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AUTOMATIC HORN HOUSING
CONVEYING AND POSITIONING
SYSTEM
A PROJECT REPORT
Submitted by
R.MOHAN PRAKASH 090112112023
P.TATAVARATHARAJAPERUMAL 100412112014
I n partial f ul fi llment for the award of the degree
Of
BACHELOR OF ENGINEERING
IN
MECHATRONICS ENGINEERING
MAHARAJA ENGINEERING COLLEGE, AVINASHI
ANNA UNIVERSITY :: CHENNAI 600 025
APRIL 2013
http://www.google.co.in/imgres?imgurl=http://www.maharaja.in/mec/images/logo.gif&imgrefurl=http://www.maharaja.in/mec/index.html&h=93&w=145&sz=6&tbnid=f4hjpOHewHg8iM:&tbnh=74&tbnw=116&prev=/search?q=maharaja+engineering+college+logo&tbm=isch&tbo=u&zoom=1&q=maharaja+engineering+college+logo&usg=__4k8bHasaYOpQs115gWoYbifWS8k=&docid=3mUBZE8lXE3NaM&hl=en&sa=X&ei=bnN9UKinHM3MrQeyrYGYCQ&ved=0CCsQ9QEwAg&dur=26577/27/2019 Automatic horn housing conveying and positioning system
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ANNA UNIVERSITY :: CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report AUTOMATIC HORN HOUSING
POSITIONER AND THREAD INSPECTION SYSTEM is the bonafide
work of MOHAN PRAKASH.R, TATAVARATHARAJAPERUMAL.P
who carried out the project work under my supervision.
SIGNATURE SIGNATURE
Mr.L.FEROZ ALI B.E., (M.E), Mr.T.VELUMANI M.E., (Ph.D),
SUPERVISOR HEAD OF THE DEPARTMENT
Department of Mechatronics Engineering Department of Mechatronics Engineering
Maharaja Engineering college Maharaja Engineering college
Avinashi-641654 Avinashi-641654
INTERNAL EXAMINER EXTERNAL EXAMINER
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ACKNOWLEDGEMENT
Our heartfelt and sincere thanks goes to our beloved and honorable chairman
Thiru K.PARAMASIVAM B.Sc., for having provided us with all necessary
infrastructure and other facilities. Our special thanks to our beloved
correspondent Thiru P.SATHIYAMOORTHY B.E., MBA., M.S., for his
extensive support to successfully complete this project.
We extend our sincere gratitude to Mr. T.VELUMANI M.E., (Ph.D), Head
of the department, Department of Mechatronics Engineering, Maharaja
Engineering College, Avinashi for extending all possible help for this work.
We heartily thank our internal project guide Mr. L. FEROZ ALI B.E.,
(M.E), Lecturer, Department of Mechatronics Engineering for his valuable
guidance in making this project to grant success.
We respect and thank to Dr. KAVIDASAN, Director - HR giving an
opportunity to do the project work in Roots Industries India Ltd., and providing
us all support and guidance which made us complete the project on time.
We owe our profound gratitude to our project guide Mr.M.Vijayakumar
Head - Facility Development and Automation who took keen interest on our
project work and guided us all along by providing all the necessary information
for developing an innovative system.
Last but not least we extend our heartfelt thanks to our beloved parents
and the friends who has always been an integral part in helping us through times
and making our project a Herculean success.
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ABSTRACT
This project we proposed is mainly focused on automation as well as
quality improvement. Basically this proposed system is controlled and
automated by PLC. Major feed forward part of project is LDR; based on the
feedback pulses the Auto-positioning table will orient the horn housings.
This project assures the manpower elimination of housing manufacturing
process. The conveyance of housing from other machines to riveting
operation machine is done by belt conveyor setup with the help of vacuum
gripper-I housings are located on auto-positioning system. The Holes present
in housing are the reference of this system, based on the light source
intensity passed through holes apparently switch the LDRs and make the
exact orientation by stopping the prime moving equipment. Further the
vacuum gripper-II will convey the housings to Auto indexing fixtures.
Obviously the machine will perform the specified task (riveting).The
automatic positioning of housing is chosen to eliminate the manual feeding
of housings and also enhance the flawless production strategy.
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COMPANY PROFILE
INTRODUCTION
Roots Industries India Ltd is a leading manufacturer of Automotive
HORNS in India and the 11th largest Horn Manufacturing Company in the
world. Headquartered in Coimbatore - India, ROOTS has been a dominant
player in the manufacture of Horns and other products like CASTINGS
and INDUSTRIAL CLEANING MACHINES. Since its establishment in 1970,
ROOTS has had a vision and commitment to produce and deliver quality
products adhering to International Standards.
With a strong innovative base and commitment to Quality, Roots Industries
India Ltd has occupied a key position in both international and domestic market
as suppliers to leading OEMs and after market. Similar to products, Roots has
leading edge over competitors on strong quality system base. Now, RIL is the
first Indian Company and first horn manufacturing company in the world to get
ISO/TS 16949 certification based on effective implementation of QS 9000 and
VDA 6.1 system requirement earlier. Roots' vision is to become a world class
company manufacturing world class product, excelling in human relation.
CORPORATE
Roots' single minded pursuit of enhancing the quality of life has led to many
other diversifications. Roots, today, is a multifaceted corporate entity with
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interests in automobile accessories, cleaning equipment, castings, precision
tools, hi-tech engineering services, healthcare and education.
In a dynamic world that is driven by technology, a successful presence
depends on the way you mould that technology to fit popular
needs. Indigenous talent, a daring attitude, courage to accept and learn new
things and the simple spark of an idea. That is the genesis of ROOTS.
MILESTONES
1970 Promotes American Auto Service for manufacture of Electric
Horns.
1972 First to manufacture Servo Brakes for Light Motor Vehicles.
1984 Roots Auto Products Private Limited was established to
manufacture Air Horns. Die Casting Unit commences commercial
operations.
1988 Polycraft, a unit for Plastic Injection Moulding was established.
1990 Roots Industries India Ltd takes over Electric Horn business.
1992 RMCL enters into Techno-Financial collaboration with M/s.
Hako Werke GmbH, Germany.
1992 Roots Industries India Ltd obtains the National Certification -
ISI mark of quality.
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1994 Production of floor cleaning equipment commences.
Roots Industries India Ltd wins American International Quality
Award.
1999 Becomes the first horn manufacturer in Asia to obtain QS 9000
2000 Becomes the first horn manufacturer in Asia to obtain VDA 6.1
and the first in the world to win ISO / TS 16949
2000 The first to introduce digitally controlled air horns and low
frequency, low decibel irritation free Jumbo Air Horns.
2003 Roots Industries India Ltd., Horn Division is accredited with ISO
14001: 1996
2003 Roots Industries India Ltd., upgraded its ISO / TS 16949 from
1999 version to 2002 version
2004 Roots Industries India Ltd (RIL) opens its 100% exclusive Export
Oriented Unit at their Horn Division, Thoppampatti, Coimbatore to
cater the needs of Ford North America.
