane’s
Maharshi Parshuram College of Engineering
University of Mumbai
2019 - 2020
 Certificate
This is to certify that, the following students have satisfactorily com-
pleted Project work on Automated Height Based Box Sorting System
Using PLC submitted to University of Mumbai in partial fulfillment of the
Last Year in Instrumentation Engineering course of Semester VII.

1. Sagar Santosh Bhosale (I 801)

2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

Ms. Pradnya Gokhale Mr. Avinash N. Pawar

Guide Head, Dept. of Instrumentation

Dr. Amitkumar Mane

Principal

i
 Approval sheet
Vidya Prasarak Mandal, Thane’s
Maharshi Parshuram Collage Of Engineering
District: Ratnagiri, Pin-415729

Department of Instrumentation Engineering

Approval Sheet

Project Entitled :Automated Height Based Box

Sorting System Using PLC

Submitted by
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

In partial fulfillment of B.E (Sem VIII) in Instrumentation Engineering Aca-

demic Year 2019-2020 is approved.

Guide Examiner
Ms. Pradnya Gokhale

Head, Dept. of Instrumentation Principal

Mr. Avinash N. Pawar Dr. Amitkumar Mane

ii
 Declaration
We declare that this written submission represents our idea in our own
words and where other idea or word have been included. We are adequately
cited and referenced the original source. We also declare that, We are ad-
hered to all principles of academic honesty, integrity and have not misrepre-
sented, fabricated or falsified any idea/data/fact/source in our submission.
We understand that any violation of the above will be cause for disciplinary
action by the Institute and can also evoke penal action from the source which
have thus not been properly cited or from whom proper permission has not
been taken when needed.

Name of the student

Signature
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

Date:

iii
 Ackowledgement

We take this opportunity to express our sincere gratitude towards our guide
Ms.Pradnya Gokhale from Department of Instrumentation Engineering,
VPM’s Maharshi Parshuram College of Engineering, Velneshwar,
(affiliated to University of Mumbai), for their encouraging and inspiring
guidance. We also wish to thank staff members of our college for their
support.

We wish to express our profound thanks to the Head of the institution,

Principal Dr.Amitkumar Mane and Head of the Department
Mr.Avinash Pawar for making us available all the facilities required to
complete the project.

Name of the students Signature

1. Sagar Santosh Bhosale (I 801)

2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)

iv
 Abstract
The drinking water crisis in Asia is reaching alarming proportions. It
might may very soon attain the nature of global crisis. Water is one of the
most essential nature’s gifts to the manhood and without water no one can
imagine their lives. Now, man recognized the water significance, particu-
larly where water is not easily available. Now this is being achieved in an
appropriate manner in city areas where the use of water is more than its
availability. Hence, it is of atmost important to preserve water for human
beings. There are several problems of electricity in rural area. Also, the
small towns are incapable to use electricity based level sensors in small in-
dustries or domestic tanks. In many agricultural fields and domestics there
is the problem of water scarcity. The water level indication can provide a
solution to this problem. In this project, the water level indication works
on the principle of diaphragm deformation. It will provide a water level in-
dication mechanism without power supply. The sensor consists of low cost
materials. Hence, sensor is cost effective, reliable and could be made easily
available in rural area.

Keywords: Level sensor, Measurement, Sensor design, Water level mea-

surement.

v
List of Tables
3.1 Technical Specification . . . . . . . . . . . . . . . . . . . . . 14

vi
List of Figures
2.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Proposed system . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 PLC Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Working of PLC . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Siemens S7-200 PLC . . . . . . . . . . . . . . . . . . . . . . 13
3.4 I/O Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6 Working Principle of DC Motor . . . . . . . . . . . . . . . . 18
3.7 IR Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Block Diagram of Overall System . . . . . . . . . . . . . . . 21

4.1 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . 23

4.2 Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Contents
Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Approval Sheet . . . . . . . . . . . . . . . . . . . . . . . . ii
Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Acknowledgement . . . . . . . . . . . . . . . . . . . . . . iv
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

1 Introduction 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Aim and objectives . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Problem statement . . . . . . . . . . . . . . . . . . . . . . . 2

