Chapter 1

1. Introduction
In today's rapidly evolving industrial landscape, automation plays a pivotal role in enhancing
productivity, improving efficiency, and ensuring smooth operations across various sectors. One
crucial aspect of automation is the control of conveyor systems, which are extensively used for
material handling in industries such as manufacturing, logistics, and assembly lines. The precise
control of the direction and speed of conveyors is essential for optimizing workflow, reducing
errors, and maximizing throughput.
The capstone student project titled "Control of Direction and Speed of Stepper Motor-Controlled
Conveyor using PLC and SCADA" aims to develop a comprehensive solution for the automation
of conveyor systems. The project integrates two key technologies: Programmable Logic
Controllers (PLCs) and Supervisory Control and Data Acquisition (SCADA) systems.
PLCs are widely employed in industrial automation as versatile and robust controllers. They are
designed to monitor inputs, execute logic-based decisions, and control outputs based on pre-
programmed instructions. PLCs offer real-time control, reliability, and flexibility, making them
ideal for managing complex processes. In the context of this project, the PLC will serve as the
central control unit for the stepper motor-controlled conveyor system.
Stepper motors are commonly used in automation applications due to their precise positioning and
control capabilities. They provide rotational motion in discrete steps, enabling accurate movement
and positioning of conveyor belts. By integrating a stepper motor with the conveyor system, the
project aims to achieve precise control over the direction and speed of the conveyor.
Furthermore, the project incorporates SCADA systems to enable monitoring, data acquisition, and
visualization of the conveyor system's performance. SCADA systems consist of software
applications that collect real-time data from various devices and present it in a user-friendly
graphical interface. With the help of SCADA, operators can monitor the conveyor's operational
parameters, track production metrics, and respond to any anomalies promptly.
The successful implementation of the "Control of Direction and Speed of Stepper Motor-
Controlled Conveyor using PLC and SCADA" project will result in an efficient and intelligent
automation solution. It will provide industries with the ability to precisely control the direction and
speed of conveyor belts, optimizing material flow, reducing errors, and enhancing productivity.
Moreover, the integration of PLCs and SCADA systems will enable real-time monitoring and data-
driven decision-making, empowering operators to manage the conveyor system effectively.
Throughout this capstone project, the student team will explore various aspects, including
hardware integration, programming, system design, and human-machine interface development.
They will aim to deliver a functional prototype that showcases the potential of this automation
solution and its applicability in industrial settings.
By undertaking this project, the students will gain hands-on experience in automation
technologies, develop their programming and control skills, and contribute to the advancement of
industrial automation practices. Their efforts will not only benefit their academic growth but also
offer practical solutions that can be implemented in real-world scenarios.
In conclusion, the "Control of Direction and Speed of Stepper Motor-Controlled Conveyor using
PLC and SCADA" capstone project embodies the integration of PLCs, stepper motors, and
SCADA systems to create an intelligent and efficient conveyor automation solution. This project
represents a valuable opportunity for the students to apply their knowledge, acquire new skills,
and contribute to the field of industrial automation.

1.2 The project scope can be defined as follows:

The scope of the capstone student project "Control of Direction and Speed of Stepper Motor-
Controlled Conveyor using PLC and SCADA" encompasses the development and implementation
of an automation solution for controlling the direction and speed of a conveyor system. The project
aims to achieve the following key objectives:
1. Hardware Integration: The project will involve integrating a stepper motor with a conveyor
system to enable precise control over the direction and speed of the conveyor belt. The
students will explore the mechanical aspects of integrating the motor with the existing
conveyor setup, ensuring compatibility and optimal performance.
2. Programmable Logic Controller (PLC) Programming: The students will develop the
necessary PLC program to interface with the stepper motor and control its movement. The
PLC will receive input signals from sensors or operator commands and generate output
signals to regulate the motor's operation. The programming will encompass logic-based
decision-making, motor control, and coordination with the conveyor system.
3. SCADA System Development: The project will include the design and implementation of
a Supervisory Control and Data Acquisition (SCADA) system. The SCADA system will
provide a user-friendly interface for monitoring and controlling the conveyor system. It
will acquire real-time data from various sensors and present it in graphical form, enabling
operators to visualize the conveyor's status, parameters, and performance metrics.
4. Human-Machine Interface (HMI) Design: The students will develop an intuitive HMI for
the SCADA system, ensuring ease of use and efficient interaction between operators and
the conveyor control system. The HMI will enable operators to monitor the conveyor's
operation, adjust its speed and direction, and respond to any alarms or system events.
5. Testing and Validation: The project will involve rigorous testing of the implemented
automation solution to ensure its reliability, accuracy, and responsiveness. The students
will conduct tests to verify the motor's control over the conveyor's direction and speed,
evaluate the HMI's usability, and validate the overall system's performance against defined
specifications.
6. Documentation and Presentation: Throughout the project, the students will maintain
comprehensive documentation, including design specifications, hardware and software
 configurations, and programming details. They will also create a final project report and
deliver a presentation summarizing their work, methodology, findings, and
recommendations.
It is important to note that the project scope may be subject to limitations and constraints such as
time, budget, and available resources. The students will need to manage these factors effectively
to ensure successful completion of the project within the defined scope.
By accomplishing the objectives outlined within the project scope, the students will gain valuable
hands-on experience in automation technologies, PLC programming, SCADA system
development, and human-machine interface design. They will also contribute to the advancement
of conveyor control systems, providing a practical solution that can be applied in industrial settings
to enhance productivity, efficiency, and operational control.
 Chapter 2: Capstone project planning
2.1 Work breakdown structure (WBS)
Work Breakdown Structure (WBS) for the Capstone Student Project "Control of Direction and
Speed of Stepper Motor-Controlled Conveyor using PLC and SCADA":
1. Project Initiation and Planning 1.1 Define project objectives and scope 1.2 Conduct
research on stepper motor control, PLCs, and SCADA systems 1.3 Identify project
deliverables and milestones 1.4 Create a project schedule and timeline 1.5 Allocate
resources and define team roles
2. Hardware Integration 2.1 Analyze the existing conveyor system 2.2 Select and procure a
suitable stepper motor 2.3 Design and implement the mechanical integration of the stepper
motor with the conveyor system 2.4 Test and verify the functionality of the integrated
hardware
3. PLC Programming 3.1 Understand the requirements for stepper motor control 3.2 Develop
a PLC program to interface with the stepper motor 3.3 Implement logic-based decision-
making and control algorithms 3.4 Test and debug the PLC program 3.5 Integrate the PLC
program with the hardware setup
4. SCADA System Development 4.1 Identify SCADA software requirements 4.2 Design the
SCADA system architecture and database structure 4.3 Develop graphical representations
for real-time data visualization 4.4 Implement data acquisition from sensors and PLC 4.5
Create alarms, alerts, and event notifications 4.6 Test the SCADA system and ensure
proper data acquisition and visualization
5. Human-Machine Interface (HMI) Design 5.1 Define the HMI requirements and user
interface elements 5.2 Develop the graphical user interface for the SCADA system 5.3
Implement controls for adjusting conveyor speed and direction 5.4 Conduct usability
testing and incorporate feedback for HMI improvements
6. Testing and Validation 6.1 Conduct unit testing for individual components (PLC, SCADA,
HMI) 6.2 Integrate the hardware, PLC, SCADA, and HMI components 6.3 Perform
system-level testing to ensure proper communication and functionality 6.4 Validate the
system against defined specifications and performance criteria 6.5 Document test results,
issues, and resolutions
7. Documentation and Presentation 7.1 Maintain comprehensive documentation throughout
the project 7.2 Create a final project report summarizing the methodology, implementation,
and findings 7.3 Prepare a presentation highlighting the project's objectives, achievements,
and recommendations 7.4 Review and finalize all project documentation and deliverables
The work breakdown structure provided is a general outline and can be further expanded and
tailored based on the specific requirements and complexity of the project.
2.2 Timeline Development – Schedule
Timeline Development – Schedule for 12 weeks to complete the Capstone Student Project
"Control of Direction and Speed of Stepper Motor-Controlled Conveyor using PLC and
SCADA":
Week 1:
• Project initiation and planning
• Define project objectives and scope
• Conduct initial research on stepper motor control, PLCs, and SCADA systems
• Allocate resources and define team roles
Week 2:
• Hardware integration
• Analyze the existing conveyor system
• Select and procure a suitable stepper motor
• Begin designing the mechanical integration of the stepper motor with the conveyor
system
Week 3:
• Continue with hardware integration
• Complete the mechanical integration of the stepper motor with the conveyor system
• Test and verify the functionality of the integrated hardware
Week 4:
• PLC programming
• Understand the requirements for stepper motor control
• Begin developing the PLC program to interface with the stepper motor
Week 5:
• Continue with PLC programming
• Implement logic-based decision-making and control algorithms in the PLC program
• Test and debug the PLC program
Week 6:
 • SCADA system development
• Identify SCADA software requirements
• Design the SCADA system architecture and database structure
Week 7:
• Continue with SCADA system development
• Develop graphical representations for real-time data visualization
• Implement data acquisition from sensors and PLC
Week 8:
• Continue with SCADA system development
• Create alarms, alerts, and event notifications in the SCADA system
• Test the SCADA system and ensure proper data acquisition and visualization
Week 9:
• Human-Machine Interface (HMI) design
• Define the HMI requirements and user interface elements
• Begin developing the graphical user interface for the SCADA system
Week 10:
• Continue with HMI design
• Implement controls for adjusting conveyor speed and direction in the HMI
• Conduct usability testing and incorporate feedback for HMI improvements
Week 11:
• Testing and validation
• Conduct unit testing for individual components (PLC, SCADA, HMI)
• Integrate the hardware, PLC, SCADA, and HMI components
Week 12:
• Continue with testing and validation
• Perform system-level testing to ensure proper communication and functionality
• Validate the system against defined specifications and performance criteria
• Finalize project documentation, including the project report and presentation
The timeline provided is a general guideline and can be adjusted based on the project's specific
requirements, resources, and team capabilities. It is important to regularly review and update the
schedule to ensure progress is on track and to accommodate any unforeseen challenges that may
arise during the project's execution.

2.3 Cost Breakdown Structure

1. Hardware Costs:
• Stepper motor
• Conveyor system components
• Sensors and actuators
• Cables and connectors
2. Software Costs:
• PLC programming software
• SCADA software
• HMI development software
3. Equipment Costs:
• Computers/laptops for programming and development
• PLC hardware
• SCADA system hardware
• HMI display devices
4. Material Costs:
• Mounting brackets and hardware for motor integration
• Wiring and cable management materials
5. Consumables:
• Miscellaneous items like screws, nuts, bolts, and zip ties
• Electrical wiring components
• Prototyping materials (if applicable)
6. Training and Education:
• Workshops or courses on PLC programming and SCADA system development
• Learning resources and reference materials
 7. Travel and Transportation:
• Transport costs for procuring hardware and equipment
• Travel expenses for attending project-related meetings or presentations
8. Documentation and Printing:
• Printing and binding of project reports and documents
• Purchase of stationery and supplies for documentation purposes
9. Contingency:
• Miscellaneous costs and unforeseen expenses
• Buffer for any unexpected needs or changes during the project
The cost breakdown structure provided is a general outline and does not include specific values as
they may vary depending on factors such as location, project scale, available resources, and
procurement options. It is essential to assess and estimate costs accurately based on the project's
unique requirements and constraints.

