Professional Documents
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1. INTRODUCTION
Today automation used in every industrial and many other application such as
loading ,shifting the material in various application point and also transferring the
material from one place to another
another place for saving time ,cost ,labor work, and do not
cause any damage to the material while shifting the material.
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1.2.1INTRODUCTION
1.2.1INTRODUCTION ABOUT CONVEYOR:
The belt consists of one or more layers of material they can be made out of
rubber. Many belts in general
general material handling have two layers. An under layer of
material to provide linear strength and shape called a carcass and an over layer called
the cover. The carcass is often a cotton or plastic web or mesh. The cover is often
various rubber or plastic compounds specified by use of the belt. Covers can be made
from more exotic materials for unusual applications such as silicone for heat or gum
rubber when traction is essential.
Material flowing over the belt may be weighed in transit using a belt weighter.
Belts with regularly spaced partitions, known as elevator belts,
belts, are used for
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transporting loose materials up steep inclines. Belt Conveyors are used in self-
unloading bulk freighters and in live bottom trucks. Conveyor technology is also used
in conveyor transport such as moving sidewalks or, escalators as well as on many
many
manufacturing assembly lines. Stores often have conveyor belts at the check-out
counter to move shopping items. Ski areas also use conveyor belts to transport skiers
up the hill. A wide variety of related conveying machines are available, different as
regards principle of operation, means and direction of conveyance, including vibrating
screw conveyors, pneumatic conveyors, the moving floor system, which uses
reciprocating slats to move cargo, and roller conveyor system, which uses a series of
powered rollers to convey boxes or pallets.Conveyors
pallets.Conveyors are used as components in
automated distribution and warehousing. In combination with computer controlled
pallet handling equipment this allows for more efficient retail, wholesale, and
manufacturing distribution. It is considered a labor saving system that allows large
volumes to move rapidly through a process, allowing companies to ship or receive
higher volumes with smaller storage space and with less labor expense.Rubber
Conveyor Belts are commonly used to convey items with irregular bottom surfaces,
small items that would fall in between rollers (e.g. a sushi conveyor bar), or bags of
product that would sag between rollers. Belt conveyors are generally fairly similar in
construction consisting of a metal frame with rollers at either end of a flat metal bed.
The rollers allow weight to be conveyed as they reduce the amount of friction
generated from the heavier loading on the belting. Belt conveyors can now be
manufactured with curved sections which use tapered rollers and curved belting to
convey products around a corner. These conveyor systemsare commonly used in
postal sorting offices and airport baggage handling systems.
Belt conveyors are the most commonly used powered conveyors because they
are the most versatile and the least expensive. Product is conveyed directly on the belt
so both regular and irregular shaped objects, large or small, light and heavy, can be
transp
transport
orted
ed success
successful
fully.
ly. These
These convey
conveyors
ors should
should use only
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highestt qualit
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y
premium belting products, which reduces belt stretch and results
re sults in less
les s maintenance
for tension adjustments. Belt conveyors can be used to transport product in a straight
line or through changes in elevation or direction. In certain applications they can also
be used for static accumulation or cartons.
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1.2.2INTRODUCTION
1.2.2INTRODUCTION ABOUT WHOLE SYSTEM:
This whole system is operated by proximity sensor, motor and PLC in our
project we use capacitive type of proximities sensor to sense the material at which
position and it gives the signal towards the PLC .The PLC of our project depends on
the number of input output module and analog signal .We select PLC in our project,
because Programmable Logic Controller, popularly known as PLC is a tool. It is the
imagination that limits it's scope.
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emerging towards controlling the speed of these conveyors by the use of computer
technology. Conveyors are used in a broad range of industries and applications to
move packaged goods, assemblies, process byproducts, or any material from one
place to another. A process designer will typically look for opportunities to use the
force of gravity to accomplish product movement. Electric motors are commonly used
when gravity cannot be employed or when the speed of a gravitational fall needs to be
controlled.
