Design and Implementation of Weight Based Quality Control and Pneumatic

Pressing System for Industrial Process Automation

Thet Htoo Aung#1, Zaw Myint Aung#2
Department of Electrical Power Engineering, Defence Services Technological Academy,
Pyin Oo Lwin, Myanmar
1
thartharyaryar2019@gmail.com
2
zawmyintaung1023@gmail.com

Abstract –This paper aims to develop pneumatic pressing system
including quality control process in order to achieve high quality
products. In this paper, the electro-pneumatic system is designed
with two main purposes of reducing electricity consumption and
understanding the working process of electro-pneumatic system.
The PLC ladder diagram programming is applied to control the
entire system as like as in industrial process control. This paper
helps not only in many industries under the Office of the Chief of
Defense Industry (OCDI) but also in other civilian industries
estates.
Keywords – Pneumatic Pressing System, Electricity
Consumption, PLC Control, Defense Industry.
I. INTRODUCTION
The automation and control processes have
developed significantly over the past decades. Only human
involved in industrial process and it caused so many
problems, like safety, health and industrial damages both to
humans and the developmental activities within the level of
industrial production and service delivery. The
development of automation in industrial process control
systems has certain advantages and disadvantages. By the
use of newest technologies in industries, the lives of human
workers become safe and the entire process can be done
easily.
For the entire process automation requirement,
software applications like the programmable logical
controller (PLC) can help to achieve this aim. PLCs operate
with the logic which is achieved by the programmer and the
program of the PLC is used for sequential operations to
complete both basic and complex task. The main advantage
of using PLC for controlling special devices in
manufacturing plant is the flexibility and change control via
program without any other alteration.
achieved by compressed air (or other inert gases) is
extensively used in hundreds of industries around the
world. Basically any factory, mine, construction site,
manufacture, many workshops, and others benefit from at
least some advantages of pneumatic system.
Conventional equipment systems lead the causing
of errors due to the involvement of humans in the data
collection and processing using complicated mathematical
expressions. Thus what we require is a system that collects
raw data, processes it and presents it in values which can be
verified and compared with the standard values.
A pneumatic press machine is always a better
choice than a hydraulic press machine for the production of
similar products if it is suited for the method. It is
comparatively more economical for production of large
quantities of products as it uses compressed air rather than
some hydraulic fluid which is rather expensive. A
pneumatic press machine uses compressed air to generate
high pressure to be applied on the piston. A solenoid valve
controls the directional flow of air into and out of the
cylinder. Polyurethane tubes are used for pressure
transmission from the pneumatic cylinder to the punch
assembly.

Fig.2 Bullet Production in Industry Using Proximity Sensor

Quality control is the most important part of the

Fig.1 Industrial Automation Process Using Pneumatic
Most of industrial equipment implemented
pneumatic systems on their installation. Pneumatic is
basically used for the requirement of high speed systems,
while hydraulic is for heavy loads. Pneumatics, which is
very popular branch of engineering, which uses power
industrial production. The proposed automation design is
using in many industrial productions. Industrial products
are needed to stamp their respective logo or product name.
Also, these products need standard weight to maintain
quality and if not, it is needed to move from assembly line.
Therefore, a suitable sequential automation process is
needed to solve this problem.
II. DIFFERENCE BETWEEN PNEUMATIC AND
HYDRAULIC
In the case of industrial automation, the pressing
process is done by pneumatic or hydraulic. These two
techniques have some advantages and disadvantages