2 Literature Review 3
2.1 Literature review . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Theoretical Analysis 7
3.1 Programmable Logic Controller . . . . . . . . . . . . . . . . 7
3.1.1 PLC Hardware: . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 How does PLC works? . . . . . . . . . . . . . . . . . 10
3.1.3 Communication: . . . . . . . . . . . . . . . . . . . . 11
3.1.4 Programming Languages in PLC: . . . . . . . . . . . 11
3.1.5 Timers and Counters in PLC : . . . . . . . . . . . . . 12
3.2 Siemens S7-200 PLC . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Technical Specifications: . . . . . . . . . . . . . . . . 14

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 3.2.2 Input Output Port: . . . . . . . . . . . . . . . . . . . 15
3.2.3 Features: . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Technical Details: . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.2 IR Sensor . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.3 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Block Diagram: . . . . . . . . . . . . . . . . . . . . . . . . . 21

4 Experimental Setup 23
4.1 Schematic Diagram: . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 FlowChart: . . . . . . . . . . . . . . . . . . . . . . . 24
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 1

Introduction
1.1 Introduction
Sorting is very important in any type of industry such as manufacturing
industry to improve the efficiency of system. In this project, we have devel-
oped a Low Cost Automation System for sorting the light weight boxes on
the basis of height variation. It will save the man power as well as increase
the consistency and flexibility. This will not only reduce manual efforts and
time consumed, but also prevents danger which might occur when human
beings work in hazardous environments such as chemical industries.

1.2 Aim and objectives

• To sort the boxes according to their height and simultaneously count
the sorted boxes.

• To save the time for inspection and reduce the efforts of the workers.

• To study overall operation of PLC.

• To design programming of the system using ladder logic software.

• To control overall operation of the system very safely.

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1.3 Motivation
• Manual sorting is the conventional approach that is preferred by indus-
tries which involves visual observation performed by human beings.

• The problem statement for the project is to create the electronic system
which can reduce the efforts of workers as well as to reduce the time
spent in inspection of components.

• In old days it was possible to implement manual labor for sorting similar
objects. But nowadays due to increased production and for minimizing
the labor expenditure for such unskilled task, industries cant afford
human errors for sorting these products. This forced industry to tend
towards atomizing the sorting process.

1.4 Problem statement

A reliable, low cost and simple level sensor design which doesn’t require
an electricity to mo.”Object Sortingnitor the water level. It will help in
reducing the water scarcity, further more it can indicate the amount of water
in the storage tank.

2
Chapter 2

Literature Review
2.1 Literature review
1. Kadiyam Sasidhar, Shaik Faiz Hussain, Syed Ali Safdar, Mohd Aleem
Uddin, published paper entitled as ”Design and Development of a PLC Based
Automatic Object Sorting”.
In this project they have sorted the objects as metallic and non-
metallic by using two DVD drives. The DVD drives acts accordingly to the
signals based on the sensing module. If the object is a metal then the first
drive pushes the object out of conveyor according to the program given in
the ladder programming and if the object is a non-metal then the second
drive pushes the object. And they both get to their initial position after
some time delay.

Figure 2.1: Block diagram

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2. Sushrut Kulkarni, Sanjay Singh, published paper entitled as Singh

Automated System Using Raspberry Pi
In this project they have used Raspberry Pi as a controller and
ultrasonic sensor for detection of the object. They have used webcam to
detect the shape and colour of object. On this basis of detection the controller
gives command to robotic arm, thus it sorts the objects as per their respective
compartments.

Figure 2.2: Block Diagram

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3. Rakhshan Zulfiqar, Bushra Mehdi, Rumaisa Iftikhar, Tahmina Khan,

et al., published paper entitled as ”PLC Based Automated Object Sorting
System”,
In this project they have distinguished metal, wood and plastic
based on their sizes viz., small, medium and large. They have used pneu-
matic double acting cylinders for sorting the objects.

Figure 2.3:

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4. R.Aravind, M.Arun Kumar, et al. published paper entitled as ”Auto-

matic Sorting In Process Industries Using PLC”,
In this paper they have used two conveyors for sorting. Both the
conveyors are perpendicular to each other. Sorting is based on the height
of object. The object will be sensed and moved forward on the next con-
veyor.Then the sorting will be done by forward or reverse movement of con-
veyor.