Airports, mines, cement plants, distribution facilities, assembly, and food processing
plants all utilize conveyors. Conveyors are typically constant torque loads, meaning
the required torque to drive a conveyor is independent of speed. A fixed amount of
torque is also required to overcome the frictional, or machine drag, portion of the total
load. Conveyors can have nominal amounts of friction and machine inertia for which
to compensate. Material flowing over the belt may be weighed in transit using a
beltweigher . Belts with regularly spaced partitions, known as elevator belts,
belts, are used
for transporting loose materials up steep inclines. Belt Conveyors are used in self-
unloading bulk freighters and in live bottom trucks. Conveyor technology is also used
in conveyor transport such as moving sidewalks or escalators
or escalators,, as well as on many
manufacturing assembly lines.
lines. Stores often have conveyor belts at the check-out
counter to
counter to move shopping items. Ski areas also use conveyor belts to transport skiers
up the hill.
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2. LIRERATURE SURVEY
The history of conveyor belts begins in the latter half of the 17th century.
Since then, conveyor belts have been an inevitable part of material transportation. But
it was in 1795 that conveyor belts became a popular means for conveying bulk
materials. In the beginning, conveyor belts were used only for moving grain sacks to
short distances.
The conveyor belt system and working were quite simple in the early days.
The conveyor belt system had a flat wooden bed and a belt that traveled over the
wooden bed. Earlier, conveyor belts were made of leather, canvas or rubber. This
primitive conveyor belt system was very popular for conveying bulky items from one
place to another. In the beginning of the 20th century, the applications of conveyor
belts became wider.
Hymle Goddard of Logan Company was the first to receive the patent for the
roller conveyor in 1908. The roller conveyor business did not prosper. A few years
Later, in 1919, powered and free conveyors were used in automotive production.
Thus, conveyor belts became popular tools for conveying heavy and large goods
within factories.
One of the turning points in the history of conveyor belts was the introduction
of synthetic conveyor belts. It was introduced during the Second World War, mainly
because of the scarcity of natural materials such as cotton, rubber and canvas. Since
then, synthetic conveyor belts have become popular in various fields.
The longest conveyor system in an Airport is the Dubai International Airport baggage
handling system at 92km. It was installed by Siemens and commissioned in 2008, and
has a combination of traditional belt conveyors and tray conveyors. With the
increasing demand in the market, many synthetic polymers and fabrics began to be
used in the manufacture of conveyor belts. Today, cotton, canvas, EPDM, leather,
neoprene, nylon, polyester, polyurethane, urethane, PVC, rubber, silicone and steel
are commonly used in conveyor belts. Nowadays, Industrial Mechanical the material
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used for making a conveyor belt is determined by its application.consists of two or
more, pulleys with a continuous loop of material - the conveyor belt - that rotates
about them. One or both of the pulleys are powered, moving the belt and the material
on the belt forward. The powered pulley is called the drive pulley while the
unpowered pulley is called the idler. There are two main industrial classes of belt
conveyors; Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport industrial
and agricultural materials, such as grain, coal, ores, boxes etc. generally in outdoor
locations. Generally companies providing general material handling type belt
conveyors do not provide the conveyors for bulk material handling. In addition there
are a number of commercial applications of belt conveyors such as those in grocery
stores.
Belt conveyors are the most commonly used powered conveyors because they are the
most versatile and the least expensive. Product is conveyed directly on the belt so
both regular and irregular shaped objects, large or small, light and heavy, can be
transported successfully. These conveyors should use only the highest quality
premium belting products, which reduces belt stretch and results in less
maintenance for tension adjustments. Belt conveyors can be used to transport
product in a straight line or through changes in elevation or direction. In certain
applications they can also be used for static accumulation or cartons.
The main problem of this system is required to keep continuous watch on each
conveyor current because of choking of transfer chute or jamming of conveyor. This
will tend to interruption of coal supply to boiler.
The existing system has sensing device like zero speed sensing,
receiving conveyor position sensing. It has also facility for selection
to operate conveyor avoiding control system i.e. manual run mod. In
some CHP there is facility of three type of selection. One is for start
or stop plant with auto mode. In this mod each conveyor will
operate sequentially after selecting the stream. Second which is in
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all CHP for start or stop of plant with manual mod. Third is operating
the system without any protection or interlock.