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 respectively. These are shown in figure 3. By the facts of sensor, that sensor will detect and then DC motor will drive
this figure, pneumatic cylinder is suitable for this project. the lead screw (1) due to the PLC command. Thus, the
carrier will move forward along its route. When the carrier
Industrial Automation touch the limit switch of lead screw (1), the forward driving
DC motor will stop at that point. And then the carrier will
stop as well and it will wait for the component. The
inductive proximity sensor will detect and lead screw (1)
DC motor will drive reverse direction at this time while the
Pneumatic Hydraulic component arrives at the end of conveyor. Consequently,
the carrier will move reverse direction as well. While the
carrier keep going reverse direction, as soon as the
component touch the limit switch (2), the reverse driving
DC motor will stop immediately.
Safe system At that time, the carrier will also stop and it will
More cost
Faster operation be waiting for the up-down cylinder (1) of cylinder section.
Suitable for heavy
Less cost After that, the up-down cylinder (1) slides down and the
loads
Do not stand for heavy gripper (1) will clamp the component to carry it to the next
Slower operation
loads section. The up-down cylinder (1) will go up to finish its
function. In the next step, the left-right cylinder will
activate and it will push out the component to the rotary
Fig.3 Industrial Automation Options table section. After the left-right cylinder finish its task, the
up-down cylinder (1) will slide down again and unclamp
III. DESIGN OF THE AUTOMATION SYSTEM the component from the gripper (1) to the rotary table.
The proposed system design can be divided into six In the cylinder section, all of the cylinders do only
major sections and they are pushing and pulling functions to the end. As soon as the
(a) Weight based quality control section component arrives on the rotary table, the rotary motor will
(b) Belt conveyor section drive the rotary table in the clockwise direction because of
(c) Cylinder section the detection of inductive proximity sensor. Another
(d) Lead screw (1) section inductive proximity sensor is installed in the position of 90°
(e) Rotary table section clockwise direction from the previous one. Thus, the
(f) Lead screw (2) section component will stop at 90° clockwise from its start point on
rotary table and it will be pressed by the pressing cylinder.
(c) (d) (e) (f) After pressing the component, the rotary motor will drive to
the next 90° clockwise direction.
And then, the up-down cylinder (2) slides down
and the gripper (2) will clamp the component to carry it.
The up-down cylinder (2) will go up to finish its function.
DC motor will drive the lead screw (2) due to the PLC
(a) command. Thus, the carrier will move forward along its
route. When the carrier touch the limit switch of lead screw
(2), the forward driving DC motor will stop at that point.
Finally, the carrier will stop as well and the up-down
cylinder (2) will slide down again and unclamp the
component from the gripper (2) to the container.
(b)
IV. SAFETY FACTOR CALCULATION FOR BELT
CONVEYOR
Fig.4 Design of the Pneumatic Pressing System including Quality Control
Process The required specifications and structural
III. GENERAL WORKING PROCEDURE OF THE specification of belt conveyor are as follows:
ENTIRE SYSTEM Total weight of belt and Load (m1) - 0.7 kg
The above described sections will be controlled by Roller mass (m2) - 3.2 kg
a Programmable Logic Controller (PLC) step by step. Roller diameter (D) - 0.08966 m
In the quality control section, weight scale, Friction coefficient of sliding surface (μ) - 0.3
accepting cylinder, rejecting cylinder and container 1 are Belt and roller efficiency (η) - 0.9
involved. Firstly, the weight scale checks the product Belt speed (V) - 0.1 m/s
weight whether in the desired range or not. If the product is External force (FA) -0N
not between the standard ranges, the rejecting cylinder will Belt conveyor tilt angle (θ) - 0˚
operate and the product is removed from the weight scale.
Firstly, find the required speed range by using above data.
When the product is in the desired range, the accepting
cylinder will move the product onto the belt conveyor.
V ×60
Since the power was on, the conveyor motor was run and it NG=
will carry the product along the belt. As soon as the πD
component passes through the infrared obstacle avoidance
2
 0 . 1×60 T M =1 . 56 Nm
= 3 . 142×0 . 08966
Safety factor,
= 21.3 r/min
TM 1 .56
And than, calculation of moment of load inertia, = =15 .21
Inertia of belt and load,
TL 0 . 1026

π ×D 2 Therefore, J<JG, the total load inertia is less than

J 1 =m 1 ( ) the permitted value, so there is no problem. Usually, a
2π motor can operate at the safety factor 1.5~2 or more.
Calculated safety factor value for belt conveyor is 15.21,
3 . 142×0 . 08966 2 so, the selected motor can operate easily.
=0 . 7×( )
2×3 .142
V. SAFETY FACTOR CALCULATION FOR LEAD
−3
= 1.41×10 kg.m2 SCREW
The required specifications and structural
Inertia of roller, specification of lead screw are as follows:
Total weight of table and load (m) - 1 kg
1
J 2 =2×( ×m2 ×D2 ) Lead screw pitch (PB) - 2.5 mm
8 Total length of Lead screw (LB) - 500
mm
1 Lead screw shaft diameter (DB) - 8 mm
=2×( ×3 .2×0 .08966 2 ) Lead screw efficiency (η) - 0.9
8 Table speed (V) - 117 mm/s
−3 Friction coefficient of sliding surface (μ) - 0.05
= 6.43×10 kg.m2 Internal friction coefficient of preload nut (μ₀) -
0.3
Load inertia, Lead screw material density (ρ) -7900
kg/m³
J J
J= 1+ 2 Distance moved for one rotation of Lead screw
(A) - 2.5 mm
External force (FA) - 0 kg
= 1.41×10−3 + 6. 43×10−3 Lead screw tilt angle (α) - 0˚
−3
= 7.84×10 kg.m
Firstly, find the required speed range by using above data.