2004 RIL's EOU commences its supplies to Ford, North America
2004 Roots Multiclean Limited (RMCL) inaugurates its 100% EOU
Plant at Kovilpalayam, Coimbatore
2004 Roots Cast Private Limited (RCPL) inaugurates its Unit II at
Arugampalayam, Coimbatore
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2004 Roots Auto Products Pvt Ltd (RAPPL) expands with its
Machining Division at Arugampalayam, Coimbatore
2004 RIL successfully launches its Malaysian Plant
2004 The group company American Auto Service is accredited with
ISO 9001: 2000
2005 Roots Industries India Ltd., is certified with MS 9000, a pre-
requisite for Q1 award for Ford Automotive Operations Suppliers.
Focus on Systems and Processes
2005 Roots Metrology & Testing Laboratory has been accredited by
National Accreditation Board for testing & calibration in the field of
Mechanical Linear & Angular
2005 Roots Industries India Ltd., is awarded Q1 by Ford Motor
Company
2005 Roots Industries India Ltd., Horn Division upgraded its ISO:
14001 from 1996 version to 2004 version
VISION
We will stand technologically ahead of others to deliver world-classinnovative products useful to our customers. We will rather lose our business
than our customers' satisfaction. It is our aim that the customer should get the
best value for his money.
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Every member of our company will have decent living standards. We care
deeply for our families, for our environment and our society. We promise to pay
back in full measure to the society by way of selfless and unstinted service.
ROOTS GROUP OF COMPANIES
Roots Industries India Ltd ElectricHorns
Roots Auto Products Private Limited Air Horns, Switches & Controllers
Roots Multiclean Limited Cleaning Machines
Roots Cast Private Limited Aluminium & Zinc Pressure Die Cast
Roots Precision Products Dies, Tools, Jigs & Fixtures
Roots Metrology Laboratory Instrument Calibration, Quality
System, Consultancy
Roots Polycraft Plastic components
R K Nature Cure Home Nature Cure Therapy, Yoga &
Massages
Satchidananda Jothi Nikethan International School
Integral Yoga Institute Yoga and Meditation
Roots Industries Malaysia Sdn. Bhd. Electric Horns
http://www.rootsindia.com/html/ril.htmlhttp://www.rootsindia.com/html/rappl.htmlhttp://www.rmclindia.com/http://www.rootsindia.com/html/rcpl.htmlhttp://www.rootsindia.com/html/rpp.htmlhttp://www.rootsindia.com/html/metrology.htmlhttp://www.rootsindia.com/html/pc.htmlhttp://www.rootsindia.com/html/rknch.htmlhttp://www.rootsindia.com/html/sjnms.htmlhttp://www.integralyogaindia.org/http://www.integralyogaindia.org/http://www.rootsindia.com/html/sjnms.htmlhttp://www.rootsindia.com/html/rknch.htmlhttp://www.rootsindia.com/html/pc.htmlhttp://www.rootsindia.com/html/metrology.htmlhttp://www.rootsindia.com/html/rpp.htmlhttp://www.rootsindia.com/html/rcpl.htmlhttp://www.rmclindia.com/http://www.rootsindia.com/html/rappl.htmlhttp://www.rootsindia.com/html/ril.html7/27/2019 Automatic horn housing conveying and positioning system
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CHAPTER 1
INTRODUCTION
1.1 OBJECTIVE
The objective of the project is to make an automatic system for conveying,
handling and feeding the semi-finished goods in the press shop. This project we
had chosen is to eliminate the human resources as well as improves the
efficiency, quality of parts being produced in shop floor. Thus turning up the
conventional process into an automatic way.
1.2 PRESS SHOP
The division which converts the raw materials such as sheet metal plates
and steel rolls into the Horn Housings, Diaphragms, Vent shields, Point plates,
Mounting brackets, Tone disc, Point holders, Clamps.
The Press shop contains both automatic and conventional kind of
machineries for producing the goods. Further sub-divisions brief about the
machine tools, materials, process and parts.
1.2.1 TYPES OF MACHINES
Power press Hydraulic press Feeder press Pneumatic press Lathe press Feeder press with multiple operations
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1.2.2 TYPES OF TOOLS
Conventional tool Progressive tool Compound tool
1.2.3 TYPES OF PROCESS
Blanking Draw RestrikingNotching Trimming Forming Embossing Flanging Edge Chamfering
Rib forming Collar draw Flattering / Planishing Turning Riveting Bending Lancing Knurling Coining Stress Relieving
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1.2.3.1 COMBINED PROCESSES
Piercing and Blanking Piercing and Blanking and Notching Piercing and Blanking and Bending Piercing and Blanking and Cropping SCR Riveting and Planishing and Lancing SCR Riveting and Planishing and Lancing and Flanging Edge Chamfering and Lancing Hour Glass Cutting Draw I, Draw II, Draw III and Restrike Collar draw, Piercing, Lettering and Trimming Blanking and Forming Forming and Flanging Piercing, Lettering and Blanking
1.2.4 TYPES OF RAW MATERIALS
Aluminium Zinc Galvanised Steel Cold rolled Carbon Steel Spring Steel Stainless Steel
1.2.5 TYPES OF PARTS
Housing with SCR assembly Housing with E-Core assembly Diaphragm Tone disc
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Point plate Point holder Grill Keeper ring Mounting bracket Mounting bracket assembly Horn cover Connector Condenser bracket Clamp
1.2.6 PROCESS SEQUENCE OF HOUSING PRODUCTION
The below flow chart describes about the step by step process of
manufacturing the horn housings.
Raw material feeding (Steel
plate roll)
Internal Storage
Blanking of steel plate
Drawing I, II
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Restrike
Piercing
A
A
Notching
Flattering/ Planishing
Riveting
Manual
feeding
By
labour
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The projected system plays at the stage of manual feeding block of the flow
chart.
Bending & Lancing
Lettering
FG Container
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CHAPTER 2
SYSTEM ANALYSIS
2.1 EXISTING SYSTEM
Presently, the Horn Housing production process utilizes the Man power in
the process of conveying/loading the Horn housing at the press shop of the
industry. The worker loads the components into auto indexing fixtures at regular
intervals for the process to be proceeded. Currently the goods are made to fallinto a trolley, a mass material holding steel box from previous machine. The
manual labour moves these components from one machine to another to
perform successive manufacturing processes. The Containers are moved by the
forklifts. The worker will get himself seated near the machine for the whole shift
or until all the components are loaded into the machine. It is to be noticed that
most of the processes are done automatically, yet this work is carried out usinglabour.
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Fig 2.1 Existing Manual System
2.2 DRAWBACKS OF EXISTING SYSTEM
The existing system has a numerous drawbacks as listed below:
The manual feeding of the housing components onto the Auto Indexingfixture is found to be physically more difficult for the workers.
The loading of these components when done conventionally, is timeconsuming which leads to increase in the cycle time of production. Thus
affecting the production rate.
The movement of the semi finished parts from one machine to another alsoconsumes some amount of time.
The mishandling of the horn housing may also take place depending uponthe labours cooperation.
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The unnecessary utilization of human source is found in this process whichis considered as an excess labour cost.
Chance of Erratic loading and irregularities due to the fatigue of humanresource.
2.3 PROPOSED SYSTEM
To overcome the above mentioned problems, automated way of approach
for the process is suggested under the name of Automatic horn housing
conveying and positioning system. This approach has a lot of features when
compared to the existing system.
Fig 2.2 Pictorial representation of proposed system
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The proposed system has the major components such as
Motor Driven Belt Conveyor Pneumatic operated Vacuum End Effector AutoOrientation detection fixture Light Dependent resistors(LDR) Programmable Logic Controller(PLC) Light source
Each of the components plays the major role in this automated system, Each and
every component will performs the specified task with optimistic resolution and
repeatability.