Figure 2.4: Proposed system

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Chapter 3

Theoretical Analysis
3.1 Programmable Logic Controller
A Programmable Logic Controller, or Programmable Controller is a dig-
ital computer used for automation of typically industrial electromechanical
processes, such as control of machinery on factory, or light fixtures. PLCs
are used in many machines, in many industries. PLCs are designed for
multiple arrangements of digital and analog inputs and outputs, extended
temperature ranges, immunity to electrical noise, and resistance to vibration
and impact. Programs to control machine operation are typically stored in
battery-backed-up or non-volatile memory. A PLC is an example of a hard
real-time system since output results must be produced in response to input
conditions within a limited time, otherwise unintended operation will result.
A Programmable Logic Controller is a specialized computer like device
used to replace bank of electromagnetic relays in industrial process control.
The PLC is also known as a programmable Logic Controller (PLC). The tile
PC for Programmable Controller could be confuse in common usage with
PC used to mean personal computer. To avoid this confusion, we shall refer
to the programmable controller as a programmable logic controller or PLC.
A Programmable Logic Controller (PLC) is an industrial computer con-
trol system that continuously monitor the state of input device and make
decision based upon a custom program to control the state of output de-
vices. Before the PLC, control, sequencing, and safety interlock logic
for manufacturing automobiles was mainly composed of relays, timers, and
dedicated closed-loop controllers. Since these could number in the hundreds

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or even thousands, the process for updating such facilities for the yearly
model change-over was very time consuming and expensive, as electricians
needed to individually rewire the relays to change their operational charac-
teristics.

3.1.1 PLC Hardware:

The hardware components of PLC system are CPU, Memory, Input/
Output, Power supply unit, and programming device. Below a diagram of
the system overview of PLC.

Figure 3.1: PLC Hardware

• CPU:
It keeps checking the PLC controller to avoid errors. They perform
functions including logic operations, arithmatic operations, computer
interface and many more. It has three subparts : memory system,
processor and power supply.

• Memory:
Fixed data is used by the CPU. System (ROM) stores the data per-
manantly for the operating system. RAM stores the information of the

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status of input and output device, and the values of timers, counters
and other internal devices.

• I/P Section :
Input keeps a track on field devices which includes sensors and switches.
Various input devices are connected to input module. Input module
gives signal to the controller and then controller takes the action based
on input signals. It acts as the interface between physical devices in the
real world outside the PLC and digital arena inside the PLC.

• O/P Section : Output has a control over the other devices which in-
cludes motors, pumps, lights and solenoids. The I/O ports are based
on Reduced Instruction Set Computer (RISC). The role of an output
module is to translate signals from the PLC’s CPU into a form that the
output device can use.

• Power Supply : The power supply provides power to memory system,

processor and I/O Modules. Certain PLCs have an isolated power sup-
ply. But, most of the PLCs work at 220 V AC or 24 V DC. It filters
and regulates the DC voltages to ensure proper computer operations.

• Programming Device : This device is used to feed the program into

memory of the processor. The program is first fed to the programming
device and later it is transmitted to the PLC’s memory. The program-
ming unit allows the engineer/technicians to enter the edit the program
to be executed.

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3.1.2 How does PLC works?

Figure 3.2: Working of PLC

Figure 3.2 In Programming mode it accepts the downloaded program

logic from the PC you would use to write the controlling program. The CPU
is then placed in run mode so that it can execute the program and operate
the desired process. In Run mode the PLC is in full operation, doing all its
self checks and operating governed by the program held in it. Reading the
inputs and setting the outputs accordingly.

Since some programming can be done while running, while some PLC
programming functions require it to be stopped. Putting a PLC into Stop
mode also turns off all the outputs. Handy for checking inputs with causing
anything to happen out of sequence. In Reset mode, it resets the PLC from
operating conditions back to switch on position. When this is done without
resetting any data memory registers, this is called a warm reset. If the reset
performed is full, for example resetting all I/O and data registers, it’s called
a cold reset.