Permitted load inertia= 0.12 kg.m2 V ×60

NG=
PB
Load Torque,

Friction coefficient of sliding surface, 117×60

= 2. 5
F=F A +m. g .(sin θ+μ . cosθ )
= 2808 r/min

And then, calculation of moment of load inertia,

=0+0 .7×9 .807×(sin 0+0 .3×cos 0)
Inertia of lead screw,
=2.059 N π
J 1= ×ρ×LB ×D 4
Load Torque, 32 B

F×D
T L= π
2η = ×7 . 9×103 ×500×10−3 ×(8×10−3 )4
32
2 . 059×0 . 08966 −6
2×0 .9 = 1.59×10 kg.m2
=
Inertia of table and load,
=0.1026 Nm

Permissible load torque,

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 A 2 Calculated safety factor value for lead screw is 3.13, so, the
J 2 =m.( ) selected motor can operate easily.
2π
−3
2. 5×10 2
=1×( )
2×3 .142
−7
= 1.58×10 kg.m2
VI. PREPARING FOR IMPLEMENTATION OF
Load inertia, THE SYSTEM

J J
J= 1+ 2
A.Flow Chart for Control Decision

−6 −7
Flow charts are the important parts of the
= 1.59×10 + 1.58×10 implementation of the project and they can show how the
system is working step by step. Also, the decision making
= 1.748×10−6 kg.m2
steps are drawn to understand which is allowed or not.

Permitted load inertia= 5.47×10−6 kg.m2

Load Torque,

Friction coefficient of sliding surface,

F=F A + m. g .(sin α +μ .cos α )

=0+1×9 . 807×(sin 0+0 .05×cos 0)

=0.49 N

Lead screw pre load,

F 0.49
F0 =
3 = 3 = 0.16 N

Load Torque,

F×PB μ0 ×F 0 ×P B
T L= ×
2πη 2π
Fig.5 Flow Chart for Weight Based Quality Control Section
=
−3 −3
0.49×2.5×10 0.3×0 .16×2.5×10
+
2×3.142×0. 9 2×3 .142
−4
= 2.36×10 Nm

Permissible load torque,

-4 2
T M =7 . 4×10 kg . m
Safety factor,

TM 7 . 4×10−4
= =
TL 2 .36×10−4 3.13

Therefore, J<JG, the total load inertia is less than Fig.6 Flow Chart For Conveyor Section
the permitted value, so there is no problem. Usually, a
motor can operate at the safety factor 1.5~2 or more.
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 Fig.9 Flow Chart for Rotary Table Section

Fig.7 Flow Chart for Lead Screw 1 Section

Fig.8 Flow Chart for Cylinder Section

Fig.10 Flow Chart for Rotary Table Section (Press)

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 Fig.11 Flow Chart for Lead Screw 2 Section

B.Selecting Items for Control System

No. Description Required Qt'y Remarks

1 Start (Pushbutton) 1No.

2 Stop (Pushbutton) 1No.

Left-Right Cylinder Solenoid

3 1No.
valve

Up-Down Cylinder 1 Solenoid

4 1No.
valve

Up-Down Cylinder 2 Solenoid

5 1No.
valve

Pressing Cylinder Solenoid

6 1No.
valve

7 Gripper 1 Solenoid valve 1No.

8 Gripper 2 Solenoid valve 1No.

9 Belt Conveyor Motor 1No.

10 Lead Screw 1 Motor 1No.

11 Lead Screw 2 Motor 1No.

12 Rotary Table Motor 1No.

13 Inductive Proximity Sensor 4Nos.

Infrared Obstacle Avoidance

14 1No.
Sensor

15 Proximity sensor 1No.

16 Limit Switch 4 Nos.

6
 Rejecting Cylinder Solenoid
From the above components list, the actuator, 17 1 No.
Valve
sensors and controller for weight based quality control
section can be classified as follow. Weight accepting Cylinder
18 1 No.
Solenoid
(a) 20kg Load cell
(b) HX711 ADC weight module
(c) 2 Channel 5V Relay 19 12 V DC Relay 4 Nos.
(d) Arduino UNO
(e) 20*4 LCD 20 24 V DC Relay 10 Nos.
For the pneumatic pressing system, the required
components lists can be classified as follow. 21 12 V DC Power Supply 2 Nos.
(a) PLC Programmer
(b) Inductive Proximity Sensor 22 24 V DC Power Supply 1No.
(c) Infrared Sensor
(d) Proximity Sensor
(e) Limit Switch 23 5 V DC Power Supply 1 No.
(f) Photoelectric Sensor
Arduino UNO
24 1No.
Microcontroller
In this paper, the actuators and motors used in
system are: 25 2 Channel 5V Relay 1No.