2.3.1 ADVANTAGES OF PROPOSED SYSTEM
Manpower elimination Higher productivity Greater Accuracy Independent Control system Lesser labour intensive Reduction in labour cost Economic facility development
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CHAPTER 3
BASIC OPERATION OF AUTO-POSITIONER
3.1 ACQUISITION AND CONVEYANCE OF HOUSINGS
The proposed system is has a conveyor belt which operates in variable speed
and convenient to haul items from one point to another. It is a mechanical loop,
usually made of rubber that goes around its mechanism for a continuous cycle.
Fig 3.1 Conveyor Belt setup
The conveyor belts are motorized. Which connects the two machines and
holds the semi finished horn housings. Basically it is operated by Compact
Brushless DC gear motor.
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3.2 PLACING OF HOUSINGS INTO AUTO ORIENT FIXTURE
There is a manipulator placed at the end of this lengthy conveyor belt. The
semi finished part is picked up by the automated-pneumatic controlled end
effector. The gripper has an optical proximity sensor head that senses the arrival or
presence of component in the conveyor belt.
Fig 3.2 Picking up of Housing from conveyor
The gripper end has a vacuum cup for holding up the part, so that if the
component arrives even upside down, it can be easily handled without any
distractions. Further the end effector displaces the housing with the help of motor
operated slide-way projection. Finally the housing located at the exact span andheight of the auto-orient fixture.
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3.3 OBTAINING OF REQUIRED ORIENTATION
The Housing placed after the Auto Orientation fixture, the setup will rotated
by DC motor.
Fig 3.3 Typical sketch of Auto positioning system
Simultaneously the light source get switched ON which is located above this
fixture. There are two reference holes in housing which helps to make the exact
positioning. The Light Dependant Resistor (LDR) is placed under the Auto
Orientation fixture below those reference holes.
Those photo diodes will make the motor of the fixture table to rotate until
both the photo diodes receive the illumination through the reference holes from
light source. Thus the motor will stopped immediately, this control action
performed by a Programmable Logic Controller (PLC).
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3.4 LOCATION OF HOUSINGS INTO AUTO INDEXING FIXTURE
There is an Auto Indexing fixture basically found to be attached to this
machine have capacity to hold four components. The fixtures profile off-set to 90
angle to one another and the table is circular in shape.
Fig 3.4 Picking Operation
At the end of exact orientation process both the manipulators are actuated by
at same time, End effector II grasps the oriented housing and placed over the auto
indexing fixture. Mean time End effector I picks up the new component from the
conveyor and placed on the Auto-orientation fixture, further the process repeated
as cyclic manner.
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CHAPTER 4
OVERVIEW OF COMPONENTS
4.1 INTRODUCTION
The Block diagram shows the various components of the Automatic Horn
Housing conveying and positioning system.
Fig 4.1 Block Diagram of proposed system
PROGRAMMABLE
LOGIC
CONTROLLER
(PLC)
LDR (Light
Dependent
Resistor)
InductiveProximity
Sensor
Optical
proximity
sensor
Conveyor
Motor
Manipulator
Actuators
Orientation
fixture motor
Power source
Light
source
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The Project Automatic horn housing conveying and positioning system
consists of a mechanical chassis that consists of several Mechanical set ups and
Electrical components. The basic information of all these components and set ups
are mentioned in this chapter. Their images are also included along with their
definition. The workings of individual parts are also specified under the same list.
4.2 MECHANICAL ELEMENT
The mechanical element here is the conveyor that is set up in between the
two processing machines that produce Horn Housing.
4.2.1 CONVEYOR
A conveyor system is a common piece of mechanical handling equipment
that moves materials from one location to another. Conveyors here are especially
useful in involving the transportation of horn housing materials. Conveyor systems
allow quick and efficient transportation for a wide variety of materials which make
them very popular in Material handling. They move the products in a timely
fashion. A conveyor system that is designed properly will last a long time with
proper maintenance.
4.2.1.1 BELT TYPE CONVEYOR
Choosing the right conveyor type for the right system design is a major
factor in all aspects. In our project, the belt type conveyor is chosen. A beltconveyor consists of two or more pulleys, with a continuous loop of material - the
conveyor belt - that rotates about them. One or both of the pulleys are powered,
moving the belt and the material on the belt forward. The powered pulley is called
the drive pulley while the unpowered pulley is called the idler. The belt is made of
Rubber with a flat metal bed such that they can handle irregular bottom surfaces.
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They are of many layers to provide linear strength. The conveyor belt is motor
driven and is controlled by computer pulse signals.
Fig 4.2 Belt Conveyor
4.2.1.2 SPECIFICATIONS
The belt conveyors used for this system are subjected to following
specifications.
Belt width110 mm Belt Length / Power3.2/0.6 (m/kW) Belt Speed0.005 (m/s) Capacity2-3 (t/h) Angle of Conveyor Belt0degree
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4.3 ELECTRICAL COMPONENTS
The Electrical components are used to perform the control actions and alsoensure the proper functioning of all the mechanical elements of entire system.
4.3.1 LIGHT DEPENDANT RESISTOR
Fig 4.3 Light Dependant Resistor with Label
A Light Dependant Resistor or Photo Resistor is a resistor whose resistance
decreases with increase in light intensity. In other words, it exhibits Photo
Conductivity. A photo resistor is made of a high resistance semiconductor. If light
falling on the device is of high enough frequency, photons absorbed by the
semiconductor give bound electrons enough energy to jump into the conduction
band. The resulting free electron (and its holepartner) conduct electricity, thereby
lowering resistance. Photo resistors are basically photocells. Which is act as
feedback element as well as input signal of the PLC.
http://en.wikipedia.org/wiki/Semiconductorhttp://en.wikipedia.org/wiki/Frequencyhttp://en.wikipedia.org/wiki/Photonhttp://en.wikipedia.org/wiki/Electronhttp://en.wikipedia.org/wiki/Conduction_bandhttp://en.wikipedia.org/wiki/Conduction_bandhttp://en.wikipedia.org/wiki/Electron_holehttp://en.wikipedia.org/wiki/Electrical_resistancehttp://en.wikipedia.org/wiki/Electrical_resistancehttp://en.wikipedia.org/wiki/Electron_holehttp://en.wikipedia.org/wiki/Conduction_bandhttp://en.wikipedia.org/wiki/Conduction_bandhttp://en.wikipedia.org/wiki/Electronhttp://en.wikipedia.org/wiki/Photonhttp://en.wikipedia.org/wiki/Frequencyhttp://en.wikipedia.org/wiki/Semiconductor7/27/2019 Automatic horn housing conveying and positioning system
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4.3.2 MOTOR
The Automatic positioning system needs three motors to perform the
specified task.
They are as follows
Brushless DC Motor (Conveyor motor) High Torque DC Gear Motor (Auto orientation motor) DC Servo Motor (End effectors actuation motor)
A DC motor is a mechanically commutated electric motorpowered
from direct current (DC). The stator is stationary in space by definition and
therefore so is its current. The current in the rotor is switched by the commutatorto
also be stationary in space. This is how the relative angle between the stator and
rotor magnetic flux is maintained near 90 degrees, which generates the maximum
torque.