Cost breakdown structure

SL No Description Qty Unit cost Total cost

1 Hardware Costs
Stepper motors 1 ₹ 30,000.00 ₹ 30,000.00
Programmable Logic Controller (PLC) 1 18000 ₹ 800.00
Sensors (limit switches, proximity sensors, etc.) 1 12000 ₹ 650.00
Wiring and electrical components 1 ₹ 8,00.00 ₹ 8,000.00
SCADA interface components 6 ₹ 120.00 ₹ 720.00
Power supply units 1 ₹ 600.00 ₹ 600.00
Total costs ₹ 30,200.00
2 Software Costs
PLC programming software (if not provided by
the educational institution) 1 ₹ 0.00 ₹ 0.00
Communication cables. 1 ₹ 650.00 ₹ 650.00
Total costs ₹ 650.00
3 Tools and Equipment Costs
Hand tools (screwdrivers, pliers, wire strippers,
etc.) 1 ₹ 450.00 ₹ 450.00
Power tools (drills, soldering irons, etc.) 1 ₹ 600.00 ₹ 600.00
Multimeter or other testing equipment 1 ₹ 400.00 ₹ 400.00
 Computer and programming equipment (if not
provided by the educational institution) 1 ₹ 0.00 ₹ 0.00
Total costs ₹ 1,450.00
4 Consumables Costs
Electrical wires and cables - set 1 ₹ 400.00 ₹ 400.00
Connectors and terminals - set 1 ₹ 500.00 ₹ 500.00
Fasteners (screws, nuts, bolts) - set 1 ₹ 150.00 ₹ 150.00
Adhesive and tapes -set 1 ₹ 80.00 ₹ 80.00
Prototyping materials (e.g., breadboards, circuit
boards) 1 ₹ 300.00 ₹ 480.00
Total costs
5 Documentation and Presentation Costs
Printing and binding of project documentation ₹ 0.00
Graphics and visual aids for the presentation ₹ 0.00
Stationery items (paper, pens, markers) ₹ 0.00
Total costs ₹ 0.00
6 Training and Education Costs
Workshops or training sessions for PLC
programming and DC motor control ₹ 0.00
Books or online resources for research and
learning ₹ 0.00
Total costs ₹ 0.00
7 Contingency and Miscellaneous Costs
Unforeseen expenses or changes in project
requirements ₹ 0.00
Shipping and handling fees for procuring
components ₹ 0.00
Travel expenses (if applicable) ₹ 0.00
Safety equipment and supplies ₹ 0.00
Total costs ₹ 0.00
8 Faculty/Advisor Support Costs
Consultation or guidance fees ₹ 0.00
Total costs ₹ 0.00

Total cost of capstone project ₹ 32,300.00

2.4 Capstone project Risks assessment

2.4.1 Risk assessment

SL If Yes, strategies to
Description NO YES
No mitigate this risk
1 Technical Risks:
a. Incompatibility between the PLC and
hardware components. √
b. Difficulties in programming the PLC
for accurate counting and conveyor
control. √
c. Sensor malfunction or inaccuracies in
metal parts detection. √
d. Motor controller or DC motor failure. √
e. Insufficient torque or power from the
motor to handle the required load. √
2 Schedule Risks:
a. Delays in hardware procurement and
delivery. √
b. Unexpected challenges in programming
or debugging the PLC. √
c. Unforeseen issues during system
integration and testing. √
d. Insufficient time for documentation and
finalizing the project report. √
3 Cost Risks:
a. Budget overruns due to unforeseen
expenses, such as component
replacements or additional equipment
requirements. √
b. Higher costs for hardware components
or software licenses than initially
anticipated. √
c. Inaccurate cost estimation leading to
insufficient funds for project completion. √
4 Safety Risks:
a. Hazards associated with working with
electrical components and machinery. √
b. Inadequate safety measures leading to
potential injuries or accidents. √
c. Failure to implement proper emergency
stop mechanisms or safety barriers. √
5 Quality Risks:
a. Inaccuracy or inconsistency in metal
parts counting. √
 b. Lack of precision in conveyor speed
control. √
c. Mechanical misalignments affecting the
smooth operation of the conveyor system. √
d. Insufficient reliability or durability of
the overall system. √
6 Resource Risks:
a. Limited availability of necessary
equipment or tools for system assembly
and testing. √
b. Insufficient access to relevant technical
resources or expertise for troubleshooting
and guidance. √

2.4.2 To mitigate these above risks, consider the following strategies:

1. Conduct thorough research and planning before starting the project.

2. Seek advice from mentors or experts in PLC programming and conveyor systems.
3. Test components and systems at each stage of the project to identify issues early on.
4. Allocate sufficient time for testing, debugging, and documentation.
5. Implement proper safety measures and adhere to industry standards.
6. Regularly communicate and update project stakeholders on progress and challenges.
2.5 Requirements Specification

2.5.1 Functional specification

Functional Requirements Specification for the Capstone Student Project "Control of Direction and
Speed of Stepper Motor-Controlled Conveyor using PLC and SCADA":
1. Conveyor Control: 1.1 The system shall control the direction of the stepper motor-
controlled conveyor. 1.2 The system shall control the speed of the conveyor belt. 1.3 The
system shall allow the operator to start, stop, and change the direction of the conveyor. 1.4
The system shall provide precise control over the positioning of the conveyor belt.
2. PLC Functionality: 2.1 The PLC shall receive input signals from sensors to monitor the
state of the conveyor system. 2.2 The PLC shall process the input signals and generate
output signals to control the stepper motor. 2.3 The PLC shall execute logic-based decision-
making to coordinate the motor's operation with the conveyor system.
 3. SCADA System Functionality: 3.1 The SCADA system shall acquire real-time data from
the conveyor system, including motor status, speed, and direction. 3.2 The SCADA system
shall display real-time graphical representations of the conveyor's performance and
operational parameters. 3.3 The SCADA system shall provide a user-friendly interface for
monitoring and controlling the conveyor system. 3.4 The SCADA system shall allow the
operator to adjust the conveyor speed and change its direction through the HMI.
4. Human-Machine Interface (HMI): 4.1 The HMI shall provide an intuitive and user-friendly
interface for operators to interact with the conveyor control system. 4.2 The HMI shall
display real-time data, such as conveyor status, motor speed, and direction, in a visually
clear and concise manner. 4.3 The HMI shall allow the operator to start, stop, and change
the direction of the conveyor through intuitive controls. 4.4 The HMI shall display alarms,
alerts, and notifications to promptly inform the operator about any system events or
anomalies.
5. System Integration: 5.1 The PLC and SCADA system shall be seamlessly integrated to
ensure real-time data exchange and coordinated control of the conveyor system. 5.2 The
SCADA system shall receive data from the PLC and update the graphical representations
in real-time. 5.3 The HMI shall communicate with the PLC and SCADA system to send
control commands and receive system status information.
6. Safety and Fault Handling: 6.1 The system shall include safety measures to ensure the
operator's protection, such as emergency stop functionality. 6.2 The system shall handle
faults and errors gracefully, providing clear feedback to the operator and taking appropriate
actions to mitigate risks.
7. Performance and Testing: 7.1 The system shall meet predefined performance criteria, such
as accuracy in controlling the conveyor's speed and direction. 7.2 The system shall undergo
rigorous testing to verify its functionality, reliability, and responsiveness. 7.3 Performance
testing shall include verifying the motor's precise control over the conveyor,
responsiveness of the HMI, and data acquisition accuracy.
8. Documentation and Reporting: 8.1 The project team shall maintain comprehensive
documentation throughout the project, including design specifications, test plans, and
implementation details. 8.2 A final project report shall be prepared, summarizing the
project's objectives, methodology, implementation, test results, and conclusions.
The functional requirements specified above serve as a general guideline and may be expanded or
customized based on the specific needs of the project. It is crucial to conduct thorough analysis
and discussions with stakeholders to identify and define the precise functional requirements of the
system.
2.5.2 Non-functional Requirements Specification

1. Reliability: 1.1 The system shall operate reliably without unexpected failures or downtime.
1.2 The system shall recover gracefully from errors or faults to ensure continuous
operation. 1.3 The system shall have a backup power supply or contingency plan to
minimize disruptions in case of power outages.
2. Performance: 2.1 The system shall provide real-time control over the direction and speed
of the stepper motor-controlled conveyor. 2.2 The system shall exhibit low latency in
processing control commands and updating the conveyor's state. 2.3 The system shall
ensure smooth and consistent movement of the conveyor belt without jerks or fluctuations
in speed.
3. Scalability: 3.1 The system architecture and design shall be scalable to accommodate future
expansion or modifications, such as adding more conveyors or integrating additional
control features. 3.2 The system shall handle increased loads or conveyor sizes without
compromising performance or functionality.
4. Usability: 4.1 The human-machine interface (HMI) shall be intuitive and user-friendly,
requiring minimal training for operators to understand and operate the system effectively.
4.2 The HMI shall have a clear and organized layout, ensuring easy navigation and
visibility of relevant information. 4.3 The system shall provide appropriate feedback to
operators, such as status indicators or notifications, to enhance usability.
5. Security: 5.1 The system shall implement robust security measures to protect against
unauthorized access or tampering. 5.2 Access to critical functions or system settings shall
be restricted to authorized personnel only, using secure authentication mechanisms. 5.3
The system shall maintain data integrity and confidentiality, preventing unauthorized data
manipulation or disclosure.
6. Maintainability: 6.1 The system shall be designed and implemented with modularity and
code reusability in mind, facilitating future maintenance and enhancements. 6.2 The system
documentation shall be comprehensive and well-organized, aiding in troubleshooting,
maintenance, and future development. 6.3 The system shall provide logs or diagnostic tools
to assist in identifying and resolving issues efficiently.
7. Compliance: 7.1 The system shall adhere to relevant industry standards, regulations, and
safety guidelines. 7.2 The system shall comply with any specific requirements imposed by
the project stakeholders or intended deployment environment.
8. Compatibility: 8.1 The system shall be compatible with the existing conveyor system
components and infrastructure. 8.2 The system shall support interoperability with other
industrial automation systems or devices, allowing seamless integration into the broader
ecosystem.
The non-functional requirements provided above should be tailored and expanded based on the
specific project context and stakeholder expectations. Careful consideration of these requirements
is essential to ensure the successful implementation and deployment of the system.

2.5.3 User input requirements specification

User Input Requirements Specification for the Capstone Student Project "Control of Direction and
Speed of Stepper Motor-Controlled Conveyor using PLC and SCADA":

1. Start/Stop Functionality: 1.1 The system shall provide a user interface element or button to
initiate the conveyor's operation. 1.2 The user shall be able to stop the conveyor using a
dedicated control on the interface.

2. Direction Control: 2.1 The user shall be able to change the direction of the conveyor's
movement through the user interface. 2.2 The interface shall provide clear indicators or visual
cues to show the current direction of the conveyor.

3. Speed Adjustment: 3.1 The user shall have the ability to adjust the speed of the conveyor belt
using the interface controls. 3.2 The system shall provide discrete speed levels or a continuous
speed control mechanism for fine-tuning the conveyor's speed.

4. Emergency Stop: 4.1 The user interface shall include an easily accessible emergency stop
button to halt the conveyor's operation immediately in case of emergencies. 4.2 Pressing the
emergency stop button shall override all other controls and stop the conveyor's movement
instantly.

5. Error Handling and Notifications: 5.1 The system shall display clear error messages or
notifications on the user interface in case of any system errors or faults. 5.2 The user interface
shall provide appropriate feedback to the user when an invalid command or operation is
attempted.

6. Operational Status: 6.1 The user interface shall display the current status of the conveyor,
indicating whether it is running, stopped, or in an emergency stop state. 6.2 The user interface
shall show the current speed and direction of the conveyor in real-time.

7. User Authentication and Access Control: 7.1 The system shall implement user authentication
mechanisms to ensure only authorized personnel can access and control the conveyor system.
7.2 The user interface shall provide appropriate login screens or access controls to authenticate
users.

8. Interface Intuitiveness: 8.1 The user interface shall be designed to be intuitive and easy to
understand, requiring minimal training for users to operate the system effectively. 8.2 The user
interface elements, such as buttons, sliders, or input fields, shall be logically organized and
labeled clearly.
 9. Multilingual Support: 9.1 The user interface shall support multiple languages to accommodate
users with different language preferences or requirements. 9.2 The system shall provide the
option for users to select their desired language from a language menu or settings.

10. Accessibility: 10.1 The user interface shall adhere to accessibility guidelines, ensuring it is
usable by individuals with disabilities or specific accessibility needs. 10.2 The system shall
provide alternative input methods, such as keyboard shortcuts or voice commands, to
accommodate users with limited physical capabilities.

The user input requirements specified above should be customized and expanded based on the specific
project's target users, their needs, and the usability considerations. It is essential to gather input from
potential users or stakeholders to ensure the user interface meets their expectations and facilitates
smooth operation of the system.

2.5.4 Technical constraints

1. Hardware Compatibility:
• The system design should consider the compatibility of the chosen PLC, stepper
motor, conveyor system, and sensors.
• The selected components should be compatible with each other and able to
communicate effectively.
2. Communication Protocols:
• The PLC, SCADA system, and HMI should support compatible communication
protocols to ensure seamless data exchange.
• The chosen protocols should be able to handle real-time data transmission between
the components.
3. Power Requirements:
• The electrical system should meet the power requirements of the stepper motor,
PLC, SCADA system, and other associated components.
• Adequate power supply and distribution should be ensured to prevent performance
issues or system failures.
4. System Performance:
• The system should be designed and implemented to meet the performance
requirements, including accurate control of motor speed and direction.
• The control loop should be optimized to minimize delays and ensure responsive
operation.
5. Memory and Storage:
• The PLC, SCADA system, and HMI should have sufficient memory and storage
capacity to accommodate the necessary software programs and data.
• Memory and storage limitations should be considered when designing the system
architecture and selecting suitable components.
6. Real-time Control:
• The system should provide real-time control capabilities, with minimal delays
between input commands and motor response.
• The chosen PLC and communication protocols should support real-time control and
data acquisition.
7. Environmental Conditions:
• The system should be designed to operate reliably in the intended environmental
conditions, such as temperature, humidity, and dust levels.
• Appropriate protection measures, such as enclosures or environmental controls,
should be considered to ensure system longevity and performance.
8. Safety Considerations:
• The system design should adhere to safety standards and guidelines, ensuring the
safe operation of the conveyor and the protection of operators.
• Safety features, such as emergency stop functionality and fault handling
mechanisms, should be incorporated into the system.
9. System Integration:
• The PLC, SCADA system, and HMI should be compatible and able to integrate
seamlessly, ensuring proper communication and data exchange.
• Compatibility with existing systems or equipment in the industrial environment
should be considered during system integration.
10. Budget Constraints:
• The project should adhere to the allocated budget for procuring hardware, software,
and other necessary components.
• Cost-effective solutions and alternatives should be considered without
compromising the system's functionality and performance.
It is crucial to thoroughly analyze and address the technical constraints specific to the project,
taking into account the available resources, project scope, and desired outcomes. Regular
communication and collaboration with stakeholders, project advisors, and experts in the field can
help identify and mitigate technical constraints effectively.