Manufacturers of conveyor belt systems offer holistic services. They will study
your needs, make recommendations, design special systems, and customize your
conveyor belt and systems. Many offer round-the-clock service and undertake
different kinds of service as well as preventive maintenance. Experts in the field of
conveyor belts, many companies share their knowledge and host content on sites that
explain in depth how one must choose a conveyor belt, how to optimize efficiency,
and all about maintenance, speeds, parts, safety concerns, and ergonomic design of
systems.
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2.4 Limitations
The main problem of this system is required to keep
continuous watch on each conveyor current because of choking of
transfer chute or jamming of conveyor. Many times it is required to
reduce the feeding rate by adjusting feeder to reduce the current of
conveyor. When current comes to normal again it is tried to
establish the required feed rate, if it is not again establish by
stopping the conveyor system the problem is identify and attended.
The major problem of this system when the conveyor motor power
fuses blown off, it will stop the rotation of conveyor but will not stop
the upstream conveyors as controller sense motor is running
because the control supply does not pick up motor off relay.
Because of this the logic of system fails.
We already told the speed of the process slow down because continuous
operation not done by this system because the material goes up take some time to shift
and the shaft also takes the some time to regain it’s position. There is also problem of
sensor in the field because sensor sense material position and then cylinder shaft goes
up by logic developed but when shaft goes up the shaft steam also sensed by sensor
and according to logic shaft not get there regain position similar thick happen in also
on upper cylinder. So this creates faulty operation.
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According to market survey we think that there is all where the problem of
shifting material from ground to up side because of area availability like in big malls,
airport so we develop the system which operated by pneumatic, advanced plc based
i.e. operated automatically and time consuming.
I think this type of technology will never heard until so we take idea of car
washing technology that developed in material shifting by use of conveyor belt.
METHODOLOGY
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3.2 WORKING
Our project is totally based on conveyor belt that is use to transfer the material
upward and downward direction. There is use of two conveyor belt first is upper side
and other is lower side and there is use of two electrically operated dcmotor and
proximity sensor to sense the material location and also use the PLC for automatic on
off the motor.
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This is total working of project by manually also we can operate this technique
without using sensor by pressing the push button of the control panel.
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The dc geared motor 1 is used to rotate the driver pulley of the conveyor belt.
As the belt moves the material passing on the belt proceeds. The speed of the belt is
maintained at certain level by the use of plc based assembly. The inductive or optical
sensors are used to count number of objects passing on the belt according to that the
speed is maintained and start /stop can also be contol.The main theme is to give
output of the sensor to plc and output of plc is given to the dc geared motor and
pneumatic cylinder for proper working .
3.4.1...Relay board:
. The Relay Card has six SPDT relays, each of which is rated to handle up to 250 V
AC, 1200 V·A (max. 10 A) or up to 30 V DC, 240 W (max. 8 A). Each relay draws
approximately 20 mA from the +24V power supply when energized. This current
draw can be reduced by approximately a factor of two by using the function call to
engage the power-save mode once a relay is energized.
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3.4.1.1 Specifications:
eight high quality relay contacts, 5A/230Vac max
relay outputs are transient suppressed using VDRs
LED confirmation on each relay contact
eight drive inputs to use with open collectors or regular switches
features 12Vdc / 200mA power output (for VM122 supply)
input power: 12Vac / 500mA (including 12V output)
(VM129)
3 Terminal
Step Down Rectifier Filter Vtg.
230vacTransformerr Reg.o/p
Regulator
Figure 3.4.2 Power Supply Design
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3.4.2.2 ADVANTAGES :
3.4.2.3 DISADVANTAGES :
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between rectifier and voltage regulator. In our project we use capacitor filter because
of his low cost, small size and litile weight and good characteristic. Capacitors are
connected in parallel to the rectifier o/p because it passes A.C. but does not pass at all.
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Size of core :
Size of core is one of the first consideration in regard of core and winding
configuration used. Generally following formula is used to find area or size of core.