Fig 4.4 DC Motor
http://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Commutator_(electric)http://en.wikipedia.org/wiki/Commutator_(electric)http://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Electric_motor7/27/2019 Automatic horn housing conveying and positioning system
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The speed of a DC motor can be controlled by changing the voltage applied
to the armature or by changing the field current. The introduction of variable
resistance in the armature circuit or field circuit allowed speed control. Here, DC
motors are controlled by power electronics systems called DC drives. They drive
the Auto Orientation fixture until LDR responds to Light.
4.3.3 LIGHT SOURCE
In this project we are about to use Halogen Lamp as light source to operate
LDR. A halogen lamp, also known as a tungsten halogen lamp or quartz iodine
lamp, is an incandescent lamp that has a small amount of a halogen such
as iodine orbromine added. The combination of the halogen gas and
the tungsten filament produces a halogen cycle chemical reaction which re-
deposits evaporated tungsten back on the filament, increasing its life and
Fig 4.5 Halogen Lamp
http://en.wikipedia.org/wiki/Power_electronicshttp://en.wikipedia.org/wiki/Incandescent_light_bulbhttp://en.wikipedia.org/wiki/Halogenhttp://en.wikipedia.org/wiki/Iodinehttp://en.wikipedia.org/wiki/Brominehttp://en.wikipedia.org/wiki/Tungstenhttp://en.wikipedia.org/wiki/Tungstenhttp://en.wikipedia.org/wiki/Brominehttp://en.wikipedia.org/wiki/Iodinehttp://en.wikipedia.org/wiki/Halogenhttp://en.wikipedia.org/wiki/Incandescent_light_bulbhttp://en.wikipedia.org/wiki/Power_electronics7/27/2019 Automatic horn housing conveying and positioning system
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Maintaining the clarity of the envelope. Because of this, a halogen lamp can be
operated at a higher temperature than a standard gas-filled lamp of similar power
and operating life, producing light of a higherluminous efficacy and colour
temperature. The small size of halogen lamps permits their use in compact optical
systems for illumination. The light output is reported as proportional to . It
produces a continuous spectrum of light, from near ultraviolet to deep into the
infrared.
4.3.3.1 HANDLING PRECAUTIONS
Any surface contamination, notably the oil from human fingertips, can
damage the quartz envelope when it is heated. Contaminants will create a hot spot
on the bulb surface when the lamp is turned on. This extreme, localized heat causes
the quartz to change from its vitreous form into a weaker, crystalline form that
leaks gas. This weakening may also cause the bulb to form a bubble, weakening it
and leading to its explosion.
Consequently, manufacturers recommend that quartz lamps should be
handled without touching the clear quartz, either by using a clean paper towel or
carefully holding the porcelain base. If the quartz is contaminated in any way, it
must be thoroughly cleaned with alcohol and dried before use.
4.3.4 PNEUMATIC ACTUATORS
A pneumatic actuator converts energy (typically in the form ofcompressed
air) into mechanical motion. The motion here is semi rotary, for the type ofoperation. A Pneumatic actuator mainly consists of a piston, a cylinder, and valves
or ports. The piston is covered by a diaphragm, or seal, which keeps the air in the
upper portion of the cylinder, allowing air pressure to force the diaphragm
http://en.wikipedia.org/wiki/Luminous_efficacyhttp://en.wikipedia.org/wiki/Color_temperaturehttp://en.wikipedia.org/wiki/Color_temperaturehttp://en.wikipedia.org/wiki/Glasshttp://en.wikipedia.org/wiki/Crystallinehttp://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Diaphragm_(mechanical_device)http://en.wikipedia.org/wiki/Diaphragm_(mechanical_device)http://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Crystallinehttp://en.wikipedia.org/wiki/Glasshttp://en.wikipedia.org/wiki/Color_temperaturehttp://en.wikipedia.org/wiki/Color_temperaturehttp://en.wikipedia.org/wiki/Luminous_efficacy7/27/2019 Automatic horn housing conveying and positioning system
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downward, moving the piston underneath, which in turn moves the valve stem,
which is linked to the internal parts of the actuator.
The system consist of following components
Steel Guide ways (Confine the Straight motions) Pneumatic cylinders (Propel the manipulators) Vacuum operated End Effectors (Grasp the housings)
Fig 4.6 Pneumatic Actuator with Vacuum Gripper
Pneumatic actuators may only have one spot for a signal input, top or
bottom, depending on action required. Having a larger piston can also be good if
air supply is low, allowing the same forces with less input. Valves input pressure is
the "control signal." There are two grippers as one to pick and place the object
from Conveyor belt to Auto Orientation fixture respectively. Another gripper is
also interlinked with previous one to pick and place the object from Auto
Orientation to Auto Indexing fixture respectively.
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4.3.5 SENSORS
Fig 4.7 Proximity Sensor
A sensor is a device which receives and responds to a signal when touched.
A sensor (also called detector) is a converterthat measures a physical quantity and
converts it into a signal which can be read by an observer or by an electronic
instrument. Sensors are designed to have a small effect on what is measured.
http://en.wikipedia.org/wiki/Energy_conversionhttp://en.wikipedia.org/wiki/Physical_quantityhttp://en.wikipedia.org/wiki/Electronicshttp://en.wikipedia.org/wiki/Electronicshttp://en.wikipedia.org/wiki/Physical_quantityhttp://en.wikipedia.org/wiki/Energy_conversion7/27/2019 Automatic horn housing conveying and positioning system
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Fig 4.8 Sensor Interface in Auto Positioning system
In this project, the sensors are used in the belt conveyors for noticing the
arrival of components near the Auto Orientation fixture, which is a Inductiveproximity sensor. At the end of Vacuum gripper head, there is a optical proximity
sensor placed to pick up the component correctly. Thus, two kind of sensors are
used.
The sensors implemented in this project has following advantages:
Is sensitive to the measured property only Is insensitive to any other property likely to be encountered in its application Does not influence the measured property.
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CHAPTER 5
MOTORS AND ACTUATORS
5.1 INTRODUCTION
In this project, the conveyor pulley is driven by the Brushless DC motor.
Brushless DC electric motor (BLDC motors) also known as electronically
commutated motors (EC motors) are synchronous motors which are powered by a
DC electric source via an integrated inverter/switching power supply, which
produces an AC electric signal to drive the motor (AC with a caveat alternating
current often implies a sinusoidal waveform; a better term would be bi-directional
current with no restriction on waveform); additional sensors and electronics control
the inverter output amplitude and waveform (and therefore percent of DC bus
usage/efficiency) and frequency (i.e. rotor speed).
Fig 5.1 Brushless DC Motor
5.2 BRUSHLESS DC MOTOR
The motor part of a brushless motor is often a permanent magnet
synchronous motor, but can also be a switched reluctance motor, orinduction
motor. Brushless motors may be described as stepper motors; however, the
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term stepper motor tends to be used for motors that are designed specifically to be
operated in a mode where they are frequently stopped with the rotor in a defined
angular position. This page describes more general brushless motor principles,
though there is overlap.
Two key performance parameters of brushless DC motors are the Motor
constants Kv and Km (which are numerically equal in SI units). Here, Wye
configuration is designed because it gives high torque at low speed, but not as high
top speed as that of Delta configuration. The conveyor should be operated
depending on the time acquired by the pick and place to handle the component.
The receive signals from Inductive proximity sensor.