2.6 Design Specification

2.6.1 Chosen System Design
Chosen System Design for the Capstone Student Project "Control of Direction and Speed of
Stepper Motor-Controlled Conveyor using PLC and SCADA":
The chosen system design for the project involves the integration of a Programmable Logic
Controller (PLC), Supervisory Control and Data Acquisition (SCADA) system, and a Human-
Machine Interface (HMI) to control the direction and speed of a stepper motor-controlled
conveyor. The system architecture is as follows:
1. Hardware Components:
• Stepper Motor: A suitable stepper motor is selected based on the requirements of
the conveyor system.
• Conveyor Belt: The conveyor belt is designed to accommodate the intended
workload and is compatible with the stepper motor.
• Sensors: Appropriate sensors, such as proximity sensors or limit switches, are
installed to monitor the state of the conveyor system.
• PLC: A reliable and compatible PLC is chosen to control the stepper motor and
communicate with the SCADA system.
• SCADA System: A SCADA system is implemented to acquire real-time data,
monitor the conveyor's performance, and provide a graphical representation of the
system.
• HMI: The HMI provides an intuitive interface for the operator to interact with the
system, control the conveyor's direction and speed, and receive system status
feedback.
2. System Integration:
• The PLC is connected to the stepper motor and sensors, receiving input signals from
the sensors and generating output signals to control the motor's direction and speed.
 • The SCADA system is integrated with the PLC to acquire data from the sensors
and update the graphical representations of the conveyor's performance in real-
time.
• The HMI communicates with the PLC and SCADA system, enabling the operator
to send control commands, adjust conveyor speed, change direction, and receive
feedback on system status.
3. Communication Protocol:
• A suitable communication protocol, such as Modbus or Ethernet/IP, is chosen to
establish communication between the PLC, SCADA system, and HMI.
• The protocol enables real-time data exchange, control commands, and system status
updates between the components.
4. Control Logic and Algorithms:
• The PLC executes control logic and algorithms to process input signals from the
sensors and generate appropriate output signals for the stepper motor.
• The control logic ensures precise control over the conveyor's direction, speed, and
positioning.
5. SCADA Visualization:
• The SCADA system provides a graphical representation of the conveyor's
performance, including motor status, speed, and direction.
• The SCADA system displays real-time data on the HMI, allowing the operator to
monitor the system's operation.
6. User Interface and Interaction:
• The HMI offers an intuitive and user-friendly interface for the operator to control
the conveyor system.
• The HMI includes buttons, sliders, or input fields to start/stop the conveyor, adjust
speed, and change direction.
• The HMI provides visual feedback, such as status indicators or alarms, to inform
the operator about the system's state.
7. Safety Measures:
• The system incorporates safety features, including an emergency stop button, to
ensure the operator's protection in case of emergencies or unexpected events.
 • Fault handling mechanisms are implemented to detect and handle errors or faults
in the system.
8. Testing and Validation:
• The system is thoroughly tested to verify its functionality, performance, and
compliance with the specified requirements.
• Testing includes validating the control of motor direction, speed accuracy,
responsiveness of the HMI, and data acquisition reliability.
9. Documentation and Reporting:
• Comprehensive documentation is maintained throughout the project, including
system design, component selection, wiring diagrams, and software programs.
• A final project report is prepared, summarizing the project's objectives,
methodology, implementation details, test results, and recommendations for future
enhancements.
The chosen system design should be tailored based on the specific requirements, resources, and
constraints of the project. Regular communication with project advisors and stakeholders is vital
to ensure the system design aligns with the project goals and expectations.

2.6.2 Discussion of Alternative Designs

1. Alternative Motor Control: Instead of using a stepper motor, an alternative design could
employ a different type of motor, such as a servo motor or an induction motor. Each motor
type has its advantages and considerations. Servo motors provide precise positioning
control, while induction motors are more suited for high-speed applications. The choice of
motor depends on the specific requirements of the conveyor system.
2. PLC Alternatives: Instead of a PLC, an alternative design could use a microcontroller, such
as Arduino or Raspberry Pi, to control the stepper motor and communicate with the
SCADA system. Microcontrollers offer flexibility, cost-effectiveness, and a wide range of
programming options. However, they may have limitations in terms of processing power
and industrial-grade reliability compared to PLCs.
3. SCADA System Options: Different SCADA systems are available in the market, each with
its features and capabilities. Some alternatives include Ignition, Wonderware, and WinCC.
The selection should be based on factors such as compatibility with the chosen PLC or
microcontroller, scalability, ease of configuration, and cost considerations.
4. Communication Protocols: While Modbus and Ethernet/IP are commonly used
communication protocols, other alternatives like Profibus, Profinet, or OPC-UA may be
 suitable for the project. The choice of protocol depends on factors such as system
compatibility, data transfer speed, real-time capabilities, and availability of supporting
hardware and software.
5. Control Interface: The HMI design can vary, ranging from physical buttons and switches
to touchscreen interfaces. Alternative designs may utilize mobile applications or web-
based interfaces for remote control and monitoring. The choice depends on factors such as
user requirements, accessibility, ease of use, and available resources.
6. Redundancy and Fault Tolerance: An alternative design could incorporate redundancy
measures to enhance system reliability. This could involve duplicating critical components,
such as PLCs or motor controllers, and implementing fault-tolerant algorithms to ensure
uninterrupted operation in case of failures.
7. Wireless Connectivity: Instead of using wired communication between the components, an
alternative design could explore wireless connectivity options, such as Wi-Fi or Bluetooth.
Wireless communication can provide flexibility in system layout and ease of installation,
but careful consideration should be given to factors like signal range, interference, and
security.
8. Cloud Integration: An alternative design could incorporate cloud-based services for data
storage, remote monitoring, and analytics. Cloud integration allows for centralized data
management, real-time insights, and remote access to the system. However, considerations
should be given to data security, privacy, and connectivity requirements.
9. Energy Efficiency: An alternative design could prioritize energy efficiency by
incorporating energy-saving features, such as variable frequency drives (VFDs) to control
motor speed based on load requirements or utilizing regenerative braking to recapture
energy during deceleration.
10. Modular Design: Instead of a single integrated system, an alternative design could adopt a
modular approach, separating control functions into individual modules. This allows for
easier maintenance, scalability, and flexibility in adding or modifying conveyor sections
or integrating additional control features.
The choice of alternative designs should be based on a careful evaluation of project requirements,
technical constraints, available resources, and stakeholder considerations. A comprehensive
analysis and comparison of the alternatives can help determine the most suitable design approach
for the Capstone Student Project.

2.6.3 Detailed Description of Components/Subsystems

1. NEMA 17 Stepper Motor:
 • The NEMA 17 stepper motor is a compact and widely used motor known for its
precision and step accuracy.
• It provides the necessary torque and control for driving the conveyor belt system.
• The motor is typically equipped with a 4-wire configuration, allowing bipolar drive
control.
2. TB6600 Stepper Motor Driver:
• The TB6600 driver is a popular choice for driving stepper motors, including the
NEMA 17 motor.
• It provides step and direction control signals to the motor.
• The driver supports microstepping, allowing for smoother motion and finer control
of the motor.
3. Conveyor Belt System:
• The conveyor belt system consists of a belt, rollers, and a supporting structure for
transporting items or materials.
• The NEMA 17 stepper motor is connected to the conveyor system, driving the
movement of the belt.
• The system may include additional components such as tensioning mechanisms or
sensors for position detection.
4. 4mm Banana Connectors:
• 4mm banana connectors are commonly used electrical connectors for establishing
reliable connections between the stepper motor, driver, and other electrical
components.
• They provide a secure and easy-to-use connection method, ensuring proper signal
transmission and power supply.
5. Delta 14DVPSS2 PLC:
• The Delta 14DVPSS2 PLC is a programmable logic controller designed for
industrial automation applications.
• It serves as the central control unit for the stepper motor and conveyor system.
• The PLC receives input signals from sensors or the HMI, processes the data, and
generates appropriate output signals for controlling the motor's direction and speed.
 • It supports various communication protocols, such as Modbus or Ethernet/IP, for
integration with the SCADA system.
6. Power Supply:
• The system requires a stable and appropriate power supply to ensure proper
operation.
• The power supply should meet the voltage and current requirements of the stepper
motor, driver, and other electrical components.
• It may include protective measures such as fuses or circuit breakers to prevent
overcurrent or short-circuit incidents.
7. Wiring and Interconnections:
• The various components are interconnected using appropriate wiring, cables, and
connectors.
• The connections between the NEMA 17 stepper motor, TB6600 driver, and Delta
14DVPSS2 PLC are made using the specified 4mm banana connectors.
• The wiring should be organized, properly labeled, and securely fastened to ensure
reliable and safe operation.
8. Mounting and Mechanical Structure:
• The components, including the stepper motor, driver, PLC, and conveyor belt
system, are mounted on a suitable mechanical structure.
• The structure should provide stability, support, and proper alignment of the
components to ensure smooth operation and minimize vibrations.
9. Safety Considerations:
• Safety measures should be implemented, such as emergency stop buttons,
interlocks, and guarding, to protect operators and prevent accidents.
• Proper grounding and insulation of electrical components should be ensured to
minimize the risk of electrical hazards.
10. Documentation and Manuals:
• Detailed documentation, including datasheets, user manuals, wiring diagrams, and
programming guidelines, should be maintained for each component.
• It is essential to follow the manufacturer's specifications and guidelines during
installation, wiring, and programming of the components.
The detailed description of components and subsystems provided above gives an overview of the
key elements required to implement the Capstone Student Project "Control of Direction and Speed
of Stepper Motor-Controlled Conveyor using PLC and SCADA" using the specified components.

2.6.4 Component 1- n

SL NO Components Qty in PC
1 PLC 1
2 Stepper motor 3
3 CNC shield 1
4 Compressor 1
5 5/2 direction control valve 1
6 12V SMPS 1
7 Electrical cables 5m
8 20*20 aluminum profiles 5m
 Chapter 3: Approach and Methodology

3.1 Description of technology used in development of Control of direction and speed of stepper motor-
controlled conveyor using PLC and SCADA

a) The development of control of direction and speed of a stepper motor-controlled conveyor using
Delta PLC, DIAView SCADA, and a conveyor belt system with a stepper motor involves the use of
several different technologies.

b) Firstly, the Delta PLC is a programmable logic controller that is used to control the operation of
the conveyor system. The PLC receives input signals from sensors and other devices and uses
these inputs to control the direction and speed of the stepper motor that drives the conveyor
belt.

c) Secondly, DIAView SCADA is a supervisory control and data acquisition software that is used to
monitor and control the conveyor system. The software provides a user interface that allows
operators to view and control the operation of the system. The software can also be used to log
data and generate reports on the performance of the system.

d) Finally, the conveyor belt system itself includes a stepper motor that is used to drive the
movement of the conveyor belt. The motor is controlled by the PLC and the speed and direction
of the motor can be adjusted based on the inputs received by the system.

e) Overall, the combination of these technologies allows for precise control of the direction and
speed of the stepper motor-controlled conveyor, resulting in efficient and reliable operation of
the system.

The combination of these components allows for the creation of a fully automated parking system that
can efficiently and safely park cars or AGVs. The Delta PLC and DIAView SCADA system provide the control
and monitoring necessary to ensure that the system operates as intended, while sensors, motors, and
actuators enable the physical movement of the cars or AGVs. The static application panel provides a user-
friendly interface that allows operators to interact with the system and simulation software allows for
testing and optimization of the system.

3.2 Details of hardware used in development of Control of direction and speed of stepper motor-
controlled conveyor using PLC and SCADA

1) The development of Control of direction and speed of stepper motor-controlled conveyor using
 Delta PLC, DIAView SCADA, and conveyor belt system with stepper motor involves several
hardware components that work together to achieve the desired outcome.

2) Delta PLC - The Delta PLC is a programmable logic controller that is the central control unit of the
system. It receives input signals from sensors and other devices and uses these inputs to control
the direction and speed of the stepper motor that drives the conveyor belt. The PLC
communicates with other components of the system via Ethernet, RS-232, or RS-485.

3) DIAView SCADA - DIAView SCADA is a software that runs on a computer connected to the Delta
PLC. The computer can be a dedicated computer or a standard computer with the software
installed. The software provides a user interface that allows operators to view and control the
operation of the system. The software can also be used to log data and generate reports on the
performance of the system.

4) Sensors - The conveyor belt system includes several sensors that provide input signals to the Delta
PLC. These sensors include proximity sensors, photoelectric sensors, and limit switches. The
sensors are used to detect the position of the conveyor belt, the presence of objects on the belt,
and other parameters that are used to control the operation of the system.

5) Stepper motor - The stepper motor is the motor that drives the conveyor belt. The motor is
controlled by the Delta PLC and the speed and direction of the motor can be adjusted based on
the inputs received by the system. The stepper motor is typically a high-torque, low-speed motor
that is well-suited for applications like conveyor systems.

6) Power supply - The power supply provides power to the Delta PLC, the DIAView SCADA computer,
and the stepper motor. The power supply typically provides DC voltage to the system.

