Inspection Conveyor for Sidharth

8/2/2019 Inspection Conveyor for Sidharth

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INSPECTION CONVEYOR

SYNOPSIS

In our project INSPECTION CONVEYOR beings with an introduction to

material Inspection, its various applications. The sensors are used to measure the material

dimensions and this signal is given to control Unit.

The control unit gives the appropriate signal to the pneumatic cylinder. The

pneumatic cylinder is used to collecting mechanism of the improper dimension materials.

The inspection conveyor is very useful for material handling in modern engineering

industries. The motor is used to drive the conveyor. The materials are transferred from one

place to another place by using conveyor. In this top of the conveyor, sensors are used to

measure the dimension. This system gives smooth operation and smooth movement of the

belts to the jobs at required time.

This is a very efficient instrument for checking the dimensions like length, breadth,

height etc., to be used in modern engineering industries. The manual efforts can be

completely avoided by using this modern equipment. It also reduces the inspection time

and manual inspection errors. If the work piece is defective, the pneumatic cylinder placed

next to the sensor will be actuated to remove the defective work piece.

INTRODUCTION


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This is an era of automation where it is broadly defined as replacement of manual

effort by mechanical power in all degrees of automation. The operation remains an

essential part of the system although with changing demands on physical input as the

degree of mechanization is increased.

Degrees of automation are of two types, viz.

Full automation.

Semi automation.

In semi automation a combination of manual effort and mechanical power is required

whereas in full automation human participation is very negligible.

Need For Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc., of these sources, pneumatics form an attractive medium for low cost automation. The

main advantages of all pneumatic systems are economy and simplicity. Automation plays

an important role in mass production.


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For mass production of the product, the machining operations decide the sequence of

machining. The machines designed for producing a particular product are called transfer

machines. The components must be moved automatically from the bins to various

machines sequentially and the final component can be placed separately for packaging.

Materials can also be repeatedly transferred from the moving conveyors to the work place

and vice versa.

Quality Control and Inspection are the most important things in factory design.

Automation plays a vital role in mass production of a product, the machining operations

decides the sequence of machining. The machines designed for producing a particular

product are called transfer machines. Conveyor Automation is a specialized activity for a

modern manufacturing concern. It has been estimated that about 60-70% of the cost

production is spent in material transferring activities.

Need for Conveyor Automation:

Reduction of lab our and material cost

Reduction of overall cost

Increased production

Increased storage capacity

Increased safety


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To reduce the inspection time

Reduction in fatigue

Improved personnel comfort

ADVANTAGES

The Automatic control of products using sensor is more efficient in the

technical field

Quick response is achieved

Simple in construction

Easy to maintain and repair

Cost of the unit is less when compared to other

No fire hazard problem due to over loading

Comparatively the operation cost is less

Continuous operation is possible without stopping

LIMITATIONS

While working, the compressed air (For Punching Operation) produces noise therefore

a silencer may be used.


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APPLICATIONS

Discharge of work piece:-

The Conveyor Feed has a wide application in low cost automation industries. It can

be used in automated assembly lines to carry up the finished product from

workstation and place them in bins. It can also be used to pick raw material

and place them on the conveyor belts.

Improper Material Removing operation:-

This unit can also be used in improper material collected in a collecting box.

The solenoid operated pneumatic cylinder is used for this mechanism.


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INSPECTION CONVEYOR:-


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TYPES OF SENSOR

The sensors are sub divided in to three types. We will see about it one by one.

1. Proximity sensors.

2. Touch sensors.

3. Force and torque sensors.

1. Proximity sensors:

Proximity sensors generally have a binary output, which indicates the presence of

an object within a specified distance interval. The proximity sensors are divided into five

types.

1. Inductive sensor.

2. Hall-effect sensor.

3. Capacitate sensor.

4. Ultrasonic sensor.

5. Optical proximity sensor.


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1. Inductive sensor:

Inductive sensors are based on a change of inductance due to the presence if a

metallic object is among the most widely used industrial proximity sensors. The principle

of operation of these sensors can be explains as a inductive sensor which basically consist

of a wound coil located next to a permanent magnet packaged in a simple, rugged housing.