Fig 5.2 Torque-Speed characteristics
5.2.1 CONTROLLER IMPLEMENTATIONS
In our project, Brushless DC motor with the back EMF being sensed is used.
A typical controller contains 3 bi-directional outputs (i.e. frequency controlled
three phase output), which are controlled by a logic circuit. Simple controllers
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employ comparators to determine when the output phase should be advanced,
while more advanced controllers employ a microcontrollerto manage acceleration,
control speed and fine-tune efficiency.
Fig 5.3 Labelling of BLDC Motor
Controllers that sense rotor position based on back-EMF have extra
challenges in initiating motion because no back-EMF is produced when the rotor is
stationary. This is usually accomplished by beginning rotation from an arbitrary
phase, and then skipping to the correct phase if it is found to be wrong. This can
cause the motor to run briefly backwards, adding even more complexity to the
startup sequence.
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Fig 5.4 Sinusoidal Back EMF
5.2.2 MOTOR CONTROL POWER SUPPLIES
Fig 5.5 Wye Configuration
Typical brushless motors are permanent magnet synchronous AC motors,
combined with sensor electronics (detecting rotor position) and an AC signal
generator (Inverter) driven by a DC supply. Typical brushless inverters use a
switched power supply pulse width modulation to generate an AC drive signal.
Various terms are used to refer to the inverters/electronic control systems,
including "Vector Drives", and "VVVF drives" (variable voltage variable
frequency).
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Fig 5.6 Block diagram of BLDC Motor
5.2.3 FORMULA
Winding Power = Kt*Kt/R Kv = 1000 rpm / Vrms Kt = oz-in / Amp Kt = Kb * 1.35 Ke = Vrms / 1000 rpm Kb = V / 1000 rpm Back EMF = V/KRPM
5.3 DC GEAR MOTOR
The DC Gear motor, consisting of a DC electric motor and a gearbox, is at
the heart of several electrical and electronic applications. It is an extension of a DC
Motor. A geared DC Motor has a gear assembly attached to the motor. The speed
of motor is counted in terms of rotations of the shaft per minute and is termed as
RPM .The gear assembly helps in increasing the torque and reducing the speed.
Using the correct combination of gears in a gear motor, its speed can be reduced to
any desirable figure. This concept where gears reduce the speed of the vehicle but
increase its torque is known as gear reduction.
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Fig 5.7 DC Gear Motor
Here the High torque DC Gear Motor is used to drive the Auto Orientation
fixture. The drive is controlled by the signals received from the LDR. The LDRfunctioning is dependent on the light rays falling over those sensors from the
Halogen light source through the two reference holes.
Fig 5.8 Dimensions of DC Gear Motor
5.3.1 GEAR BLOCK
The RPM of the DC gear motor is 300 RPM. Thus enough torque that can be
obtained from it by which the complete setup can be moved. A set of planetary and
spur gears are used to get a gear ratio of 6:1. Therefore if the speed of the motor is
300 RPM then the output from the gear shaft is 50 RPM. This is a much more
manageable speed, and now the output torque has also been increased by
decreasing the speed.
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Power 3.6 W
Current 300 mA
Voltage 12v DC
Starting Current 300 mA
Torque 1.2Kgcm
Table 5.1 Rating of DC Motor
Fig 5.9 DC Gear Motor Characteristics
5.3.2 FEATURES
300RPM 12V DC motors with Metal Gearbox and Metal Gears 18000 RPM base motor 6mm Dia shaft with M3 thread hole Gearbox diameter 37 mm.
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Motor Diameter 28.5 mm Length 63 mm without shaft Shaft length 15mm 180gm weight 30kgcm torque No-load current = 800 mA, Load current = upto 7.5 A(Max) Recommended to be used with DC Motor Driver 20A orDual DC Motor
Driver 20A
Miniature gear motor work smoothly and efficiently, supporting theseelectrical and electronic applications.
DC geared motors reduce the complexity and cost of designing andconstructing for driving Auto Orientation fixture.
5.4 DC SERVO MOTOR
A servomotor is a rotary actuatorthat allows for precise control of angular
position. It consists of a motor coupled to a sensor for position feedback, through a
reduction gearbox. It also requires a relatively sophisticated controller, often a
dedicated module designed specifically for use with servomotors. In our project,
the DC servo motor actuates the Pick and Place that holds the vacuum gripper.
5.4.1 MECHANISM
As the name suggests, a servomotor is a servomechanism. More specifically,
it is a closed-loop servomechanism that uses position feedback to control its
motion and final position. The input to its control is a digital signal, representing
the position commanded for the output shaft.
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Fig 5.10 DC Servo Motor
The motor is paired with encoderto provide position and speed feedback.
The measured position of the output is compared to the command position, the
external input to the controller. If the output position differs from that required,
an error signal is generated which then causes the motor to rotate in either
direction, as needed to bring the output shaft to the appropriate position. As the
positions approach, the error signal reduces to zero and the motor stops.
The position-only sensing is done via a potentiometerand bang-bang
control of their motor; the motor always rotates at full speed (or is stopped). They
form the basis of the simple and cheap servos used forradio-controlled models. If
necessary both Speed and Position is sensed. Both of these enhancements, usually
in combination with a PID control algorithm, allow the servomotor to be brought
to its commanded position more quickly and more precisely, with
less overshooting.
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Fig 5.11 Characteristics of DC Servo Motor
5.4.2 ENCODERS
It would be possible to electrically differentiate their position signal to
obtain a speed signal, PID controllers that can make use of such a speed signal
generally warrant a more precise encoder.
The servomotors use optical encoders, eitherabsolute orincremental.
Absolute encoders can determine their position at power-on, but are more
complicated and expensive. Incremental encoders are simpler, cheaper and work at
faster speeds. Incremental systems, like stepper motors, often combine their
inherent ability to measure intervals of rotation with a simple zero-position sensor
to set their position at start-up.
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Fig 5.12 Dimensions of DC Servo Motor
The servomotors are rotary, but are used for ultimate control of a linear
motion. In some of these cases, a linear encoder is used. These servomotors avoid
inaccuracies in the drive train between the motor and linear carriage, but their
design is made more complicated as they are no longer a pre-packaged factory-
made system. They are designed with a controller module.
5.4.3 SPECIFICATIONS
Table 5.2 Rating of DC Servo Motor
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5.5 LIMIT SWITCH
A limit switch is a switch operated by the motion of a machine part or
presence of an object. They are used for control of a machine, as safety interlocks,
or to count objects passing a point
Fig 5.13 Limit Switch
Standardized limit switches for industrial control components with a roller
plunger operated. Limit switches may be directly mechanically operated by the
motion of the operating lever. Rarely, a final operating device will be directly
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controlled by the contacts of an industrial limit switch, but more typically the limit
switch will be wired through a control relay, a motorcontactorcontrol circuit, or as
an input to a programmable logic controller.
5.5.1 LIMIT SWITCH OPERATION
In most cases, a limit switch begins operating when a moving machine or a
moving component of a machine makes contact with an actuator or operating lever
that activates the switch. The limit switch then regulates the electrical circuit that
controls the machine and its moving parts. These switches can be used as pilot
devices for magnetic starter control circuits, allowing them to start, stop, slow
down, or accelerate the functions of an electric motor. Limit switches are installed
into machinery as control instruments for standard operations or as emergency
devices to prevent machinery malfunction. The switches are made as momentary
contact models.