7) Cables and connectors - The various components of the system are connected together using
cables and connectors. Ethernet cables are used to connect the Delta PLC to the DIAView SCADA
computer. RS-232 or RS-485 cables are used to connect the Delta PLC to other devices like sensors
and actuators. Power cables are used to connect the power supply to the various components of
the system.

3.3 Detail of software products used in development of Control of direction and speed of stepper motor-
controlled conveyor using PLC and SCADA

1) PLC programming software: PLC programming software is used to create the logic and control
programs that are loaded onto the PLC. Some popular examples of PLC programming software
include Delta WPLSoft, Siemens Step 7, Allen-Bradley RSLogix, and Mitsubishi GX Works.

2) CAD software: CAD software is used to create the 3D models and engineering drawings of the
robot and its components. The CAD models can be used to test and optimize the design before it
is built. Examples of CAD software include SolidWorks, AutoCAD, and Inventor.

3) Simulation software: Simulation software is used to simulate the operation of the pick and place
 robot before it is built. Simulation software allows engineers to test and optimize the robot's
performance and identify potential problems. Examples of simulation software include Siemens
Tecnomatix, Dassault Systemes DELMIA, and Simulink from MathWorks.

4) Communication software: Communication software is used to enable communication between

the PLC and other devices in the system, such as sensors, actuators, and the HMI. Examples of
communication software include OPC Server and Modbus TCP.

5) Delta DVP-SS2 PLC programming software: This is the software used to program Delta's DVP-SS2
series of PLCs. The software is user-friendly and supports various programming languages,
including ladder diagram, function block diagram, and structured text.

Delta WPLSoft is a PLC programming software used to program Delta's DVP series PLCs. The software
is designed to be user-friendly and supports various programming languages, including ladder diagram
(LD), function block diagram (FBD), and structured text (ST).

1) WPLSoft provides a comprehensive platform for programming, testing, and troubleshooting

Delta's PLCs. The software includes a rich set of tools and features, including:

2) PLC program editing: WPLSoft provides a user-friendly interface for creating, editing, and
testing PLC programs. The software supports a wide range of instructions and functions,
allowing engineers to create complex control logic easily.

3) Simulation and monitoring: WPLSoft allows engineers to simulate and monitor the operation
of the PLC program without the need for physical hardware. This feature allows engineers to
test and optimize the program before deploying it in the field.

4) Online debugging: WPLSoft allows engineers to connect to the PLC and debug the program in
real-time. This feature enables engineers to identify and troubleshoot issues quickly and
efficiently.

5) Documentation and management: WPLSoft includes tools for documentation and

management of PLC programs. The software allows engineers to create and manage project
files, generate reports, and export documentation in various formats.

Delta DIAView is a Supervisory Control and Data Acquisition (SCADA) software developed by Delta
Electronics. It is designed to provide a centralized platform for monitoring and controlling a wide range of
industrial processes, including the pick and place pneumatic cylinder robot controlled by PLC.
DIAView provides a comprehensive set of features and tools for data acquisition, visualization, control,
and analysis, including:

1) Real-time data acquisition: DIAView supports real-time data acquisition from various devices,
including Delta's PLCs, HMIs, and other third-party devices. The software allows engineers to
collect data from multiple sources and store it in a centralized database for analysis.

2) HMI design: DIAView includes an HMI design tool, allowing engineers to create a custom HMI
interface for the pick and place pneumatic cylinder robot. The HMI interface can display real-time
data, trends, alarms, and control buttons, enabling efficient monitoring and control of the system.

3) Alarm management: DIAView includes a comprehensive alarm management system, allowing

engineers to define alarms and configure notification settings. The software can send email or
SMS notifications to designated personnel when an alarm is triggered.

4) Historical data analysis: DIAView allows engineers to analyze historical data to identify trends and
patterns. The software includes a range of data analysis tools, such as data filtering, charting, and
reporting, enabling engineers to gain insights into the performance of the pick and place system.

5) SCADA server: DIAView includes a SCADA server, allowing engineers to access the system
remotely. The software supports secure communication protocols, such as SSL and SSH, ensuring
that the system is protected from unauthorized access.

3.4 Programming languages used in development of Control of direction and speed of stepper motor-
controlled conveyor using PLC and SCADA

1) Delta PLCs support multiple programming languages, including ladder logic, function block
diagram (FBD), and structured text (ST). These programming languages are used in the
development of the pick and place pneumatic cylinder robot controlled by the PLC.

2) Ladder logic is the most commonly used programming language in Delta PLCs. It is a graphical
programming language that uses ladder-like diagrams to represent logic functions. Engineers
can create ladder diagrams using the WPLSoft software, which includes a comprehensive set
of ladder logic instructions.

3) Function block diagram (FBD) is another programming language supported by Delta PLCs. It is
a graphical language that uses blocks to represent logic functions. Engineers can create FBD
programs using the WPLSoft software, which includes a range of pre-defined function blocks.
 4) Structured text (ST) is a text-based programming language that is similar to C programming
language. It allows engineers to write complex programs using structured syntax. Engineers
can create ST programs using the WPLSoft software, which includes a text editor with syntax
highlighting and auto-completion features.

Ladder diagram (LD) is a graphical programming language that is commonly used in programmable logic
controllers (PLCs), including Delta PLCs. Delta WPLSoft software provides a comprehensive set of tools for
creating, editing, and testing ladder diagrams.

1) A ladder diagram consists of two vertical power rails and multiple horizontal rungs. Each rung
represents a separate control circuit. The left power rail represents the "hot" or "live" side of the
circuit, and the right power rail represents the "neutral" side. The rungs contain different types of
elements such as contacts, coils, timers, and counters.

2) Contacts are represented by horizontal lines that cross the rungs. Contacts can be normally open
(NO) or normally closed (NC). A NO contact is represented by a line that has a break in it, and it is
used to turn a circuit on. An NC contact is represented by a line that has a slash through it, and it
is used to turn a circuit off.

3) Coils are represented by horizontal lines that do not cross the rungs. They can be used to turn a
device on or off. A coil that is energized will activate the corresponding device, and a coil that is
de-energized will deactivate the device.

4) Timers and counters are used to control time-based events. Timers can be used to delay the
activation of a device, while counters can be used to count the number of times a device has been
activated.

5) In Delta WPLSoft software, engineers can create and edit ladder diagrams using a graphical editor.
The editor provides a range of tools for adding and editing ladder diagram elements, such as
contacts, coils, timers, and counters. Engineers can also use the software to simulate the
operation of the ladder diagram and test the logic of the control circuit.

Delta DIAView SCADA software is used to develop graphical user interfaces for supervisory control and
data acquisition (SCADA) systems. The development of a Delta DIAView SCADA screen involves several
steps, including:

1) Creating a new project: The first step in developing a Delta DIAView SCADA screen is to create a
new project in the DIAView SCADA software. This involves selecting the project type and
communication settings.
 2) Adding tags: Once the project is created, engineers can start adding tags to the project. Tags are
data points that are used to represent the status of the control system. For example, a tag might
represent the temperature of a machine or the status of a motor.

3) Creating screens: After the tags are added, engineers can start creating screens for the SCADA
system. Each screen represents a separate interface for the user to interact with the control
system.

4) Adding objects: Once screens are created, engineers can start adding objects to the screens.
Objects are graphical elements that can be used to display information and receive input from the
user. Examples of objects include buttons, text boxes, images, and charts.

5) Configuring objects: Once objects are added to the screens, engineers can configure their
properties, such as size, position, font, and color. Engineers can also define the behavior of the
objects, such as what happens when a button is pressed or when data is entered into a text box.

6) Adding animations: Animations can be added to objects to provide visual feedback to the user.
For example, a button can change color or shape when pressed, or a gauge can display data in
real-time.

7) Defining communication settings: Delta DIAView SCADA programming involves configuring

communication settings between the SCADA system and the control system. This includes
selecting the communication protocol, defining communication parameters, and setting up data
exchange between the SCADA system and the control system.

8) Testing and debugging: Once the screens and objects are configured, engineers can test the
SCADA system to ensure that it works as intended. The DIAView SCADA software includes a
simulation feature that allows engineers to test the interface without connecting to a real control
system. Any errors or issues can be identified and corrected during the testing phase.

9) Uploading to the SCADA system: After the testing phase is complete, the SCADA project can be
uploaded to the Delta DIAView SCADA system. The SCADA system can then be connected to the
control system and used to monitor and control the system.

3.5 Descriptions of the components in the system in development of Control of direction and speed of
stepper motor-controlled conveyor using PLC and SCADA

a) Delta PLC trainer kit with Delta 14SS2 PLC

b) Conveyor belt system.
c) Stepper motor.
d) RS232 communication cable to communicate PC to PLC
 e) Delta WPLSoft software to program PLC
f) Delta DIAView SCADA software to develop SCADA screen.

a) Delta PLC trainer kit with Delta 14SS2 PLC

1) Delta 14SS2 PLC - This is the main component of the trainer kit and is used to control the various
functions of the system.

2) Digital Input/Output Modules - The kit includes multiple digital input/output modules, which can
be used to connect various sensors and actuators to the PLC. DI8 and DO6 are inputs and outputs.

3) Communication Modules - Communication modules are used to connect the PLC to other devices
and systems. The trainer kit typically includes communication modules such as RS-232, RS-485,
and Ethernet.

4) Power Supply - The trainer kit includes a power supply that can be used to provide power to the
PLC and other components of the system.

5) Programming Software - The kit typically includes programming software that can be used to
program the PLC and develop control programs.

6) Documentation - The kit may include documentation such as user manuals, programming guides,
and sample programs to help users get started with the system.

b) Conveyor belt system.

A conveyor belt system with a 0.5m length and 100mm width refers to a type of mechanical handling
equipment that is designed to transport goods, materials, or products from one location to another.

The system consists of a continuous belt that is looped around a series of rollers, with one or more
powered pulleys driving the belt. The belt is made of durable materials such as rubber, PVC, or polyester
and can be designed to handle various types of loads and weights.

The 0.5m length and 100mm width of the conveyor belt system refer to the dimensions of the belt itself.
The 0.5m length indicates that the belt can transport materials up to half a meter in length, while the
100mm width indicates the maximum width of the materials that can be transported. These dimensions
may vary depending on the specific application and requirements of the conveyor belt system.

c) Stepper motor.
The Nema 17 2.5 Kg-cm Bipolar Stepper Motor with a 10mm shaft is a type of stepper motor that is
commonly used in CNC robotics, DIY projects, and 3D printers. Here are its specifications:

i. Nema 17 size (42mm x 42mm x 40mm)

ii. 2.5 Kg-cm (35.4 oz-in) holding torque
iii. Bipolar stepper motor with 4 wires
iv. Step angle of 1.8 degrees per step (200 steps per revolution)
v. Rated current of 1.7A per phase
vi. Resistance of 1.5 ohms per phase
vii. Inductance of 3.0 mH per phase
viii. 10mm diameter shaft with flat surface
ix. Shaft length of 22mm
x. Weight of approximately 280g

This stepper motor is designed to provide precise and reliable motion control in various applications. Its
high holding torque and compact size make it suitable for applications that require precise positioning
and control, such as in CNC machines and 3D printers. The 10mm diameter shaft with a flat surface allows
for easy coupling with other mechanical components, such as gears or pulleys.

d) RS232 communication cable to communicate PC to PLC

1) RS232 is a standard serial communication protocol used for transmitting data between devices.
The RS232 communication cable used to connect a PC to a PLC typically has the following
specifications:

2) Connector: The RS232 cable has a 9-pin D-sub connector on one end to connect to the PC's serial
port, and a 9-pin or 25-pin D-sub connector on the other end to connect to the PLC's serial port,
depending on the PLC model.

3) Cable length: The length of the cable can vary depending on the application, but it is usually
between 1 and 5 meters long.

4) Wiring: The cable has three wires: one for transmitting data (TX), one for receiving data (RX), and
one for ground (GND).

5) Baud rate: The baud rate is the rate at which data is transmitted over the cable and is set in the
PLC and PC's communication settings. The baud rate for RS232 communication cables used to
connect PCs to PLCs typically ranges from 9600 to 115200 baud.

6) Handshaking: Some RS232 communication cables support hardware handshaking, which allows
the PC and PLC to exchange signals to control data transmission. The handshaking lines are usually
connected to pins 4 (RTS), 5 (CTS), 6 (DSR), and 8 (CD) on the connector.
RS232 communication cables are widely used to connect PCs to PLCs for programming, monitoring, and
data exchange.

d) Delta WPLSoft software to program PLC

Delta WPLSoft is a programming software used to develop, edit, and debug ladder logic programs for
Delta programmable logic controllers (PLCs). The software is designed to be user-friendly, and it provides
a wide range of features to help programmers create complex control systems.

Some of the key features of Delta WPLSoft include:

1) Ladder Editor: The software provides a graphical ladder editor interface that allows programmers
to create and edit ladder logic programs. The editor includes a wide range of standard ladder logic
functions, as well as advanced functions such as PID control.

2) Function Block Diagram Editor: In addition to ladder logic programming, Delta WPLSoft also
supports function block diagram (FBD) programming. The FBD editor allows programmers to
create complex control systems using graphical function blocks.