A PLC program is generally executed repeatedly as long as the con-

trolled system is running. The status of physical input point is coppied to
an area of memory accessible to the processor, sometimes called the “I/O
image table”. The program is then run from its first instruction rung down

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to the last rung. It takes some time for the processor of the PLC to evaluate
all the rungs and update the I/O image table with the status of output. This
scan time may be a few milliseconds for a small program or on a fast pro-
cessor, but older PLCs running very large programs could take much longer
to execute the program.

3.1.3 Communication:
PLCs have built-in communications ports, usually 9-pin RS-232, RS-
422, RS-485, Ethernet. Various protocols are usually included. Many of
these protocols are vendor specific.

Most modern PLCs can communicate over a network to some other

system, such as a computer running SCADA system or web browser. PLCs
used in larger I/O systems may have peer-to-peer communication between
processors. This allows seperate parts of a complex process to have individual
control while allowing the subsystems to co-ordinate over the communication
link.

3.1.4 Programming Languages in PLC:

PLC programs are typically written in a special application on a per-
sonal computer, then downloaded by a direct connection cable or over a
network to the PLC. PLCs can be programmed using standards based pro-
gramming languages. There are five programming languages
1. Ladder Diagram
2. Functional Block Diagram
3. Structured Text
4. Instruction List
5. Sequential Function Chart

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3.1.5 Timers and Counters in PLC :

Many times we will want to take action in a control program based on
more than the states of discrete inputs and outputs. Sometimes, we will
want tonturn something on after a delay, or count the number of times a
switch is hit. To do these simple tasks, we will need timers and counters.
• Timers

A timer is simply a control block that takes an input and changes an

output based on time. The operation of timer is different in different PLCs.
There are two basic timers :
1. On-Delay Timer : This timer takes an input, waits for given
amount of time and then turns ON an output after the preset time.
2. Off-Delay Timer : This timer takes an input, and after taking input
it turns ON an output and keeps that output ON until the set amount of
time has elapsed. As the preset time is reached, then it turns an output OFF.

• Counters :

A counter simply counts the number of events that occur on an input.

There are two types of counters- Up counter and Down counter.
1. Up-Counter : Whenever a triggering event occurs, an up counter incre-
ments the counter by one. If the current value is equal to the preset value,
the output is set. When the reset is turned highnit set the count value back
to zero.
2. Down-Counter : Whenever a triggering event occurs, a down counter
decrements the counter by one. If the current value is equal to the preset
value, the output is set.

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3.2 Siemens S7-200 PLC

Figure 3.3: Siemens S7-200 PLC

The S7-200 CPU combines a microprocessor, an integrated power sup-

ply, input circuits, and output circuits in a compact housing to create a
powerful Micro PLC. Refer Figure 2.3. After you have downloaded your
program, the S7-200 contains the logic required to monitor and control the
input and output devices in your application. Siemens provides different
S7-200 CPU models with a diversity of features and capabilities that help
you create effective solutions for your varied applications.

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3.2.1 Technical Specifications:

Table 3.1: Technical Specification

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3.2.2 Input Output Port:

Figure 3.4: I/O Port

Fig. 2.4 shows the I/O port of Siemens S7-200 CN. In I/O port, eight
inputs and eight outputs are present. Voltage of Input terminal is 24 V
and Ouput terminal is 5V. Addresing of input and output devices is given
in table 2.2 and 2.3. In this I/O port, we can connect external inputs and
outputs by giving the same addresses of inbuilt input devices.

The connections from inbuilt input devices are given to the I/O port
and hence we can use the same address to the external input devices. The
connections of inbuilt output devices are given to the I/O port and hence
we can use the same address of inbuilt output devices to the external output
devices. 16

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Types of PLC

• Based on size
1. Micro PLC or Small PLC
2. Medium PLC or Mini
3. Large PLC or Rack

• According to it’s working

1. Relay based
2. Transistor based
3. SCR based

3.2.3 Features:
1. High execution speed
2. Easy downloading of programs
3. Industrial feel look
4. Powerful instruction sets
5. PC based Ladder programming
6. High execution speed
7. Extremely easy and student friendly
8. Software to develop different programs
9. Several sample ladder programs
10. Choice of PLC and expansion modules
11. Easy downloading of programs
12. Practice troubleshooting skills

3.3 Technical Details:

The process requires programmable logic controller as a main controller. The
various components required for a system are
1. Programmable Logic Controller
2. DC Motor

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3. Conveyer Belt Assembly

4. IR Sensor
5. Stepper Motor

3.3.1 DC Motor

Figure 3.5: DC Motor

A DC Motor is any of a class of rotary electrical machines that con-

verts direct current electrical energy into mechanical energy. The very basic
construction of a DC motor contains a current carrying armature which is
connected to the supply and through commutator segments and brushes.