Ai = (p1/0.87)
Where
Ai = Area of cross section in sq. cm.
P1 = Primary voltage
In Transformer P1 = P2
P2 = 12 X 500 X 10 –3 w.
= 6w.
so ,
Ai = (6/0.87)
= 2.62
Generally 10% of area should be added to core accommodate all turns for low Iron
losses and compact size.
So,
Ai = 2.88.
3.4.2.7Rectifier design :
C= -----------------------------
4. 3 r f RL
1
C = ------------------- = 1000F
4 3 0.1*50*28
3.5.1 PLC :
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Input module
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Choose from over 60 modules to control digital, analog, and temperature signals.
Numerous specialty modules from Rockwell Automation and third-party partners are
also available. With this complete and varied assortment of modules we can offer you
the flexibility and speed you need to configure all your control systems.
OUTPUT MODULE
These modules act as link between the CPU and the output devices in the
field.
Analog output module : Typical output from these modules is 4-20 mA, 0-10
V
Digital output module : Typical output from these modules is 24 V DC, 115 V
AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control
Applications
The SLC 500 provides cost-effective, reliable control in hundreds of thousands of
applications around the world — everything from amusement park rides and
microbreweries to pharmaceutical and food processes.
The smaller size of the SLC means that you can use an SLC in applications where you
can't afford the size and overhead of a traditional, full-size PLC. And its modular
design offers you the flexibility to buy exactly what you need.
SLC 500 controllers are ideally suited for OEM applications on the following types of
machinery:
• Packaging Machinery
• Conveyors and other Material Handling Machinery
• Machine Tools
• Textile Machinery
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capacitive proximity sensor have either a flat disc or rectangular sensing element
surrounded by a guard electrode that provides electrical isolation between the
proximity sensor and its housing. The guard also ensures that the lines of electrostatic
field emanating from the probe are parallel and perpendicular to the surface of the
proximity sensor.
In optical sensor one transmitter and receiver plate in build is located inbuilt it
use the optical ray to detect the object when object in target position the ray is
reflected back and received by inner plate and is operated.
Specification:
1. Switching Range:100mm
2. Switching freq.:10hz
3. Operating temp.: -14 to 158 0f
4. Measuring time:100micro sec.
3.5.3 DC MOTOR :
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Introduction
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Once actuated, compressed air enters into the tube at one end of the piston and, hence,
imparts force on the piston. Consequently, the piston becomes displaced (moved) by
the compressed air expanding in an attempt to reach atmospheric pressure.
Pneumatic systems are often found in settings where even rare and brief system
failure is unacceptable. In such situations locks can sometimes serve as a safety
mechanism in case of loss of air supply (or its pressure falling) and, thus, remedy or
abate any damage arising in such a situation. Due to the leakage of air from input or
output reduces the pressure and so the desired output.
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Although the diameter of the piston and the force exerted by a cylinder are related,
they are not directly proportional to one another. Additionally, the typical
mathematical relationship between the two assumes that the air supply does not
become saturated. Due to the effective cross sectional area reduced by the area of the
piston rod, the instroke force is less than the outstroke force when both are powered
pneumatically and by same supply of compressed gas.
This is derived from the relationship, between force, pressure and effective cross-
sectional area, which is:
F = p A\,
With the same symbolic notation of variables as above, but also A represents the
effective cross sectional area.
On instroke, the same relationship between force exerted, pressure and effective cross
sectional area applies as discussed above for outstroke. However, since the cross
sectional area is less than the piston area the relationship between force, pressure and
radius is different. The calculation isn't more complicated though, since the effective
cross sectional area is merely that of the piston less that of the piston rod.
For instroke, therefore, the relationship between force exerted, pressure, radius of the
piston, and radius of the piston rod, is as follows:
Where:
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Specification:
1. Model: DGS/SMS
2. Bore size: 12mm
3. Stroke: Up to 14 & 300mm
4. End cover: Aluminium
5.Barrel: Aluminium/Brass/S.S.
6.Piston: Brass/: Aluminium
7.Piston Rod: EN 8/ S. Steel
8.Pressure: Up to 12 bar
9.Temp.: 85 0c Max.