3) Simulation Mode: Delta WPLSoft includes a simulation mode that allows programmers to test
their ladder logic programs without connecting to an actual PLC. This feature is useful for
debugging and testing the logic of the control system.

4) Online Monitoring: The software supports online monitoring of the PLC's status and data. This
allows programmers to monitor the PLC's inputs and outputs, as well as its internal variables and
timers, in real-time.

5) Documentation: Delta WPLSoft includes a comprehensive documentation system that provides

detailed information on the software's features and functions. The documentation also includes
tutorials and examples to help programmers get started with Delta PLC programming.

Delta WPLSoft is compatible with Delta PLCs such as the DVP-SV, DVP-ES, and DVP-EX series, and it
supports communication protocols such as RS232, RS485, and Ethernet. The software can be downloaded
for free from Delta's website.

e) Delta DIAView SCADA software to develop SCADA screen.

Delta DIAView is a Supervisory Control and Data Acquisition (SCADA) software that is used to develop HMI
(Human Machine Interface) and SCADA applications. It allows the user to create and develop SCADA
screens for a wide range of applications, including automated guided vehicle parking simulations.
Some of the key features of Delta DIAView SCADA software include:

1) Drag-and-Drop Interface: DIAView features an intuitive drag-and-drop interface that makes it

easy to design and develop SCADA screens. The user can simply drag and drop different
components such as buttons, sliders, and graphs onto the screen, and then configure them as
needed.

2) Real-Time Data Visualization: DIAView supports real-time data visualization, which allows the user
to see live data from the automated guided vehicle parking simulation. The software can display
data in a variety of formats, including graphs, charts, and gauges.

3) Alarm Management: DIAView includes an alarm management system that can be configured to
trigger alarms based on specific conditions. When an alarm is triggered, the software can display
a pop-up notification, sound an audible alarm, or send an email or SMS message.

4) Remote Monitoring: DIAView allows the user to monitor the automated guided vehicle parking
simulation remotely. The user can access the SCADA screens from any device with an internet
connection, including smartphones and tablets.

5) Data Logging and Reporting: DIAView can log data from the automated guided vehicle parking
simulation, and generate reports based on that data. The software can generate reports in a
variety of formats, including PDF, Excel, and CSV.

Delta DIAView SCADA software is compatible with a wide range of Delta PLCs, including the 14SS2 series,
and it supports communication protocols such as Modbus and Ethernet. The software can be downloaded
for free from Delta's website.

3.6 Components diagrams and required design and development of Control of direction and speed of
stepper motor-controlled conveyor using PLC and SCADA
1) Input sensors: Sensors are placed at the start and end of the conveyor belt system to detect the
presence of objects or materials on the belt. These sensors provide input signals to the control
system.

2) Delta PLC: The Delta PLC receives input signals from the sensors and processes them to generate
control signals for the stepper motor. The PLC controls the direction and speed of the motor based
on the input signals and the programmed logic.

3) Stepper motor driver: The control signals generated by the PLC are sent to the stepper motor
driver, which amplifies the signals and provides the necessary current and voltage to drive the
stepper motor.

4) Stepper motor: The stepper motor is responsible for driving the conveyor belt system. It receives
control signals from the stepper motor driver and rotates the shaft to move the belt in the desired
direction and at the desired speed.

5) SCADA: A SCADA system is used to monitor and control the conveyor belt system remotely. It
provides real-time feedback on the status of the conveyor, including the direction and speed of
the motor and the position of the objects on the belt.

6) HMI: A human-machine interface (HMI) allows operators to interact with the control system and
monitor the conveyor belt system. It provides a graphical interface that displays relevant
information about the conveyor system, such as speed, position, and status.
 7) Conveyor belt system: The conveyor belt system consists of the belt, rollers, and other mechanical
components that transport materials from one end of the conveyor to the other. The stepper
motor-controlled conveyor system drives the belt to move the materials along the conveyor.

8) Overall, this block diagram represents the various components and systems involved in the design
and development of a stepper motor-controlled conveyor system using Delta PLC, SCADA, and a
conveyor belt system.

3.7 Construction or fabrication details in development of Control of direction and speed of stepper
motor-controlled conveyor using PLC and SCADA

1) Mounting the sensors: The sensors used to detect the presence of objects or materials on the
conveyor belt system must be mounted securely in the appropriate locations, such as at the start
and end of the conveyor. They may be mounted using brackets, clamps, or other types of
mounting hardware.

2) Mounting the Delta PLC: The Delta PLC must be mounted in an appropriate location, such as in a
control panel or enclosure, to protect it from environmental factors such as dust, moisture, and
temperature fluctuations. The PLC may be mounted using DIN rails or other types of mounting
hardware.

3) Wiring: Wiring must be installed to connect the sensors, PLC, stepper motor driver, and HMI
together. Wiring must be done according to the wiring diagram and wiring standards to ensure
proper operation and safety of the system.

4) Mounting the stepper motor and driver: The stepper motor and driver must be mounted securely
to prevent any movement or vibration that may affect the accuracy of the system. The motor and
driver may be mounted using brackets, clamps, or other types of mounting hardware.

5) Fabricating the conveyor belt system: The conveyor belt system must be fabricated according to
the desired dimensions, specifications, and requirements. This may involve cutting and welding
the frame, attaching the rollers, and installing the belt. The construction and fabrication of the
conveyor belt system must be done according to safety standards and regulations.

6) Programming the PLC and SCADA: The PLC and SCADA system must be programmed to perform
the desired functions, including controlling the direction and speed of the stepper motor. The
programming must be done according to the programming standards and regulations.
3.8 There are some additional considerations that may be helpful in executing a capstone project in the
development of Control of direction and speed of stepper motor-controlled conveyor using PLC and
SCADA

Plan and design the system carefully: Before beginning the project, it is important to carefully plan and
design the system. This includes creating a detailed block diagram, selecting the appropriate hardware
and software components, and determining the specific functionality that the system should have.

1) Test the system thoroughly: It is important to thoroughly test the system to ensure that it works
as intended. This includes testing the PLC program, SCADA interface, and any other software or
hardware components. It is also important to test the system under different scenarios to ensure
that it is robust and reliable.

2) Use industry-standard components: When selecting hardware and software components, it is

important to choose industry-standard components that are reliable and widely used. This will
ensure that the system can be easily maintained and updated in the future.

3) Document the system: Documenting the system is important for troubleshooting and
maintenance purposes. This includes creating detailed wiring diagrams, system manuals, and
other documentation that can be used to troubleshoot and maintain the system.

4) Consider safety and security: Safety and security are important considerations when developing
a car parking simulation system. It is important to implement safety features such as emergency
stop buttons and safety interlocks to ensure that the system is safe to operate. Additionally, it is
important to implement security features to prevent unauthorized access to the system.

5) Collaborate with team members: If working in a team, it is important to collaborate effectively

and communicate clearly with team members. This includes dividing tasks, setting deadlines, and
providing regular updates on progress.

6) Consider the end-user: When designing the system, it is important to consider the needs and
preferences of the end-user. This includes designing an intuitive and user-friendly SCADA
interface, as well as implementing features that will make the system easy and convenient to use.
 Chapter 4: Test and validation
4.1 Test Plan
1. Component Testing: a. NEMA 17 Stepper Motor:
• Test the motor's rotation by providing appropriate power and verifying that it moves
smoothly and accurately.
• Verify that the motor responds correctly to step and direction signals.
b. TB6600 Stepper Motor Driver:
• Test the driver's functionality by providing control signals and confirming that it
accurately controls the stepper motor's rotation.
• Verify that the driver supports microstepping and adjust the settings accordingly.
c. 4mm Banana Connectors:
• Verify the connectivity and reliability of the banana connectors by checking for
secure connections and ensuring proper signal transmission.
d. Delta 14DVPSS2 PLC:
• Test the PLC's communication with the TB6600 driver by sending step and
direction signals and verifying that the motor responds accordingly.
• Test the PLC's communication with the SCADA system or HMI to ensure data
exchange and control commands are functioning correctly.
2. Integration Testing: a. Motor Control:
• Test the PLC's control over the stepper motor's direction by sending various
direction commands and verifying the motor moves accordingly.
• Test the PLC's control over the stepper motor's speed by adjusting the frequency or
step rate and verifying the motor's speed changes accordingly.
b. Communication:
• Test the communication between the PLC and SCADA system or HMI by sending
control commands and verifying the system responds accordingly.
• Test data exchange between the PLC and SCADA system to ensure real-time
monitoring and accurate display of motor status and speed.
3. System Testing: a. Conveyor Operation:
• Test the conveyor system's functionality by placing objects on the belt and verifying
that it moves smoothly and transports the objects without issues.
 • Verify that the conveyor system stops appropriately when commanded to do so.
b. User Interface:
• Test the HMI's functionality by interacting with the interface and verifying that the
control commands for direction and speed are accurately reflected.
• Test the HMI's feedback mechanism to ensure proper display of motor status,
speed, and any alarms or alerts.
4. Performance Testing: a. Motor Accuracy and Speed Control:
• Test the accuracy of the motor's movement by commanding it to move a specific
distance and measuring the actual displacement.
• Test the motor's speed control by commanding it to operate at different speeds and
measuring the actual speed using appropriate sensors or instruments.
b. Responsiveness:
• Test the system's responsiveness by issuing control commands and verifying the
motor's prompt response.
• Measure the time taken for the system to reflect changes made through the HMI or
SCADA system.
5. Safety Testing: a. Emergency Stop Functionality:
• Test the emergency stop button to ensure it immediately halts the conveyor system's
operation.
• Verify that the emergency stop function overrides any other commands and brings
the system to a safe state.
b. Fault Handling:
• Simulate fault conditions, such as motor stall or communication failure, and verify
that the system handles these scenarios appropriately.
• Test the system's ability to recover from faults and resume normal operation.
6. Documentation and Reporting:
• Maintain a record of all test cases executed, including their results, any observed
issues, and any necessary remedial actions.
• Prepare a comprehensive test report summarizing the testing process, test results,
and recommendations for improvements or further enhancements.
It is important to adapt and modify the test plan based on the specific requirements, functionalities,
and constraints of the project. Regular collaboration with project advisors and stakeholders will
help ensure comprehensive and effective testing of the system.
4.2 Test Approach
1. Unit Testing:
• Perform individual unit testing for each component, including the NEMA 17
stepper motor, TB6600 driver, 4mm banana connectors, and Delta 14DVPSS2
PLC.
• Verify the functionality and reliability of each component according to their
specifications.
• Ensure proper wiring and connections between components.
2. Integration Testing:
• Test the integration of the NEMA 17 stepper motor, TB6600 driver, 4mm banana
connectors, and Delta 14DVPSS2 PLC.
• Verify the communication and compatibility between these components.
• Ensure the correct exchange of control signals and data.
3. System Testing:
• Test the overall system functionality and performance.
• Verify the control of direction and speed of the stepper motor-controlled conveyor
using the PLC and SCADA system.
• Perform functional testing to ensure the motor moves in the desired direction and
at the specified speed.
• Test the response time of the system when receiving commands from the SCADA
system or HMI.
• Verify the accuracy of the motor's movement and speed control.
4. User Interface Testing:
• Test the user interface, whether it is an HMI or SCADA system.
• Verify the proper display of motor status, direction, and speed.
• Test the control functionality to ensure that the user can easily and accurately
control the motor's direction and speed.
• Perform usability testing to ensure a user-friendly interface.
5. Performance Testing:
 • Measure and verify the system's performance in terms of motor accuracy, speed
control, and responsiveness.
• Test the system's ability to handle various load conditions and adjust the motor's
speed accordingly.
• Evaluate the system's performance under peak load conditions.
6. Safety Testing:
• Verify the emergency stop functionality and its effectiveness in halting the
conveyor system.
• Test the system's response to fault conditions, such as motor stall or communication
failure, to ensure the safety of operators and equipment.
• Evaluate the system's fault handling mechanisms and its ability to recover from
faults.
7. Documentation and Reporting:
• Maintain comprehensive documentation of the testing process, including test cases,
test results, and any issues encountered.
• Prepare a test report summarizing the testing activities, results, and
recommendations for improvements or further testing.
• Provide clear instructions and guidelines for future maintenance, troubleshooting,
and testing.
It is essential to plan and execute the tests in a systematic manner, ensuring adequate coverage of
all critical functionalities and scenarios. The test approach should be tailored to the specific
requirements and constraints of the project, and regular communication with project advisors and
stakeholders is crucial for a successful testing process.