5.6 SOLENOID VALVE
A solenoid valve is an electromechanically operated valve. The valve is
controlled by an electric current through the solenoid. In the two-port valve the
flow is switched on or off.
Fig 5.14 Solenoid Valve
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Multiple solenoid valves can be placed together on a manifold. Solenoid
valves are the most frequently used control elements in fluidics. Solenoids offer
fast and safe switching, high reliability, long service life, good medium
compatibility of the materials used, low control power and compact design.
5.6.1 OPERATION
A solenoid valve has two main parts: the solenoid and the valve. The
solenoid converts electrical energy into mechanical energy which, in turn, opens or
closes the valve mechanically. A direct acting valve has only a small flow circuit,
shown within section E of the diagram (this section is mentioned below as a pilot
valve). In this example, a diaphragm piloted valve multiplies this small pilot flow,
by using it to control the flow through a much larger orifice. Solenoid valves may
use metal seals or rubber seals, and may also have electrical interfaces to allow for
easy control. A spring may be used to hold the valve opened (normally open) or
closed (normally closed) while the valve is not activated.
Fig 5.15 Operation of Solenoid Valve
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A- Input side
B- Diaphragm
C- Pressure chamber
D- Pressure relief passage
E- Solenoid
F- Output side
The diagram to the right shows the design of a basic valve, controlling the
flow of air in this example. At the top figure is the valve in its closed state. The air
under pressure enters at A. B is an elastic diaphragm and above it is a weak spring
pushing it down. The function of this spring is irrelevant for now as the valve
would stay closed even without it. The diaphragm has a pinhole through its centre
which allows a very small amount of air to flow through it. This air fills the
cavity C on the other side of the diaphragm so that pressure is equal on both sides
of the diaphragm; however the compressed spring supplies a net downward force.
The spring is weak and is only able to close the inlet because air pressure is
equalized on both sides of the diaphragm.
In the previous configuration the small passage D was blocked by a pin
which is the armature of the solenoid E and which is pushed down by a spring. If
the solenoid is activated by drawing the pin upwards via magnetic force from the
solenoid current, the air in chamberC will flow through this passage D to the
output side of the valve. The pressure in chamberC will drop and the incoming
pressure will lift the diaphragm thus opening the main valve. Air now flows
directly from A to F.
When the solenoid is again deactivated and the passage D is closed again,
the spring needs very little force to push the diaphragm down again and the main
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valve closes. In practice there is often no separate spring, the elastomer diaphragm
is molded so that it functions as its own spring, preferring to be in the closed shape.
From this explanation it can be seen that this type of valve relies on a differential
of pressure between input and output as the pressure at the input must always be
greater than the pressure at the output for it to work. Should the pressure at the
output, for any reason, rise above that of the input then the valve would open
regardless of the state of the solenoid and pilot valve.
In some solenoid valves the solenoid acts directly on the main valve. Others use a
small, complete solenoid valve, known as a pilot, to actuate a larger valve. While
the second type is actually a solenoid valve combined with a pneumatically
actuated valve, they are sold and packaged as a single unit referred to as a solenoid
valve. Piloted valves require much less power to control, but they are noticeably
slower. Piloted solenoids usually need full power at all times to open and stay
open, where a direct acting solenoid may only need full power for a short period of
time to open it, and only low power to hold it.
5.7 SINGLE ACTING CYLINDER
A single-acting cylinder is a cylinderin which the working fluid acts on one
side of the piston only. A single-acting cylinder relies on the load, other cylinders,
or spring, to push the piston back in the other direction. Single-acting cylinders are
found in most kinds of reciprocating engine.
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Fig 5.16 Single CylinderActing
They are found to be the simple operated, cheapest and less fluid required
for operation. When the solenoid is operated and air pushes the cylinder forward, it
stays in that position until the air is inside it. When the air flow is stopped, the
cylinder retracts due to spring action.
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CHAPTER 6
SENSORS
6.1 INTRODUCTION
A sensor (also called detector) is a converterthat measures a physical
quantity and converts it into a signal which can be read by an observer or by an
(today mostly electronic) instrument. A sensor is a device which receives and
responds to a signal when touched. A sensor's sensitivity indicates how much the
sensor's output changes when the measured quantity changes. Sensors that measure
very small changes must have very high sensitivities. Sensors need to be designed
to have a small effect on what is measured; making the sensor smaller often
improves this and may introduce other advantages.
6.2 INDUCTIVE PROXIMITY SENSOR
An inductive sensor is an electronic proximity sensor, which detects metallic
objects without touching them.
Fig 6.1 Inductive Proximity Sensor
The sensorconsists of an induction loop. Electric current generates
a magnetic field, which collapses generating a current that falls asymptotically
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toward zero from its initial level when the input electricity ceases.
The inductance of the loop changes according to the material inside it and since
metals are much more effective inductors than other materials the presence of
metal increases the current flowing through the loop. This change can be detected
by sensing circuitry, which can signal to some other device whenever metal is
detected. Because the sensor does not require physical contact it is particularly
useful for applications where access presents challenges or where dirt is prevalent.
6.2.1 INDUCTION LOOP
An induction loop is an electromagnetic communication or detection system
which uses a moving magnet to induce an electrical current in a nearby wire.
Induction loops are used for transmission and reception of communication signals,
or for detection of metal objects in metal detectors or vehicle presence indicators.
Fig 6.2 Wiring Diagrams
6.2.2 INDUCTANCE
Inductance is the property of a conductor by which a change in current in the
conductor "induces" (creates) a voltage (electromotive force) in both the conductor
itself (self-inductance) and any nearby conductors (mutual inductance). This effect
derives from two fundamental observations of physics: First, that a steady current
creates a steady magnetic field (Oersted's law) and second, that a time-varying
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magnetic field induces a voltage in a nearby conductor (Faraday's law of
induction).
Fig 6.3 Dimensions of Inductive Proximity Sensor
From Lenz's law, in an electric circuit, a changing electric current through a
circuit that has inductance induces a proportional voltage which opposes the
change in current (self inductance). The varying field in this circuit may also
induce an e.m.f. in a neighbouring circuit (mutual inductance).
6.2.3 SPECIFICATIONS
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Table 6.1 Inductive Proximity Sensor Specifications
6.3 OPTICAL PROXIMITY SENSORS
Optical proximity sensors generally cost more than inductive proximity
sensors, and about the same as capacitive sensors. They are widely used in
automated systems because they have been available longer and because some can
fit into small locations. These sensors are more commonly known as light beam
sensors of the thru-beam type or of the retro reflective type. Both sensor types are
shown below.
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Fig 6.4 Optical Proximity Sensor
6.3.1 CONSTRUCTION AND WORKING
A complete optical proximity sensor includes a light source, and a sensor
that detects the light. The light source is supplied because it is usually critical that
the light be "tailored" for the light sensor system. The light source generates light
of a frequency that the light sensor is best able to detect, and that is not likely to be
generated by other nearby sources. Infra-red light is used in most optical sensors.
To make the light sensing system more foolproof, most optical proximity sensor
light sources pulse the infra-red light on and off at a fixed frequency. The light
sensor circuit is designed so that light that is not pulsing at this frequency is
rejected.