2. Hall-effect sensor:

The Hall Effect related the voltage between two points in a conducting or semi

conducting material to a magnetic field across the material. The all-effect sensors can only

detect magnetized objects.

The Hall-effect sensors are based on the principle of Lorenz force which acts on a

changed partial traveling through a magnetic field. This force acts on the axis

perpendicular to the plane established by the direction of motion of the charged particle and

the direction of the field.

3. CAPACTIVE SENSOR:


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Unlike inductive and Hall-effect sensors which detect only Ferromagnetic materials,

capacitive sensors are potentially capable (with various degrees of sensitivity) of detecting

all solid and liquid materials. As this name implies, these sensors are based on detecting a

change in capacitance induced by a surface that is brought near the sensing elements.

4. ULTRASONIC SENSORS:

In our project we are using ULTRASONIC SENSOR. Now, we will see about

it in detail. The response of all the proximity sensors discussed thus far depends strangely

on the material being sensed. This dependence can be reduced considerably by using

ultrasonic sensors. The following figure shows the structure of a typical ultrasonic

transducer used for proximity sensing.

The basic element is an Electro-acoustic transducer, often of the piezoelectric

ceramic type. The resin layer protects the transducer against humidity, dust, and other

environmental factors; it also acts as an acoustical impedance receiving, fast damping of

the acoustic energy is necessary to detect objects at close range.


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This is accomplished by providing acoustic absorbers, and by de coupling the

transducer from its housing. The housing is designed so that it produces a narrow acoustic

beam for efficient energy transfer and signal directionality.

The operation of an ultrasonic proximity sensor is best understood by analyzing the

waveforms used for both transmission and detection of the acoustic energy signals.

5. OPTICAL PROXIMITY SENSORS:

These are similar to ultrasonic sensor in the sense that they detect proximity of an

object by its influence on a propagating wave as it travels from a transmitter to a receiver.

This sensor consist of a solid state light emitting diode (LED), which acts as a transmitter

of infrared light, and a solid state photo diode which acts as a receiver.

The cones of light formed by focusing the source and detector on the same plane

intersect in a long, pencil-like volume. This volume defines field of operation of the sensor

since a reflective surface. Which intersects the volume is illuminated by the source and

simultaneously seen by the receiver.


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2. TOUCH SENSOR:

Touch sensor are used in robotics to obtain information associated with the contact

between a manipulator hand and objects location in the workspace. The touch sensors are

divided in to two types.

1. Binary sensors.

2. Analog sensors.

3. FORCE AND TORQUE SENSOR:

Force and torque sensors are used primarily for measuring the reaction forces

developed at the interface between mechanical assemblies. The principal developed for

doing this are joint and wrist sensing.

PNEUMATICS COMPONENTS AND CONTROL VALVES

SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by mechanical

power. Pneumatics is an attractive medium for low cost mechanization particularly for

sequential or repetitive operations. Many factories and plants already have a compressed

air system, which is capable of providing both the power or energy requirements and the

control system (although equally pneumatic control systems may be economic and can be

advantageously applied to other forms of power).


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The main advantages of an all-pneumatic system are usually economy and simplicity,

the latter reducing maintenance to a low level. It can also have out standing advantages in

terms of safety.

PNEUMATIC COMPONENTS AND ITS DESCRIPTION:

The pneumatic bearing press consists of the following components to fulfill the

requirements of complete operation of the machine.

Pneumatic cylinder

Solenoid valve

Flow control value

Connectors and

Hoses

1. CYLINDER:

The cylinder is a double acting cylinder one, which means that the air pressure

operates alternatively (forward and backward). The air from the compressor is passed

through the regulator which controls the pressure to required amount by adjusting its knob.

A pressure gauge is attached to the regulator for showing the line pressure.


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Then the compressed air is passed through the directional control valve for

supplying the air alternatively to either sides of the cylinder. Two hoses take the output of

the directional control valve and they are attached to two ends of the cylinder by means of

connectors. One of the outputs from the directional control valve is taken to the flow

control valve from taken to the cylinder.

Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of compressed

air i.e. pneumatic power is converted in to mechanical output power, by reducing the

pressure of the air to that of the atmosphere.

It consist a cylinder of highly polished inner of mirror finish. A plunger slides

inside the cylinder. The plunger is connected to the tool slide. The plunger is provided

with seals to prevent leakage. When highly compressed air is passed into the cylinder, it

expands and work is done this is used for sharing the metal.

Double acting cylinder:

A double acting cylinder is employed in control systems with the full pneumatic

cushioning and it is essential when the cylinder itself is required to retard heavy messes.

This can only be done at the end positions of the piston stock.


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In all intermediate position a separate externally mounted cushioning derive most be

provided with the damping feature. The normal escape of air is out off by a cushioning

piston before the end of the stock is required. As a result the sit in the cushioning chamber

is again compressed since it cannot escape but slowly according to the setting made on

reverses. The air freely enters the cylinder and the piston stokes in the other direction at full

force and velocity.

2. SOLINOID CONTROL VALVE:

The solenoid valve is responsible for reciprocating motion of the Ram. It is

electrically powered. The trip dogs actuate the solenoid valve.

Technical Data:

Size :

Pressure : 0 to 10 kg / cm2

Media : Air

Working of Solenoid Valve:


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The Solenoid control valve is used to control the flow direction is called cut off

valve or solenoid valve. This solenoid cut off valve is controlled by the electronic control

unit.

In our project 3/2 Single acting solenoid valve is used. This solenoid valve is used

to push the dimensionless materials into the collecting tray which is placed bellow the

conveyor.


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3. FLOW CONTROL VALVE:

(a) Technical Data:

Size :

Pressure : 0 to 10 kg / cm2

Media : Air

(b) Purpose:

This valve is used to speed up the piston movement and also it acts as an one way

restriction valve which means that the air can pass through only one way and it cant return

back.

By using this valve the time consumption is reduced because of the faster

movement of the piston.

4. CONNECTIORS:

In our pneumatic system there are two types of connectors used; one is the hose

connector and the other is the reducer. Hose connectors normally comprise an adapter


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(connector) hose nipple and cap nut. These types of connectors are made up of brass or

Alluminium or hardened steel.

Reducers are used to provide inter connection between two pipes or hoses of

different sizes. They may be fitted straight, tee, V or other configurations. These

reducers are made up of gunmetal or other materials like hardened steel etc.

PERMANENT MAGNET D.C. MOTOR

The D.C motor is used to control the direction of hot air flow. In our project the hot

air is distributed in all direction with the same rate by using D.C motor tilting mechanism.

PRINCIPLE OF OPERATION:

The basic principle of motor action lies in a simple sketch. The working principle

tells that, when a current carrying conductor is placed in a magnetic field, a force is

produced to move the conductor away from the magnetic field.


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Movement of

Conductor

Magnetic flux current carrying

Conductor

The force given by the equation,

F = B I L Newtons

Where,

B = Flux density in WB/sq.m

I = Current through the conductor

L = Length of the conductor

Let us consider a single turn coil. The coil side A will be forced to move

downward, where as the coil side B will be forced to move upward. Due to this

movement now the coil is made to rotate. Since the coil is arranged into rotate. Since the

coil is arranged in the armature when it rotates in emf is induced in the coil and that emf

which is induced in the coil is in opposite to supply emf. Therefore we can call the emf

N S


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induced as back emf (B-emf). Hence when motor runs normally the supply emf (V) is

equal to B-emf.

Therefore V = Vb + Va (or) V = Vb + Ia Ra (Since V= IR)

Multiplying both sides by Ia,

Therefore Via = Vb Ia + (Ia x Ia) Ra

Where Via is the electrical equivalent of the mechanical power developed in the

motor and (Ia x Ia) Ra is armature drop.