(a) Double Acting Cylinder

(b) Lead Screw Motor 26 20 kg Load Cell 1No.
(c) Belt Conveyor motor
(d) Solenoid Valve
HX 711 Analog to Digital
(e) Pneumatic Parallel Gripper 27 1No.
Converter Weight Module
(f) 12V DC Relay

C.Wiring Diagrams of the Systems 28 230 V AC Relay 1 No.

The wiring diagrams are drawn for the purpose of 29 IVC1-1614MAR PLC 1 No.
knowing how the wires are connected to run the entire
system. These diagrams should be clear for the people
who don’t know the electrical wiring subject. Component List 48 Nos.

Fig.13 Wiring Diagram of Lead Screw 1 Motor

Fig.12 Wiring Diagram of Automated Pneumatic Pressing System

7
 Fig.17 Wiring Diagram of Inductive Proximity Sensor

Fig.14 Wiring Diagram of Conveyor Motor

Fig.18 Wiring Diagram of Rotary Table Motor

VII. HARDWARE IMPLEMENTATION AND TEST

RUN

(b)
(a)

(c)

Fig.15 Wiring Diagrams of Inductive Proximity Sensors

Fig.19 Implementation of the Automated Pneumatic Pressing System

Fig.16 Wiring Diagram of Lead Screw 2 Motor

Fig.20 Implementation of Pneumatic Pressing Control Section

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Fig.21 Implementation of Weight Based Quality Control Section

Fig.24 Implementation of Lead Screw 1 Section\

Fig.25 Implementation of Cylinder Section

Fig.22 Implementation of Weight Based Quality Control Section

Fig.26 Implementation of Rotary Table Section

Fig.23 Implementation of Conveyor Section

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 REFERENCES
[1] Peter Croser, Frank Ebel, 2002, “Pneumatic Basic Level”,©
Copyright by Festo Didactic GmbH & Co., 73770 Denkendorf.
[2] J. E. Hill, M.I.Prod.E., A.M.I. Mech.E.,1995, “Hydraulic &
Pneumatic Operation of Machines”, ODHAMS PRESS LIMITED,
LONG ACRE LONDON.
[3] John R. Hackworth and Frederick D. Hackworth, Jr.,
“Programmable Logic Controller: Programming Methods and
Application ”.
[4] Delmar, “Modern Control Technology Components & Systems”
(2nd Edition.)
[5] “Mechanical and Metal Trades Handbook”, VERLAG EUROPA
LEHRMITTEL. Nourney , Vollmer GmbH & Co. KG, 1st English
Edition.
[6] S. Ilango and V. Soundararajian, 2007, “Introduction to Hydraulics
and Pneumatics”, © 2007 by Pretice-Hall of India Private
Fig.27 Implementation of Lead Screw 2 Section Limited, New Delhi.
[7] https://www.google.com/url?sa=i&url=http%3A%2F%2Fatesci.com
%2Fdosyalar%2Fdosya
%2Fdosya_24122018114335.pdf&psig=AOvVaw3x2wGhLNakqvK
PNTAoQMa8&ust=1625624254855000&source=images&cd=vfe&
ved=0CAoQjRxqFwoTCJi3k9uq1fECFQAAAAAdA
AAAABAD

VI. CONCLUSION
A PLC-based controller for pneumatic press machine
including the quality control in manufacturing process has
been successfully designed and developed. Usually, a
motor can operate at the safety factor of 1.5~2 or more.
Calculated safety factor value for belt conveyor is 15.21
and lead screw is 3.13. In the actual system construction,
the conveyor and lead screw have to operate easily as well.
The actual and theory results of conveyor and lead screw
have to be the same. Moreover, when the load carrying on
the lead screw is operating with 2 times heavier than the
former one, it is also found out that the lead screw cannot
operate in this condition. This system is not located very
close to the pressing area though, when the component is
simply put on the conveyor, the press operation will be
automatically operated. According to the requirement, an
automation system should be considered as shown in the
following procedure. Firstly, the type of system will be
chosen and determined due to the operating component.
And then the sketch diagram should be drawn and the
including sensors, actuators and usable controller are
selected. After selecting the sensor, actuator and controller,
the phase of hardware implementation can be done for each
section. After that inputting the program and offline
simulation are accomplished. If the offline simulation step
is correct, the actuators can be installed to test and run the
system. The current constructed automation system is lower
cost than the ready-made machines. The automation lessons
can also be used for the teaching aid of under graduate
students. When the PLC trainings are learnt by the recruits
of Defend Industry, they will understand the lessons easily.
PLC based automation will reduce manufacturing time by
cutting down the delay occurring at every stage, which is
unavoidable in manual mode.

ACKNOWLEDGEMENT
The author would like to express his gratitude to his
supervisor Captain Zaw Myint Aung, Assistant Lecturer,
and Lt. Colonel Ohn Myat Win, Head of Electrical Power
Engineering.

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