4.3 Features Tested

1. Motor Control:
• Verification of motor rotation in both directions (forward and reverse).
• Testing of motor speed control by adjusting the frequency or step rate.
• Testing of motor accuracy in terms of distance covered and positioning.
2. Direction Control:
• Verification of correct motor response to direction control signals from the PLC.
• Testing of motor movement in different directions (forward and reverse).
 • Validation of motor response to changes in direction during operation.
3. Speed Control:
• Testing of motor speed control through varying frequency or step rate.
• Verification of smooth acceleration and deceleration of the motor.
• Validation of the motor's ability to maintain a constant speed under different loads.
4. Communication:
• Testing of communication between the PLC and the TB6600 driver.
• Verification of proper exchange of control signals and data.
• Validation of real-time communication between the PLC and the SCADA system
or HMI.
5. Emergency Stop Functionality:
• Testing of the emergency stop button to ensure it halts the motor and conveyor
system immediately.
• Verification of the system's response to emergency stop commands and restoration
to a safe state.
6. Fault Handling:
• Testing of the system's response to fault conditions such as motor stall or
communication failure.
• Verification of appropriate error handling and recovery mechanisms.
• Validation of the system's ability to resume normal operation after encountering
faults.
7. User Interface:
• Testing of the user interface, whether it is an HMI or SCADA system.
• Verification of accurate display of motor status, direction, and speed.
• Validation of user control functionalities, such as commanding motor direction and
adjusting speed.
8. Performance:
• Testing of motor accuracy in terms of distance covered and positioning.
• Verification of the motor's ability to maintain the desired speed under varying
loads.
 • Measurement of system response time to control commands and changes in motor
direction or speed.
9. Safety:
• Testing of safety features such as emergency stop functionality.
• Verification of proper grounding and insulation of electrical components.
• Validation of protective measures to prevent electrical hazards.
It is crucial to design comprehensive test cases to cover all the features and functionalities of the
system. The tests should ensure that the system operates as intended, meets the project
requirements, and adheres to safety standards.

4.4 Features not Tested

1. Conveyor Load Capacity:
• The project may not involve testing the conveyor system's maximum load capacity
or the ability to handle heavy objects. If this feature is not within the scope of the
project, it would not be tested.
2. Conveyor Belt Material Compatibility:
• Compatibility testing of different conveyor belt materials (such as rubber, PVC, or
metal) with the NEMA 17 stepper motor and TB6600 driver may not be conducted
in the project, as it is not specified as a requirement.
3. Advanced Motor Control Modes:
• The project may focus on basic motor control functionalities, such as speed and
direction control. Advanced motor control modes like position control, torque
control, or sensor-based feedback control may not be tested.
4. Integration with External Systems:
• The project may not involve testing the integration of the conveyor system with
external systems, such as barcode scanners, weight sensors, or PLC network
communication protocols.
5. Environmental Testing:
• Testing the system's performance under extreme environmental conditions, such as
high or low temperatures, humidity, or vibration, may not be within the scope of
the project.
6. Long-Term Reliability and Durability:
 • The project may not involve long-term testing to assess the reliability and durability
of the components, such as the stepper motor, driver, connectors, and PLC, over
extended periods of operation.
7. Power Efficiency:
• Testing the power efficiency of the system, including motor power consumption
and energy optimization techniques, may not be specifically evaluated in the
project.
8. Customization and Scalability:
• The project may not include testing the system's ability to be easily customized or
scaled for different conveyor configurations or integration with other industrial
processes.
It is important to clarify and define the scope of the project and identify the specific features and
functionalities that will be tested. This will help ensure that the testing efforts are focused and
aligned with the project objectives.

4.5 Findings
After the completion of the capstone student project "Control of direction and speed of stepper
motor-controlled conveyor using PLC and SCADA" with Delta PLC and SCADA DIAView, the
following results were achieved:
1. Successful Control of Conveyor Direction: The project successfully implemented control
over the direction of the stepper motor-controlled conveyor using the Delta PLC. The
PLC programming allowed operators to switch the conveyor's direction, enabling
flexibility in material handling processes.
2. Precise Speed Control: The Delta PLC effectively controlled the speed of the stepper
motor-driven conveyor. Operators could adjust the speed through the PLC programming,
allowing for precise control based on the specific requirements of the material being
transported.
3. Real-time Monitoring and Visualization: The integration of SCADA DIAView enabled
real-time monitoring and visualization of critical parameters related to the conveyor
system. Operators could observe the conveyor's status, speed, and direction through the
SCADA interface, facilitating easy monitoring and control.
4. Reliable System Performance: The implemented system demonstrated reliable
performance throughout the project. The Delta PLC effectively communicated with the
stepper motor, ensuring accurate control of speed and direction. The system met the
specified requirements and showcased its reliability during testing.
 5. User-friendly Interface: The SCADA DIAView provided a user-friendly interface for
operators to interact with the system. The intuitive design and clear visualization of
conveyor parameters enhanced the user experience, allowing for efficient monitoring and
control of the conveyor's direction and speed.
6. Flexibility for Customization: The project allowed for flexibility in customizing the
control parameters of the stepper motor-controlled conveyor. Operators could modify the
PLC programming and SCADA configuration to adapt to specific application
requirements, making the system versatile and suitable for different material handling
scenarios.
7. Potential for Integration with Other Processes: The successful completion of the project
demonstrated the potential for integrating the stepper motor-controlled conveyor system
with other processes in an industrial setup. The control capabilities offered by the Delta
PLC and SCADA DIAView allow for seamless integration and coordination with
upstream and downstream processes.
8. Practical Application in Industrial Automation: The outcomes of the project highlighted
the practical application of PLC and SCADA technologies in industrial automation. The
ability to control the direction and speed of a stepper motor-controlled conveyor provides
valuable solutions for optimizing material handling and production processes.
These results confirm the successful implementation of control over the direction and speed of a
stepper motor-controlled conveyor using Delta PLC and SCADA DIAView. The integrated
components facilitated precise control, real-time monitoring, and customization capabilities,
showcasing the potential for practical applications in industrial automation scenarios.
4.5 Inference
After the completion of the capstone student project "Control of direction and speed of stepper motor-
controlled conveyor using PLC and SCADA" with Delta PLC and SCADA DIAView, several key
inferences can be drawn:
1. Precise Control over Conveyor Direction: The project successfully demonstrated precise control
over the direction of the stepper motor-controlled conveyor using the Delta PLC. This capability
allows operators to easily switch the conveyor's direction as required for different material
handling processes. Inferences suggest that the PLC programming effectively communicated with
the stepper motor, resulting in reliable and accurate control over the conveyor's direction.
2. Accurate Speed Control: The Delta PLC exhibited effective control over the speed of the stepper
motor-driven conveyor. By adjusting the parameters within the PLC programming, operators
were able to regulate the conveyor's speed accurately. This inference highlights the reliability and
precision of the implemented control system, enabling optimal handling of materials with varying
speed requirements.
3. Real-time Monitoring and Visualization: The integration of SCADA DIAView provided real-time
monitoring and visualization of critical parameters related to the conveyor system. Through the
SCADA interface, operators were able to monitor the conveyor's status, speed, and direction,
facilitating quick decision-making and efficient control. Inferences suggest that the SCADA
system successfully communicated with the Delta PLC, ensuring reliable data visualization and
real-time updates.
4. Enhanced System Performance and Reliability: The project's completion inferred that the
implemented control system, comprising the Delta PLC and SCADA DIAView, performed
reliably. The PLC programming effectively communicated with the stepper motor, resulting in
precise control over the conveyor's direction and speed. The system consistently delivered
accurate and reliable performance, meeting the specified requirements of the project.
5. Flexibility and Customization: The implemented control system demonstrated flexibility and
customization capabilities. Inferences indicate that the Delta PLC and SCADA DIAView allowed
for easy customization and adaptation to specific application requirements. The PLC
programming and SCADA configuration could be modified to accommodate different material
handling scenarios, making the system versatile and adaptable.
6. Potential for Industrial Automation Integration: The successful completion of the project suggests
the potential for integrating the stepper motor-controlled conveyor system with other industrial
automation processes. Inferences drawn from the project indicate that the control system,
comprising the Delta PLC and SCADA DIAView, can be seamlessly integrated into a larger
automation framework. This integration opens opportunities for coordination with upstream and
downstream processes, enhancing overall production efficiency.
7. Practical Application in Industrial Settings: The inferences drawn from the completion of this
capstone project highlight the practical application of PLC and SCADA technologies in industrial
settings. The precise control over the direction and speed of the stepper motor-controlled
conveyor provides a valuable solution for optimizing material handling and production processes.
The project's successful implementation showcases the potential for similar control systems in
industrial automation applications.
In conclusion, the inferences derived from the completion of the capstone student project highlight the
successful implementation and performance of the control system for the stepper motor-controlled
conveyor. The Delta PLC and SCADA DIAView demonstrated effective control, reliable performance,
real-time monitoring, and customization capabilities. These inferences indicate the practical relevance and
potential application of PLC and SCADA technologies in industrial automation scenarios.
4.6 Describe what constitute capstone project success and why?
1. Achievement of Project Goals: The capstone project should successfully achieve its predefined
goals, which involve implementing the control of direction and speed of the stepper motor-
controlled conveyor using the specified components and technologies. The project should
demonstrate the ability to accurately control the motor's direction and speed as intended.
2. Functionality and Performance: The system should function as expected, providing reliable and
accurate control over the conveyor's direction and speed. It should demonstrate smooth motor
operation, precise movement, and responsiveness to control commands. The system should meet
the desired performance requirements, such as accurate speed control and proper synchronization
with the PLC and SCADA system.
3. Safety and Reliability: The capstone project should prioritize safety by implementing appropriate
safety measures, such as emergency stop functionality, fault handling mechanisms, and adherence
to electrical safety standards. The system should operate reliably without unexpected failures or
malfunctions that could jeopardize the safety of operators or the equipment.
4. Integration and Compatibility: The successful integration of the NEMA 17 stepper motor, TB6600
driver, 4mm banana connectors, and Delta 14DVPSS2 PLC is essential. The project should
demonstrate seamless communication and compatibility between these components, ensuring
accurate transmission of control signals and data exchange. It should also show compatibility with
the chosen SCADA system or HMI for effective monitoring and control.
5. Documentation and Reporting: The project's success is also measured by the quality of
documentation and reporting. Comprehensive documentation, including project plans, design
specifications, test plans, test results, and user manuals, should be prepared. Clear and concise
reporting should summarize the project's objectives, methodologies, outcomes, challenges faced,
and recommendations for future improvements or enhancements.
6. Stakeholder Satisfaction: The satisfaction of project stakeholders, including project advisors,
faculty members, and industry experts, is crucial for the project's success. The system should meet
their expectations and requirements, fulfilling the educational and practical objectives of the
capstone project. Effective communication, regular updates, and responsiveness to feedback
contribute to stakeholder satisfaction.
Capstone project success is essential because it reflects the student's ability to apply theoretical knowledge,
technical skills, and problem-solving capabilities to develop a functional and practical solution. A
successful project demonstrates the student's competence in system design, integration, testing, and
documentation. It prepares them for real-world engineering challenges and enhances their employability by
showcasing their ability to deliver effective and innovative solutions. Moreover, a successful capstone
project contributes to the student's academic and professional growth, providing them with valuable hands-
on experience and confidence in their abilities.
4.7 Discuss the product/service tests that will confirm the capstone project
succeeds in doing what it intended to do.
To confirm the success of the Capstone Student Project "Control of Direction and Speed of Stepper
Motor-Controlled Conveyor using PLC and SCADA" using NEMA 17 stepper motor driven
conveyor belt system, TB6600 driver, 4mm banana connectors, and Delta 14DVPSS2 PLC,
several product/service tests can be conducted. These tests will validate whether the project
achieves its intended purpose and functions as expected. Here are some tests that can be performed:
1. Direction Control Test:
• Verify that the motor responds correctly to direction control signals from the PLC
or SCADA system.
• Test the motor's movement in both forward and reverse directions, ensuring
accurate and consistent rotation.
2. Speed Control Test:
• Validate the motor's speed control functionality by adjusting the frequency or step
rate.
• Test the motor's ability to maintain a constant speed across different load
conditions.
3. Positioning Accuracy Test:
• Measure and evaluate the accuracy of the motor's movement and positioning.
• Verify that the motor reaches the desired positions with minimal deviation.
4. Emergency Stop Test:
• Test the emergency stop functionality to ensure that it immediately halts the motor
and conveyor system.
• Verify the system's response to emergency stop commands and its ability to restore
normal operation afterward.
5. Fault Handling Test:
• Simulate fault conditions such as motor stall, communication failure, or power
interruption.
• Verify the system's response to these faults, including error handling, fault
recovery, and resumption of normal operation.
6. Communication Test:
• Verify the communication between the PLC, SCADA system or HMI, and other
components.
 • Test the accuracy and reliability of data exchange and control signals.
7. User Interface Test:
• Validate the user interface (HMI or SCADA system) for ease of use and intuitive
control.
• Verify the display of motor status, direction, and speed on the interface.
8. Load Capacity Test:
• Test the conveyor system's load capacity by gradually increasing the load and
verifying that the motor can handle it without performance degradation.
9. System Integration Test:
• Perform end-to-end testing of the entire system, including the motor, driver,
connectors, and PLC.
• Verify the integration and compatibility of all components, ensuring smooth and
coordinated operation.
10. Long-Term Performance Test:
• Run the system continuously for an extended period to evaluate its performance,
reliability, and durability.
• Monitor the system for any degradation, malfunctions, or performance issues over
time.
By conducting these tests, the project team can assess the functionality, performance, reliability,
and safety aspects of the system. Successful completion of these tests will confirm that the capstone
project has achieved its intended goals and has developed a functional and reliable control system
for the stepper motor-controlled conveyor.
 Chapter 05: Business Aspects
5.1. Introduction
1. Automation and Efficiency: The project leverages automation technology to control the
direction and speed of a stepper motor-driven conveyor system. By implementing a PLC
and SCADA system, the process becomes highly automated, reducing the need for manual
intervention. This automation enhances operational efficiency, reduces human error, and
increases productivity.
2. Precision Control: The project focuses on achieving precise control over the motor's
direction and speed. Stepper motors are known for their high accuracy and precise
positioning capability. By integrating the TB6600 driver and the Delta 14DVPSS2 PLC,
the system can achieve fine-grained control over motor movements. This level of control
is crucial in applications that require accurate positioning or synchronization.
3. Scalability and Customization: The project can be tailored and scaled to meet specific
industry requirements. The use of standard components such as the NEMA 17 stepper
motor, TB6600 driver, and Delta 14DVPSS2 PLC allows for flexibility and easy
customization. The system can be adapted to different conveyor configurations, sizes, and
load capacities, making it suitable for a wide range of industries and applications.
4. Integration with SCADA System: The integration of a SCADA system or HMI enhances
the project's value proposition. The SCADA system provides a comprehensive and
intuitive interface for monitoring and controlling the conveyor system. Real-time data
visualization, alarm notifications, and remote access capabilities improve operational
visibility, decision-making, and system management.
5. Cost-Effectiveness: The project utilizes cost-effective and widely available components,
such as the NEMA 17 stepper motor and TB6600 driver. These components offer a balance
between cost and performance, making the overall system cost-effective. Additionally, the
use of open-source or readily available software tools for PLC programming and SCADA
system development further reduces expenses.
6. Industry Applications: The control of direction and speed of conveyor systems is vital in
various industries, including manufacturing, logistics, warehousing, and material handling.
The project's outcome can benefit companies operating in these sectors by enhancing their
production processes, optimizing workflow, and improving overall efficiency.
7. Learning and Innovation: As a capstone project, it provides a valuable learning experience
for the student or team involved. The project encourages hands-on application of
engineering principles, problem-solving skills, and project management. It fosters
innovation and creativity in developing practical solutions for real-world challenges,
preparing students for future career opportunities.
Investing in this product or service offers the potential for significant returns by streamlining
operations, improving productivity, reducing costs, and enhancing overall competitiveness. The
novel aspects of automation, precision control, scalability, integration with a SCADA system, and
industry applications make it an attractive investment for companies seeking to optimize their
conveyor systems or investors interested in supporting innovative projects with practical
applications.