This process that motor converts electrical energy mechanical energy where (Ia x Ia)

Ra is the copper loss which is to be neglected. The conductor carrying current to North and

South poles is being removed. In the above stated two conditions there is no movement of

the conductors. Whenever a current carrying conductor is placed in a magnetic field. The

field due to the current in the conductor but opposes the main field below the conductor. As

a result the flux density below the conductor. It is found that a force acts on the conductor

to push the conductor downwards.

If the current in the conductor is reversed, the strengthening of the flux lines occurs

below the conductor, and the conductor will be pushed upwards. As stated above the coil

side A will be forced to move downwards, where as the coil side B will be forced to move

upwards. The forces acting on the coil sides A and B will be the same coil magnitudes, but

their directions will be opposite to one another.


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In DC machines coils are wound on the armature core, which is supported by the

bearings, enhances rotation of the armature. The commutator periodically reverses the

direction of current flow through the armature. Thus the armature rotates continuously.

An electric motor is all about magnets and magnetism: a motor uses magnets to

create motion. If you have ever played with magnets you know about the fundamental law

of all magnets: Opposites attract and likes repel.

So if you have 2 bar magnets with their ends marked north and south, then the North

end of one magnet will attract the South end of the other. On the other hand, the North end


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of one magnet will repel the North end of the other (and similarly south will repel south).

Inside an electric motor these attracting and repelling forces create rotational motion. In the

diagram above and below you can see two magnets in the motor, the armature (or rotor) is

an electromagnet, while the field magnet is a permanent magnet (the field magnet could be

an electromagnet as well, but in most small motors it is not to save power).

WORKING OPERATION

The 12 volt power supply is used to drive the permanent magnet D.C motor. The

two conveyor roller is fixed to the two ends of the frame stand with the help of end bearing

(6202) with bearing cap. The conveyor roller shaft is coupled to the D.C. permanent

magnet motor with the help of spur gear mechanism. This total arrangement is used to

transfer the material from one place to another place with the help of conveyor.

The limit sensor switch is vertically fixed on the limit sensor frame stand by means

of rack and pinion arrangement. This sensor is used to measuring the abnormal height

variation of the material. The rack and pinion is used to adjust the limit switch up and down

motion. This arrangement is used to set the height of the material.

The IR transmitter and IR receiver circuit is used to sense the minute height

variation of the material. It is fixed to the frame stand with a suitable arrangement. This


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1 8

2 7

IC 555

3 6

4 5

mechanism is also adjustable with the help of bolt and nut. The pneumatic cylinder is fixed

to the frame stand by right angles to the limit sensor frame stand. This cylinder

arrangement is used to remove the dimensionless material from the conveyor. The

pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve and

control unit.

IR TRANSMITTER CIRCUIT:

+Vcc

R4 (47) T1 (BD140) 150K

3 1

2

C3 (100/25V) R1

R2 (47) 1.5K

R5 4.7

L1 IR LED C2 C1

0.01pF 0.1pF


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IR RECEIVER CIRCUIT:

1K

12V

RELAYR12 (680) R1 (4.7K)

RL1 L1 (IR SENSOR)

D2 R10 C3 (100) C2 (100) L2 (IR SENSOR)

L3 (LED) 1N4007 4.7K R3 R2

R7 (100K) 4.7K 4.7K

D1 (1N 4007) T3 C4 (0.1pF) C1 (0.01 pF)

T5 (BC547B) R9 (4.7K) R8 BC 557

T4 (BC 547B) T2 (BC549C) R13

120 C8 (47 pF) 120

R5

T1 (BC 549C)

R11 C7

22F (50V) R6

22K 2.2K C5 (0.1pF)


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AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC

timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor T1,

T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF

condition. At that time relay is OFF, so that the solenoid valve is in OFF condition.

AT OBNORMAL CONDITION:

At abnormal dimension conditions the IR transmitter and IR receiver, the resistance

across the Transmitter and receiver is high due to the non-conductivity of the IR waves. So

the output of transistor T5 goes from OFF condition to ON stage. The relay is ON to the

3/2 solenoid valve, so that the air from the compressor is goes to the pneumatic cylinder.

The dimensionless material is pushed to the collecting tray by the pneumatic cylinder.

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Inspection Conveyor for Sidharth