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The armature is placed in between north south poles of a permanent or an

electromagnet.

Working principle of DC motor:-

It is based on the principle that when a current carrying conductor is
placed in a magnetic field, it experiences a mechanical force whose direction
is given by Fleming’s Left-hand rule and it’s magnitude is given by F=BIL
where, B=magnetic flux density, I= current, and L=length of conductor.

Fleming’s left hand rule:

If we stretch the first finger, second finger and thumb of our left
hand to be perpendicular to each other and direction of magnetic field is
represented by the first finger, direction of the current is represented by
second finger then the thumb represents the direction of the force experienced
by the current carrying conductor.

Figure 3.6: Working Principle of DC Motor

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If an electric current flows through two copper wires that are between
the poles of a magnet, an upward force will move one wire up and a downward
force will move the other wire down. The loop can be made to spin by fixing
a half circle of copper which is known as commutator, to each end of the
loop. Current is passed into and out of the loop by brushes that press onto
the strips. The brushes do not go round so the wire do not get twisted. This
arrangement also makes sure that the current always passes down on the
right and back on the left so that the rotation continues.

3.3.2 IR Sensor

Figure 3.7: IR Sensor

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3.3.3 Stepper Motor

Figure 3.8: Stepper Motor

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3.4 Block Diagram:

Figure 3.9: Block Diagram of Overall System

The basic block diagram (as shown in fig.3.7 above)of the process and
its explanation is given below :

• Input Module : The input module consist of IR sensor and toggle switch.
There is one IR sensor whose output is given as an input to the PLC. The IR
sensor is used for detecting the boxes according to their height. The output
of IR sensor is given to PLC for running or stopping the conveyer. Toggle
switch is used to start the process.

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• Signal Conditioning :

The output of the sensors cannot be given directly to the PLC as the in-
put voltage to PLC is 24V. Hence they are given through signal conditioning
circuits which condition the input signals and in turn give it as an input to
PLC. For safety purpose the inputs are not given directly to the PLC. They
are given through relay circuits. The relay consist of 3 terminals common,
NO and NC. The 24V which is to be inputted into the PLC will be available
in the common terminal. Hence depending upon the necessary signals, the
circuit closes or opens thereby connecting to the PLC.

• PLC :

All control operations are done using the PLC. The entire box sorting
process is automated by feeding the necessary conditions into the PLC using
ladder logic. Ladder logic is one of the methods of programming a PLC.
Thus, depending on the logic developed the various operations take place
and the sorting of boxes are done.

Output Module:

The output module includes DC motor, stepper motor. The DC motor

is used to run the conveyor in forward direction. Than the stepper motor
will sort the boxes according to their height, if the boxes are large then it
will rotate right direction and if the boxes are small than it will rotate left
direction.

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Chapter 4

Experimental Setup
4.1 Schematic Diagram:

Figure 4.1: Schematic Diagram

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4.1.1 FlowChart:

Figure 4.2: Flowchart

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References
[1] Kadiyam Sasidhar, Shaik Faiz Hussain et. ”Design and Development of a PLC
Based Automatic Object Sorting”, in International Journal of Research and Scientfic
Innovation (IJRSI) Volume IV, Issue XII,December 2017..

[2] Sushrut Kulkarni, Sanjay Singh,et al. ””Object Sorting Automated System Using
Raspberry Pi”, in International Conference on Communication and Electronics Sys-
tem,2018..

[3] Rakhshan Zulfqar, Bushra Mehdi, Rumaisa Iftikhar, Tahmina Khan, et al. ”PLC
Based Automated Object Sorting System”, in 4th International Electrical Engineer-
ing Conference, 2019.

[4] R.Aravind, M.Arun Kumar, et al. ”Automatic Sorting In Process Industries Using
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