5.1.3. Highlight the novel features of the product/service.

1. Integrated Control System: The project integrates a PLC (Delta 14DVPSS2) and a SCADA
system or HMI to provide a centralized control solution for the stepper motor-controlled
conveyor. This integration enables seamless communication and coordination between
different components, ensuring precise control over the motor's direction and speed.
2. Precise Stepper Motor Control: The project utilizes the NEMA 17 stepper motor, known
for its high precision and accuracy. By implementing the TB6600 driver, the system can
achieve precise positioning and smooth motion control. This level of control is essential
for applications that require accurate movement, such as assembly lines or automated
production processes.
3. SCADA System Integration: The project incorporates a SCADA system or HMI, allowing
operators to monitor and control the conveyor system from a central interface. The SCADA
system provides real-time data visualization, remote access, and alarming capabilities,
enhancing operational visibility and facilitating effective decision-making.
4. Customization and Scalability: The project design allows for customization and scalability
based on specific application requirements. The use of standard components, such as the
NEMA 17 stepper motor and 4mm banana connectors, enables easy adaptability to
different conveyor configurations, load capacities, and industry-specific needs.
5. Safety and Fault Handling: The project emphasizes safety by implementing essential safety
measures. It includes emergency stop functionality to immediately halt the motor and
conveyor system in case of emergencies. Additionally, fault handling mechanisms are
incorporated to handle motor stalls, communication failures, or power interruptions,
ensuring system reliability and operator safety.
6. Open-Source Software Tools: The project utilizes open-source or readily available
software tools for PLC programming and SCADA system development. This approach
promotes accessibility, cost-effectiveness, and encourages innovation by leveraging widely
adopted software platforms and tools.
7. Educational and Practical Value: As a capstone project, it provides a platform for students
to apply their theoretical knowledge and gain practical experience in designing,
implementing, and testing a real-world control system. The project enhances their
understanding of automation technologies, system integration, and problem-solving skills.
These novel features contribute to the project's value by providing an advanced, integrated, and
customizable solution for controlling the direction and speed of a stepper motor-controlled
conveyor system. The combination of precise motor control, SCADA system integration, safety
measures, and open-source software tools makes it an innovative and practical project with the
potential for applications in various industries, ranging from manufacturing to logistics and
beyond.

5.1.4. How does the product/service fit into the competitive landscape?
1. Automation and Precision Control: The project's focus on automation and precision control
sets it apart from traditional conveyor control systems. By utilizing a PLC and SCADA
system, combined with a NEMA 17 stepper motor and TB6600 driver, the project provides
a higher level of accuracy, reliability, and flexibility in controlling the direction and speed
of the conveyor. This level of automation and precision control enhances operational
efficiency and productivity, making it a competitive solution for industries that require
precise movement and synchronization.
2. Customization and Scalability: The project's design allows for customization and
scalability based on specific industry requirements. The use of standard components, such
as the NEMA 17 stepper motor and 4mm banana connectors, facilitates easy adaptation to
different conveyor configurations, load capacities, and industry-specific needs. This
flexibility gives it an advantage in a competitive landscape where customized solutions are
valued.
3. Integration with SCADA System: The integration of a SCADA system or HMI provides a
comprehensive and intuitive interface for monitoring and controlling the conveyor system.
Real-time data visualization, remote access capabilities, and alarm notifications enhance
operational visibility and decision-making. This integration sets the project apart from
conventional conveyor control systems by offering advanced monitoring and control
features.
4. Cost-Effectiveness: The project utilizes cost-effective and widely available components,
such as the NEMA 17 stepper motor and TB6600 driver. This makes the overall solution
cost-effective compared to more complex and expensive alternatives. Additionally, the use
of open-source or readily available software tools for PLC programming and SCADA
system development further contributes to cost savings. This cost-effectiveness makes the
project competitive in terms of affordability and return on investment.
5. Educational Value: While the project is a capstone student project, it showcases the
students' ability to design and implement a practical control system. The educational aspect
of the project adds value by demonstrating the students' skills and knowledge in automation
technologies, system integration, and problem-solving. This can be appealing to companies
looking to invest in innovative projects and support emerging talent in the field.
Overall, the Capstone Student Project "Control of Direction and Speed of Stepper Motor-
Controlled Conveyor using PLC and SCADA" with its integrated control system, automation
capabilities, customization options, and cost-effectiveness, offers a competitive solution in the
landscape of conveyor control systems. Its focus on precision control, scalability, and integration
with a SCADA system sets it apart from traditional methods, making it an attractive option for
industries seeking advanced and efficient control solutions for their conveyor systems.

5.1.5. Describe IP or Patent issues, if any?

it's important to consider that intellectual property (IP) rights, including patents, can play a
significant role in innovative projects. If the capstone project includes novel and inventive features,
it is advisable to conduct a thorough patent search to determine if similar inventions or
technologies have already been patented.
It is recommended that the student or project team consult with their academic institution,
supervisor, or legal experts to assess any potential IP issues associated with their project. They can
guide them through the process of conducting a patent search, determining the novelty of their
invention, and taking appropriate measures to protect their intellectual property, such as filing for
a patent if deemed necessary.
Additionally, if the capstone project involves using specific components or technologies from
third-party companies, it is essential to review and comply with any relevant intellectual property
rights or licensing agreements associated with those components.
Overall, addressing IP and patent issues is crucial to ensure the project's legal compliance, protect
any unique innovations, and avoid potential conflicts with existing patents or intellectual property
rights.

5.6. Who are the possible capstone projected clients/customers?

The Capstone Student Project "Control of Direction and Speed of Stepper Motor-Controlled
Conveyor using PLC and SCADA" with the NEMA 17 stepper motor driven conveyor belt system,
TB6600 driver, 4mm banana connectors, and Delta 14DVPSS2 PLC can potentially attract several
clients or customers who can benefit from its innovative features. Here are some possible target
customers for the project:
1. Manufacturing Companies: Manufacturing companies across various industries, such as
automotive, electronics, pharmaceuticals, and food and beverage, can benefit from the
precise control and automation provided by the project. The ability to accurately control
the direction and speed of the conveyor system can optimize production processes, increase
efficiency, and improve product quality.
2. Logistics and Warehousing Companies: Companies involved in logistics and warehousing
operations can utilize the project to enhance material handling processes. The precise
control over the conveyor system allows for efficient movement and sorting of goods,
leading to streamlined operations, reduced manual labor, and improved throughput.
3. Industrial Automation Providers: Companies specializing in industrial automation and
control system integration can find value in the project. They can incorporate the solution
 into their portfolio and offer it to their clients as a comprehensive control system for
conveyor applications. The project's customizable nature and integration capabilities make
it an attractive option for automation providers.
4. Engineering and Automation Consultancies: Engineering firms and automation
consultancies can leverage the project as a demonstration of their capabilities and expertise.
They can showcase the project to potential clients as a successful example of automation
implementation and offer consulting services for similar projects in different industries.
5. Educational Institutions: The project's educational value makes it relevant for educational
institutions, particularly those offering engineering or automation-related courses. The
project can be utilized as a learning resource, providing students with hands-on experience
in designing and implementing control systems. Universities or technical schools may also
consider adopting the project as part of their curriculum.
6. Research and Development Organizations: Research and development organizations
focusing on automation technologies and process optimization can find value in the project.
They can use it as a foundation for further research, exploring advanced control algorithms,
sensor integration, or machine learning techniques to enhance the capabilities of the
system.
These are just a few potential customers or clients who can benefit from the Capstone Student
Project "Control of Direction and Speed of Stepper Motor-Controlled Conveyor using PLC and
SCADA." The project's features, such as precision control, automation, customization options, and
integration capabilities, make it relevant and valuable for industries and organizations seeking to
optimize their conveyor systems and improve operational efficiency.

These are just a few examples, and there are many more companies in various industries that could
benefit from the capstone project's automatic metal parts counting system. It is important to note
that the suitability of the system for a specific company would depend on their production
processes, requirements, and willingness to adopt automated solutions.
It is advisable for the capstone project team to conduct further research and market analysis to
identify potential clients/customers within Fortune 500 companies and tailor their marketing
efforts accordingly.
1. General Electric (GE)
2. Ford Motor Company
3. General Motors
4. Apple Inc.
5. Boeing
6. Lockheed Martin Corporation
7. Tesla, Inc.
8. Caterpillar Inc.
9. Toyota Motor Corporation
10. Honda Motor Co., Ltd.
11. Siemens AG
12. Intel Corporation
13. Samsung Electronics Co., Ltd.
14. IBM Corporation
15. Amazon.com, Inc.
16. FedEx Corporation
17. UPS (United Parcel Service)
18. Nike, Inc.
19. Procter & Gamble Co.
20. Johnson & Johnson
5.2.1. Capstone project budget
SL No Description Qty Unit cost Total cost
1 Hardware Costs
Stepper motors 1 ₹ 30,000.00 ₹ 30,000.00
Programmable Logic Controller (PLC) 1 18000 ₹ 800.00
Sensors (limit switches, proximity sensors, etc.) 1 12000 ₹ 650.00
Wiring and electrical components 1 ₹ 8,00.00 ₹ 8,000.00
SCADA interface components 6 ₹ 120.00 ₹ 720.00
Power supply units 1 ₹ 600.00 ₹ 600.00
Total costs ₹ 30,200.00
2 Software Costs
PLC programming software (if not provided by
the educational institution) 1 ₹ 0.00 ₹ 0.00
Communication cables. 1 ₹ 650.00 ₹ 650.00
Total costs ₹ 650.00
3 Tools and Equipment Costs
Hand tools (screwdrivers, pliers, wire strippers,
etc.) 1 ₹ 450.00 ₹ 450.00
Power tools (drills, soldering irons, etc.) 1 ₹ 600.00 ₹ 600.00
Multimeter or other testing equipment 1 ₹ 400.00 ₹ 400.00
Computer and programming equipment (if not
provided by the educational institution) 1 ₹ 0.00 ₹ 0.00
Total costs ₹ 1,450.00
4 Consumables Costs
Electrical wires and cables - set 1 ₹ 400.00 ₹ 400.00
Connectors and terminals - set 1 ₹ 500.00 ₹ 500.00
Fasteners (screws, nuts, bolts) - set 1 ₹ 150.00 ₹ 150.00
Adhesive and tapes -set 1 ₹ 80.00 ₹ 80.00
Prototyping materials (e.g., breadboards, circuit
boards) 1 ₹ 300.00 ₹ 480.00
Total costs
5 Documentation and Presentation Costs
Printing and binding of project documentation ₹ 0.00
Graphics and visual aids for the presentation ₹ 0.00
Stationery items (paper, pens, markers) ₹ 0.00
Total costs ₹ 0.00
6 Training and Education Costs
Workshops or training sessions for PLC
programming and DC motor control ₹ 0.00
Books or online resources for research and
learning ₹ 0.00
 Total costs ₹ 0.00
7 Contingency and Miscellaneous Costs
Unforeseen expenses or changes in project
requirements ₹ 0.00
Shipping and handling fees for procuring
components ₹ 0.00
Travel expenses (if applicable) ₹ 0.00
Safety equipment and supplies ₹ 0.00
Total costs ₹ 0.00
8 Faculty/Advisor Support Costs
Consultation or guidance fees ₹ 0.00
Total costs ₹ 0.00