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Fig 6.5 Light Intensity detected as a function of (a) Orientation, (b) Distance
The light sensor in the optical proximity sensor is typically a semiconductor
device such as a photodiode, which generates a small current when light energy
strikes it, or more commonly a phototransistor or a photo-darlington that allows
current to flow if light strikes it. Early light sensors used photoconductive materials
that became better conductors, and thus allowed current to pass, when light energy
struck them. Sensor control circuitry is also required. The control circuitry may
have to match the pulsing frequency of the transmitter with the light sensor.
Control circuitry is also often used to switch the output circuit at a certain light
level. Light beam sensors that output voltage or current proportional to the
received light level are also available.
Through beam type sensors are usually used to signal the presence of
an object that blocks light. If they have adjustable switching levels, they can be
used, for example, to detect whether or not bottles are filled by the amount of light
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that passes through the bottle. Retroflective type light sensors have the transmitter
and receiver in the same package. They detect targets that reflect light back to the
sensor. Retroreflective sensors that are focused to recognize targets within only a
limited distance range are also available.
Fig 6.6 Working of Optical Proximity Sensor
6.3.2 SPECIFICATIONS
Model - FU-10
Detection typeDiffuse reflective Head shapeThreaded Head sizeM6 ViewEnd LensBuilt-in lens
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Smallest object detectable0.3 Detecting distance Mega10 to 30 mm Fine10 to 30 mm
Fibre type - Standard Fibre details2 m free out CommentBeam spot can be adjusted to target size. (Approx. 5g)
6.4 LIGHT DEPENDANT RESISTOR
A light dependent resistor (LDR) or a Photoresistor is a resistor in
which the resistance decreases with increasing incident light intensity; in other
words, it exhibits photoconductivity.
Fig 6.7 Light Dependant Resistor
A photoresistor is made of a high resistance semiconductor. If light falling
on the device is of high enough frequency, photons absorbed by the semiconductor
give bound electrons enough energy to jump into the conduction band. The
resulting free electron (and its holepartner) conduct electricity, thereby
lowering resistance. A photoelectric device can be either intrinsic or extrinsic.
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Fig 6.8 Symbol of LDR
An intrinsic semiconductor has its own charge carriers and is not an efficient
semiconductor, for example, silicon. In intrinsic devices the only available
electrons are in the valence band, and hence the photon must have enough energy
to excite the electron across the entire bandgap. Extrinsic devices have impurities,
also called dopants, added whose ground state energy is closer to the conduction
band; since the electrons do not have as far to jump, lower energy photons (that is,
longer wavelengths and lower frequencies) are sufficient to trigger the device.
Fig 6.9 Resistance as Function Illumination
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Fig 6.10 Spectral Response
If a sample of silicon has some of its atoms replaced by phosphorus atoms
(impurities), there will be extra electrons available for conduction. This is an
example of an extrinsic semiconductor. Photoresistors are basically photocells.
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Fig 6.11 Dimensions of LDR
6.4.1 ABSOLUTE MAXIMUM RATINGS
Voltage AC or DC Peak100V Current5mA Operating Dissipation at 25C 50mW* Operating Temperature Range - -25C + 75C*Derate Linearity from 50mW at 25C to 0W at 75C
6.4.2 ELECTRICAL CHARACTERISTICS
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LDRs or Light Dependent Resistors are very useful especially in light/dark
sensor circuits.
Table 6.2 Electrical Characteristics of LDR
Normally the resistance of an LDR is very high, sometimes as high as 1000
000 ohms, but when they are illuminated with light resistance drops dramatically.
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CHAPTER 7
PROGRAMABLE LOGIC CONTROLLER
7.1 INTRODUCTION
A Programmable Logic Controller, PLC or Programmable Controller is
a digital computerused forautomation ofelectromechanicalprocesses, such as
control of machinery on factory assembly lines, amusement rides, orlight fixtures.
The abbreviation "PLC" and the term "Programmable Logic Controller" are
registered trademarks of the Allen-Bradley Company (Rockwell Automation).
Fig 7.1 Programmable Logic Controller
PLCs are used in many industries and machines. Unlike general-purpose
computers, the PLC is designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to
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vibration and impact. Programs to control machine operation are typically stored in
battery-backed-up ornon-volatile memory.
Table 7.1 Functions of various terminals
A PLC is an example of a hard real time system since output results must be
produced in response to input conditions within a limited time, otherwise un
intended operation will result.
7.2 FUNCTIONALITY
The functionality of the PLC has evolved over the years to include
sequential relay control, motion control, process control, distributed control
systems and networking. The data handling, storage, processing power and
communication capabilities of some modern PLCs are approximately equivalent
to desktop computers.
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Fig 7.2 PLC Functions
PLC-like programming combined with remote I/O hardware, allow a
general-purpose desktop computer to overlap some PLCs in certain applications.
Regarding the practicality of these desktop computer based logic controllers, it is
important to note that they have not been generally accepted in heavy industry
because the desktop computers run on less stable operating systems than do PLCs,
and because the desktop computer hardware is typically not designed to the same
levels of tolerance to temperature, humidity, vibration, and longevity as the
processors used in PLCs. In addition to the hardware limitations of desktop based
logic, operating systems such as Windows do not lend themselves to deterministic
logic execution, with the result that the logic may not always respond to changes in
logic state or input status with the extreme consistency in timing as is expected
from PLCs. Still, such desktop logic applications find use in less critical situations,
such as laboratory automation and use in small facilities where the application is
less demanding and critical, because they are generally much less expensive than
PLCs.
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7.3 FEATURES OF PLC
The control actions of the entire system are done by KEYENCE - KV Series
PLC.
The salient features of Preferred PLC as follows
Ultra smaller in size High speed scan time Built - in access window Installation flexibility with expansion units User friendly Operator interface panel AC power built-in type Program write in RUN mode Improved debug environment
7.3.1 COMMON I/O SPECIFICATIONS
INPUT SPECIFICATION
Table 7.2 Input specification of PLC
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Fig 7.3 Frequency response chart
OUTPUT SPECIFICATION
Table 7.3 Output specification of PLC
7.3.2 SCAN TIME
A PLC program is generally executed repeatedly as long as the controlled
system is running. The status of physical input points is copied to an area of
memory accessible to the processor, sometimes called the "I/O Image Table".
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The minimum scan time is 140 s and minimum instruction execution time
is 0.7s, which is the fastest control than other PLCs. The program is then run
from its first instruction rung down to the last rung
It takes some time for the processor of the PLC to evaluate all the rungs and
update the I/O image table with the status of outputs. This scan time may be a few
milliseconds for a small program or on a fast processor, but older PLCs running
very large programs could take much longer (say, up to 100 ms) to execute the
program. If the scan time was too long, the response of the PLC to process
conditions would be too slow to be useful.
Fig 7.4 Scan time of PLC
As PLCs became more advanced, methods were developed to change the
sequence of ladder execution, and subroutines were implemented. This simplified
programming could be used to save scan time for high-speed processes; forexample, parts of the program used only for setting up the machine could be
segregated from those parts required to operate at higher speed.
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7.3.3 SYSTEM SCALE
A small PLC will have a fixed number of connections built in for inputs and
outputs. Typically, expansions are available if the base model has insufficient I/O.
KV series PLCs have a chassis (also called a rack) into which are placed modules
with different functions. The processor and selection of I/O modules are
customized for the particular application.