10. Medium :Air
3.5.5 SOLENOIDVALVE:
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The actuator is mechanically linked to a mechanical valve inside the solenoid valve.
The valve then changes state, either opening or closing to allow a liquid or gas to
either flow through or be blocked by the solenoid valve. A spring is used to return the
actuator and valve back to their resting state when the current flow is removed.
Specification:
1. Model: ARMSS/ARMDS
2. Size: 1/4”&1/2” BSP/NPT
3. Pressure: Up to 100 Bar
4. Medium:Air
5. Coil: All std. voltage available
Control panel is used for manual operation. we use here material for control panel is
plywood as frame. In control panel we design input and out put connection our
project. Here we use for input as switches and output as 10mm LED .while designing
inputs connection give +24v supply to the one terminal of all switches and respective
terminal given to the input card of plc. while designing outputs connection give -24v
supply to the cathodes terminal of all LED and by connecting 10kohm resister to the
anode terminal of LED given to the out terminal of plc.
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3.6.2: Frame:
The material use for frame is aluminum. we take the cutting plates aluminum
and develop the 3m length ,0.5m breadth and 3m height frame. The two conveyor are
placed on that at 1.5m first and 2.5m second conveyor belt is located. This conveyor
is placed on bicycle hub so we use four hub to support the one conveyorand four for
other conveyor second conveyor.the weight of frame is about 5kg.
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3.7.2 Flowchart
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4.IMPLEMENTATION
4.1 INTERFACING
4.2COMPONENT COSTING
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4.3.1 FEATURES
1. Maintain ace free operation. Break downs avoided hence no production loss.
2. The pc interface shows the entire data of the process occurred hence off line
data record can be done.
5. DC geared motor provides the gradual speed variation of the conveyer belt
system.
4.3 .2 LIMITATION
1. The system with PLC requires the programming which is done by the expense
in industry only hence the maintenance of the system is difficult.
2. As the conveyor belts are used the wear and tear is prominent
3. The torque speed characteristics of DC geared motors are not up to the mark
hence system suffers.
4.3.3Application of project
In chemical industries
In big malls
In pharmaceutical company
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Fertilizer industry
Automobiles industry
Marine industries
Cement industry
Food industry
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In few years ago we use simple electrically operated conveyor belt which is
time consuming and several labor power is required it has several disadvantage for
shifting of material from one place to other place Maintains free operation as break
downs avoided hence no production loss. The pc interface show the entire data of the
process occurred hence off line data record can be done. PLC interface provides much
flexibility for further enhancements. The system can be enhanced for parallel belts. It
is best auto operated conveyer belt system.
This report has been focused on the required conveyor control system, which
will fulfill requirements smooth material shifting . The control system, which will
replace the existing system, must overcome all the drawbacks of old system.
This system also work on reverse manner to shift material up to down, also for shift at
different height
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BIBLIOGRAPHY
M.A .Mazidi & J.G. Mazidi , 8051 Microcontroller and embedded systems()
• http:// www.plant-maintenance.com/articles/dust_suppression.pdf
• http://www.galtech.co.uk/gsm-autodialler.php
• http://www.emucamp.com.enhanced-wireless-gsm-trafficemulation-
• http://www.scribd.com/doc/7029820/Gsm-Wcdma-Seamless-Network
• http://portal.acm.org/citation.cfm?id=1598474
• http://linkinghub.elsevier.com/retrieve/pii/S108480450900073
• http://sciencelinks.jp/j-east/article/200510/000020051005A0295017.php
• http://www.encyclopedia.com/doc/1G1-161290543.html
• http://hobbyproject.com
• VB Pro
• Resonance Kit
• Kile Compiler
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CONTENTS
3.6.2 Frame
3.7 software design
3.7.1 ladder dig
3.7.2flowchart
4 IMPLEMENTATION
4.1Interfacing diagram
4.2 component costing
4.3 feature ,limitation &application
5 Conclusion & Future scope
BIBLIOGRAPHY
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LIST OF FIGURES.
ABSTRACT