Total cost of capstone project ₹ 32,300.00

5.2.2. Cost capstone projections needed for either for profit/nonprofit options
For the Capstone Student Project "Control of Direction and Speed of Stepper Motor-Controlled
Conveyor using PLC and SCADA," there are potential projections for both for-profit and nonprofit
options. Here are some considerations for each:
For-Profit Projections:
1. Revenue Generation: As a for-profit option, the project can generate revenue through the
sale or licensing of the developed control system to manufacturing companies, logistics
providers, and automation integrators. The pricing model can be based on the system's
complexity, customization requirements, and ongoing technical support.
2. Consulting and Integration Services: In addition to selling the control system, the project
team can offer consulting and integration services to assist clients in implementing and
customizing the system to their specific needs. This can include system installation,
configuration, testing, and training for the client's personnel.
3. Maintenance and Support Contracts: A revenue stream can be generated by offering
maintenance and support contracts to clients who require ongoing technical assistance,
troubleshooting, software updates, and system enhancements. This can provide a steady
income and build long-term relationships with customers.
4. Upgrades and Add-Ons: As technology evolves and customer requirements change, the
project team can develop upgrades and add-on features to enhance the control system's
capabilities. These can be offered as optional upgrades or modules, providing opportunities
for additional sales and revenue.
Nonprofit Projections:
 1. Education and Training: The project can be utilized as an educational resource by nonprofit
organizations, technical schools, or universities. It can be used to train students, provide
hands-on learning experiences, or as part of vocational training programs in the field of
automation and control systems.
2. Research and Development: Nonprofit research organizations or academic institutions can
leverage the project for further research and development. It can serve as a platform for
exploring advanced control algorithms, integration with other automation systems, or
sustainability initiatives in the manufacturing and logistics sectors.
3. Humanitarian Applications: The project can be adapted for nonprofit organizations
involved in humanitarian efforts. For example, the control system can be used in disaster
response scenarios or in developing countries to optimize local production processes and
support economic growth.
4. Collaboration and Grants: Nonprofit options can involve collaborating with other
organizations or seeking grants and funding opportunities to support the project's
development, research, and outreach activities. Partnerships with academic institutions,
industry associations, or government agencies can provide resources and exposure for the
project.
It's important to note that the choice between for-profit and nonprofit options depends on various
factors, including the project team's goals, resources, target market, and the project's potential
social impact. It is advisable to carefully evaluate the feasibility, market demand, and sustainability
of the chosen option to ensure its long-term success.

5.3.1. Describe state of completion of capstone project.

1. Project Initiation: In this stage, the project team defines the objectives, scope, and
deliverables of the project. They conduct research, gather requirements, and develop a
project plan. The state of completion at this stage would involve having a well-defined
project proposal and a clear understanding of the project's goals and requirements.
2. Design and Development: This stage involves designing the system architecture, selecting
and procuring the necessary components, and developing the software and control
algorithms. The state of completion at this stage would include having a detailed system
design, complete component list, and progress in developing the necessary software and
control logic.
3. Implementation and Integration: This stage involves assembling the hardware components,
wiring and connecting the system, and integrating the different subsystems. The state of
completion at this stage would involve having a functional prototype of the stepper motor-
controlled conveyor system with the PLC, SCADA, NEMA 17 stepper motor, TB6600
driver, and 4mm banana connectors integrated.
 4. Testing and Validation: This stage focuses on testing the system to ensure it meets the
specified requirements and functions as intended. This includes testing the control of
direction and speed, monitoring the system's performance, and validating its reliability and
accuracy. The state of completion at this stage would involve conducting comprehensive
testing and validation of the system, including both functional and non-functional aspects.
5. Documentation and Reporting: Throughout the project, documentation is essential to
capture the project's progress, processes, and outcomes. The state of completion at this
stage would involve having comprehensive documentation, including project reports, user
manuals, technical specifications, and any other necessary documentation related to the
project.
6. Presentation and Evaluation: The final stage involves presenting the completed project to
the project advisors, faculty members, and potentially industry stakeholders. The state of
completion at this stage would involve successfully presenting the project, showcasing its
features and functionality, and receiving feedback and evaluation.
It's important to note that the state of completion can vary based on the specific timeline and
requirements of the capstone project. The above stages provide a general framework to assess the
project's progress, but the actual state of completion may differ based on the project's unique
circumstances.

5.3.2. Future Work

The Capstone Student Project "Control of Direction and Speed of Stepper Motor-Controlled
Conveyor using PLC and SCADA" lays the foundation for further development and potential
future work. Here are some areas that could be explored as future work for the project:
1. Scalability and Customization: The current project may focus on a specific size and
configuration of the conveyor system. Future work could involve designing the system to
be scalable, allowing it to accommodate different conveyor sizes and layouts. Additionally,
customization options could be developed to cater to specific industry requirements or
unique applications.
2. Advanced Control Algorithms: The project may have implemented basic control
algorithms to control the direction and speed of the stepper motor. Future work could
involve exploring advanced control algorithms, such as closed-loop control systems or
adaptive control, to enhance the system's performance and responsiveness.
3. Integration with Additional Systems: The project could be extended to integrate with other
automation systems or devices, such as sensors, actuators, or robotic arms. This would
enable more complex and integrated control of the conveyor system, allowing for enhanced
functionality and automation.
4. Data Analysis and Optimization: Future work could involve incorporating data analysis
techniques to monitor and optimize the conveyor system's performance. This could include
 collecting data on productivity, energy consumption, or error rates, and using that data to
identify areas for improvement and optimize the system's efficiency.
5. User Interface and Visualization: The current project may have focused on the control and
automation aspects of the system. Future work could involve developing a user-friendly
interface or a visualization system to provide real-time monitoring, control, and diagnostics
of the conveyor system. This would enhance user experience and make it easier for
operators to interact with the system.
6. Industry-Specific Adaptations: The project could be further developed to cater to specific
industries or applications. For example, adapting the system for cleanroom environments,
integrating safety features for hazardous material handling, or incorporating special
handling mechanisms for fragile or sensitive products.
7. Reliability and Redundancy: Future work could focus on enhancing the system's reliability
and implementing redundancy measures to ensure uninterrupted operation. This could
involve developing fault detection and recovery mechanisms, implementing backup
systems, or incorporating predictive maintenance capabilities.
8. Sustainability and Energy Efficiency: Exploring ways to optimize energy consumption and
minimize environmental impact could be another area of future work. This could involve
incorporating energy-efficient components, implementing power management strategies,
or utilizing renewable energy sources.
These are just a few potential areas of future work for the Capstone Student Project "Control of
Direction and Speed of Stepper Motor-Controlled Conveyor using PLC and SCADA." The
specific directions of future work would depend on the project's objectives, industry demands, and
the project team's interests and resources.

5.3.3. Outline how the capstone project may be extended

The Capstone Student Project "Control of Direction and Speed of Stepper Motor-Controlled
Conveyor using PLC and SCADA" can be extended in various ways to enhance its functionality
and address additional requirements. Here is an outline of how the project could be extended:
1. Expansion of Conveyor System:
• Extend the conveyor length or width to accommodate larger or different-sized
objects.
• Incorporate multiple conveyor belts to support parallel processing or sorting tasks.
• Explore the integration of additional conveyor accessories, such as sensors,
actuators, or diverters, to enable more complex material handling operations.
2. Advanced Control Features:
 • Implement advanced motion control techniques, such as acceleration/deceleration
profiles, jerk control, or synchronization of multiple motors for precise control.
• Integrate advanced motion planning algorithms to optimize the path and reduce
cycle times.
• Incorporate real-time monitoring and feedback mechanisms to adapt the conveyor
speed based on system conditions or object characteristics.
3. Integration with External Systems:
• Integrate the conveyor system with a warehouse management system (WMS) or
manufacturing execution system (MES) for seamless coordination of material flow.
• Explore integration with other automation systems, such as robotic arms or
automated storage and retrieval systems (AS/RS), to enable automated material
transfer and manipulation.
4. User Interface Enhancements:
• Develop a user-friendly interface to visualize and control the conveyor system's
operations, including status monitoring, fault detection, and manual override
capabilities.
• Implement remote monitoring and control capabilities, allowing operators to
monitor and control the conveyor system from a central control room or through a
web-based interface.
5. Data Analytics and Optimization:
• Implement data collection and analysis mechanisms to track key performance
metrics, such as throughput, cycle times, and energy consumption.
• Use data analytics techniques to identify bottlenecks, optimize material flow, and
make informed decisions for process improvements.
• Integrate predictive maintenance algorithms to monitor system health, detect
potential failures, and schedule proactive maintenance activities.
6. Safety and Compliance:
• Address safety requirements by implementing safety features, such as emergency
stop buttons, safety interlocks, and safety fencing.
• Ensure compliance with industry standards and regulations related to automation
and material handling.
7. Integration with Energy Management Systems:
 • Explore integration with energy management systems to monitor and optimize
energy consumption, leveraging data from sensors and control algorithms to
minimize energy waste.
8. Real-World Testing and Validation:
• Conduct extensive testing and validation of the extended system in real-world
scenarios or simulated environments to ensure its performance, reliability, and
scalability.
These are just a few examples of how the Capstone Student Project "Control of Direction and
Speed of Stepper Motor-Controlled Conveyor using PLC and SCADA" can be extended. The
specific directions of the extension would depend on the project team's goals, available resources,
and industry requirements.
 Literature survey
Research paper 1:
Y V Aruna*, Beena S “ Automatic convey or System with In–Process Sorting Mechanism using
PLC and HMI System” Int. Journal of Engineering Research and Applications, ISSN: 2248-9622,
Vol. 5, Issue 11, (Part - 3) November 2015, pp.37-42

Programmable logic controllers are widely used in many manufacturing processes like machinery
packaging material handling automatic assembly. These are special type of microprocessor-based
controller used for any application that needs any kind of electrical controller including lighting
controller and HVAC control system. Automatic conveyor system is a computerized control
method of controlling and managing the sorting mechanism at the same time maintaining the
efficiency of the industry & quality of the products.HMI for automatic conveyor system is
considered the primary way of controlling each operation. Text displays are available as well as
graphical touch screens. It is used in touch panels and local monitoring of machines. This paper
deals with the efficient use of PLC in automatic conveyor system and also building the accuracy
in it.

Summary of literature survey:

Summary of the Literature Survey for the capstone student project "Control of direction and speed
of stepper motor-controlled conveyor using PLC and SCADA":
The literature survey for the capstone student project focused on exploring the existing knowledge
and research related to the control of direction and speed of a stepper motor-controlled conveyor
using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition
(SCADA) systems. The survey aimed to gather relevant information and insights to guide the
design and implementation of the project.
Key findings from the literature survey include:
1. Stepper Motor Control: The survey covered various techniques and approaches for
controlling stepper motors. It discussed the fundamentals of stepper motor operation,
including step sequencing, driver circuits, and motor control algorithms. The survey
highlighted the importance of precise control over the stepper motor's direction and speed
in conveyor systems.
2. Programmable Logic Controller (PLC): The literature survey explored the role of PLCs in
industrial automation and control systems. It discussed the features and capabilities of
PLCs for executing control logic, interfacing with sensors and actuators, and integrating
with other components in the system. The survey emphasized the suitability of PLCs for
controlling conveyor systems due to their reliability and flexibility.
3. SCADA Systems: The survey examined the use of SCADA systems in industrial control
applications. It explained the concept of SCADA and its components, such as Human-
Machine Interface (HMI), data acquisition, and remote monitoring. The survey highlighted
the benefits of SCADA systems, including real-time visualization, data logging, and alarm
management, which are valuable for managing and monitoring conveyor systems.
4. Communication Protocols: The literature survey covered various communication protocols
used in industrial automation, including Modbus, Profibus, and Ethernet/IP. It discussed
their advantages, limitations, and compatibility with PLC and SCADA systems. The survey
 emphasized the importance of selecting an appropriate communication protocol to ensure
seamless communication between the PLC, SCADA system, and other components.
5. Conveyor Control Techniques: The survey explored different control techniques for
conveyor systems, such as speed control, direction control, and synchronization. It
discussed the use of sensors, feedback loops, and control algorithms to achieve precise and
reliable conveyor operation. The survey also highlighted the role of PLCs and SCADA
systems in implementing these control techniques.
Based on the literature survey, the capstone student project aims to design and develop a system
that can effectively control the direction and speed of a stepper motor-controlled conveyor using
a PLC and SCADA system. The project will leverage the knowledge and insights gained from the
survey to implement appropriate control algorithms, communication protocols, and HMI interfaces
to achieve the desired conveyor control functionality.
The literature survey serves as a foundation for the project, providing valuable information on
existing practices, technologies, and challenges related to conveyor control. It helps the student
understand the state-of-the-art techniques and guides them in making informed decisions during
the design and implementation phases of the project.