7.3.4 PERFORMANCE SPECIFICATION
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Table 7.4 Performance specification
Several racks can be administered by a single processor, and may have
thousands of inputs and outputs. A special high speed serial I/O link is used so that
racks can be distributed away from the processor, reducing the wiring costs for
large plants.
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7.3.5 USER INTERFACE
PLCs may need to interact with people for the purpose of configuration,
alarm reporting or everyday control. A human-machine interface (HMI) is
employed for this purpose. HMIs are also referred to as man-machine interfaces
(MMIs) and graphical user interface (GUIs). A simple system may use buttons and
lights to interact with the user. Text displays are available as well as graphical
touch screens. More complex systems use programming and monitoring software
installed on a computer, with the PLC connected via a communication interface.
Fig 7.5 PLC User Interface
7.3.6 COMMUNICATIONS
PLCs have built in communications ports, usually 9-pin RS-232, but
optionally EIA-485 orEthernet. Modbus, BACnet orDF1 is usually included as
one of the communications protocols. Other options include
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various fieldbuses such as DeviceNet orProfibus. Other communications protocols
that may be used are listed in the List of automation protocols.
Most modern PLCs can communicate over a network to some other system,
such as a computer running a SCADA (Supervisory Control and Data Acquisition)
system or web browser.
PLCs used in larger I/O systems may have peer-to-peer(P2P)
communication between processors. This allows separate parts of a complex
process to have individual control while allowing the subsystems to co-ordinate
over the communication link. These communication links are also often used
forHMI devices such as keypads orPC-type workstations.
7.3.7 PROGRAMMING
PLC programs are typically written in a special application on a personal
computer, and then downloaded by a direct-connection cable or over a network to
the PLC. The program is stored in the PLC either in battery-backed-up RAM or
some other non-volatile flash memory. Often, a single PLC can be programmed to
replace thousands ofrelays.
Under the IEC 61131-3 standard, PLCs can be programmed using standards-
based programming languages. A graphical programming notation
called Sequential Function Charts is available on certain programmable controllers.
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Fig 7.6 AND, OR, NOT in PLC Programming
Initially most PLCs utilized Ladder Logic Diagram Programming, a modelwhich emulated electromechanical control panel devices (such as the contact and
coils of relays) which PLCs replaced. This model remains common today.
IEC 61131-3 currently defines five programming languages for
programmable control systems: function block diagram (FBD), ladder
diagram (LD), structured text (ST; similar to the Pascal programming
language), instruction list (IL; similar to assembly language) and sequentialfunction chart (SFC). These techniques emphasize logical organization of
operations.
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Fig 7.7 Ladder Logic Programming in PLC
While the fundamental concepts of PLC programming are common to all
manufacturers, differences in I/O addressing, memory organization and instruction
sets mean that PLC programs are never perfectly interchangeable between differentmakers. Even within the same product line of a single manufacturer, different
models may not be directly compatible.
7.3.8 DISCRETE AND ANALOGUE SIGNALS
Discrete signals behave as binary switches, yielding simply an ON or OFF
signal (1 or 0, True or False, respectively). Push buttons, Limit switches,
and photoelectric sensors are examples of devices providing a discrete signal.
Discrete signals are sent using either voltage orcurrent, where a specific range is
designated as ON and another as OFF. For example, a PLC might use 24 V DC
I/O, with values above 22 V DC representing ON, values below 2VDC
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representing OFF, and intermediate values undefined. Initially, PLCs had only
discrete I/O.
Fig 7.8 Discrete and Analogue Signal
Analogue signals are like volume controls, with a range of values between
zero and full-scale. These are typically interpreted as integer values (counts) by the
PLC, with various ranges of accuracy depending on the device and the number of
bits available to store the data. As PLCs typically use 16-bit signed binary
processors, the integer values are limited between -32,768 and +32,767. Pressure,
temperature, flow, and weight are often represented by analogue signals. Analogue
signals can use voltage orcurrent with a magnitude proportional to the value of the
process signal. For example, an analogue 0 - 10 V input or4-20 mA would
be converted into an integer value of 0 - 32767. Current inputs are less sensitive to
electrical noise (i.e. from welders or electric motor starts) than voltage inputs.
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CHAPTER VIII
SOFTWARE
8.1 INTRODUCTION
The Ladder Builder is software which allows creating sequence of programs.
It offers excellent functionality and advanced programming processing ability. The
Ladder logic is widely used to program PLCs, where sequential control of a
process or manufacturing operation is required.Ladder logic can be thought of as arule-based language rather than a procedural language. A "rung" in the ladder
represents a rule. When implemented with relays and other electromechanical
devices, the various rules "execute" simultaneously and immediately. When
implemented in a programmable logic controller, the rules are typically executed
sequentially by software, in a continuous loop (scan).
In this project KV Ladder builder is the software used to implement the
process control logics in PLC.
8.2 OVERVIEW OF SOFTWARE
The KV Builder can simulate program execution even without a PLC
connected. Providing a single step execution (forward and reverse) in addition to a
regular scan execution function increases debugging efficiency.
The following functions are provided in the Ladder Builder
Editor function Simulator function Monitor function
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8.2.1 EDITOR FUNCTION
The function which creates the ladder diagram using diversified instruction
words of the ladder language, Registers comments to contacts. Comments can be
transferred to PLC. Which Converts the ladder diagram into machine code and
displays the ladder diagram, mnemonic list, label comment and device use status
list, etc., on the screen
Fig 8.1 Editor Window
8.2.2 SIMULATOR FUNCTION
It simulates the operation of the ladder diagram even if the PLC is not
connected, and allows debugging of the program.
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Fig 8.2 Simulator Window
Which provides a continuous scan execution mode, one scan execution mode, one
step execution mode, etc. so that errors be confidently located and also enables
execution of a step in the reverse direction once or continuously.
8.2.3 MONITOR FUNCTION
This window monitors the contact ON/OFF status on a real-time, on-line
basis using the ladder diagram created.
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Fig 8.3 Monitor Window
Simultaneously displays the timing chart, and transfers programs to PLC.
8.3 LADDER DIAGRAM
Ladder logic has contacts that make or break circuits to control coils each
coil or contact corresponds to the status of a single bit in the programmable
controller's memory. The coil (output of a rung) may represent a physical output
which operates some device connected to the programmable controller, or may
represent an internal storage bit for use elsewhere in the program.
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Fig 8.4 Relay ladder logicAuto operation
Fig 8.5 Relay ladder logicManual operation
Fig 8.6 Relay ladder logicEmergency Stop
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8.3.1 I/O DESCRIPTIONS
S. No Address Description
1 0000 Main power ON/OFF
2 0001 INDUCTIVE PROXIMITY SENSOR-1
3 0002 SERVO MOTOR ON
4 0003 OPTICAL PROXIMITY SENSOR
5 0004 LIMIT SWITCH
6 0005 REED SWITCH
7 0006 INDUCTIVE PROXIMITY SENSOR-2
8 0007 LIGHT DEPENDANT RESISTOR
9 0008 EMERGENCY STOP
Table 8.1 Input Descriptions
S. No Address Description
1 0500 CONVEYOR MOTOR ON/OFF
2 0501 SENSOR SIGNAL SET COIL
3 0502 SOLENOID VALVE EXCITATION
4 0503 VACUUM SOURCE ON/OFF
5 0504 SERVO MOTOR FORWARD/REVERSE
6 0505 DC MOTOR