Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC

GRD Journals- Global Research and Development Journal for Engineering | Volume 3 | Issue 5 | April 2018 ISSN: 2455-5703

Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC Mrs. K. Uma Maheswari Assistant Professor Department of Electrical and Electronics Engineering V. S. B Engineering College S. Malathi BE Student Department of Electrical and Electronics Engineering V. S. B Engineering College

M. Taruni BE Student Department of Electrical and Electronics Engineering V. S. B Engineering College

R. Yuvapriya BE Student Department of Electrical and Electronics Engineering V. S. B Engineering College

M. Chaarumathi BE Student Department of Electrical and Electronics Engineering V. S. B Engineering College

Abstract Nowadays Automation plays a vital role in industrial applications. This proposal deals with PLCs (Programmable Logic Controller) for automation in material handling. This system is mainly used for storing and retrieving the unprocessed materials in a manufacturing unit. We use proximity sensors to detect the nearby objects. The main objective of this paper is to built an automation system coordinated by using PLC integration.

Keywords- Proximity Sensor–Programmable Logic Controller –Conveyor

I. INTRODUCTION A Programmable Logic Controller, is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. It is a solid state device that uses soft wired logic contained in the controller’s memory to duplicate the functions of relays and hard wired solid state control devices. In operation, the memory unit sequentially scans inputs (Sensors, limit switches, push buttons, photo cells) in cyclic fashion to determine which output (contacts, motor starters, pilot lights, converters) should be turned on or off.

It uses a programmable memory to store instructions and execute specific functions that include ON/OFF control, timing, counting, sequencing, arithmetic and data handling.

II. IMPORTANCE OF AUTOMATION Automation plays a very important role in our generation. It has brought a drastic changes in home applications and industries.

One of its applications in the industry is automated storage and retrieval system (ASRS). ASRS is an integrated engineering system that requires the knowledge of electrical, electronics, mechanical and computer engineering in its design. The storage retrieval equipment consists of special mechanism responsible for transferring the products input/output to a point in the shelves, a system for recording and arranging the products, a system for reading and executing an order, a system for locating and retrieving the products through an advanced technology.

III. EXISTING SYSTEM In dynamic industrial location the collection of unprocessed materials or composed products is done by automated guided vehicles, which has an important role in the movement of these competitive conditions. The control and speed of production and storage retrieval systems is done by means of human operated forklifts and hence the stock data management are more difficult. The sensing capacity of the system is very poor. The existing method is unable to find the present materials in the storage area. The storing and delivery time of the system is very low and some errors are created by human work.

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

IV. DRAWBACKS OF EXISTING SYSTEM The various drawbacks of existing system used for controlling the loads are, – Production is less, – Time consumption is more, – Accuracy and detection is less, – Human error, – Possibility for the occurrence of damages in the material, – Storage and retrieval is difficult.

V. PROPOSED SYSTEM The above flaws can be overcome by using PLC. This system uses Induction motor, Proximity sensors, Stack crane to pick the material and place it in the required position. The materials that are stored can be easily retrieved by using Tri axis stack crane which is controlled by PLC. The stack crane can move in X, Y and Z axis to store and retrieve the material in the particular location.

This system completely eliminates manual work and reduces the errors. The damage of the materials is completely reduced because of automation. The performance of ASRS is coordinated with the help of PLC. Ladder logic program for programmable logic controller were used for the control of storage and retrieval system. The storage system has thousands of locations so that the material can be handled easily during the time of large production. WPL SOFT2.41 is the software used for simulation.

VI. ADVANTAGES – –

Efficiency is high.

Palletizing is done automatically.

VII.

BLOCK DIAGRAM

Fig. 1: Block Diagram

VIII. COMPONENTS USED Conveyors—Proximity sensors—Shrink wrapping machine—Hydraulic pusher—Pallet—Stack crane.

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

IX. CONVEYORS

Fig. 2: Roller Conveyor

Here the roller conveyors are used. A shaft runs along the conveyor which is driven by an electric motor that is controlled by an PLC. The rotating of the rollers pushes the product along the conveyor.

A. Specification – Conveyor movement speed: 0.22 m/s.i.e.15 mpm. – Photo cells for bundle detecting

X. INDUCTIVE PROXIMITY SENSOR

Fig. 3: Inductive Sensor

Elements of a simple inductive sensor.

1) Field sensor 2) Oscillator 3) Demodulator 4) Flip-flop 5) Output An inductive sensor is an electronic proximity sensor, which detects metallic objects without touching them. The sensor consists of an induction loop. Electric current generates a magnetic field, which collapses generating a current that falls asymptotically 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.

XI. SHRINK WRAPPING MACHINE Shrink wrap, also shrink film, is a material made up of polymer plastic film. When heat is applied, it shrinks tightly over whatever it is covering. Heat can be applied with a hand held heat gun (electric or gas) or the product and film can pass through a heat tunnel on a conveyor.

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

Fig. 4: Shrink Wrapping Machine

XII.

HYDRAULIC PUSHER

Hydraulic pushers (also called linear hydraulic motors) are mechanical actuators that are used to give a linear force through a linear stroke. Hydraulic pushers are able to give pushing and pulling forces of millions of metric tons with only a simple hydraulic system. Very simple hydraulic cylinders are used in presses; here, the cylinder consists of a volume in a piece of iron with a plunger pushed in it and sealed with a cover. By pumping hydraulic fluid in the volume, the plunger is pushed out with a force of pressure.

The pushing or pulling force of a hydraulic cylinder is as follows: F = Ab * pb - Ah * ph F = Pushing Force in N Ab = (Ď€/4) * (Bottom-diameter) ^2 [in m2] Ah = (Ď€/4) * ((Bottom-diameter) ^2-(Piston-rod-diameter) ^2)) [in m2] pb = pressure at bottom side in [N/m2] ph = pressure at cylinder head side in [N/m2]

XIII. STACK CRANE It is used to store and retrieve the materials from the location to the desire point. It is a Tri functional axis that moves in X, Y and Z axis to move the material from the input conveyor to the desired location. The stack crane controller is connected to several sensors, limit switches to get physical inputs. Once when the user enters the rack number for storing or retrieving the material, stack cane controller places the fork in the required position to store or retrieve the material. The position of the fork at center is also detected by the limit switch. These switches are controlled by using PLC.

Fig. 5: Stack Crane

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

XIV. WORKING The basic block diagram for ASRS is shown above. This system consists of conveyors, proximity sensors, shrink wrapping machine and stack crane which are all controlled by PLC. Initially reams are loaded in the conveyor. A bundle of 500 sheets are called as ream. The bundle of paper which is called as reams are the output of the shrink wrapping machine that are collected by the extended conveyor. Prescribed load withstanding limit of ream is approximately 60-70 kg. When the START is ON the ream which is from the shrink wrapping Machine moved to the extended conveyor. The reams moved are sensed by using proximity sensors. This sensor sends the signal to the hydraulic pusher which pushes ream to the perpendicular conveyor. These reams are loaded in the pallet and is lifted by the stack crane controller. The pallet loaded in the stack crane moves in tri functional axis to the storage location. If the storage area is completely full, it indicates an alarm and the reams are moved to the manual storage. The above process is handled by the use of PLC (Programmable Logic Controller).

XV.

LAYOUT

Fig. 6: layout of ASRS

The layout of ASRS in paper machine is as shown above. The graphical view of the block diagram is as shown. The reams from the conveyor are pushed to the perpendicular conveyor by the hydraulic pusher. Here, four conveyors are used for large amount of production. This complete performance is controlled and coordinated with the help of PLC.

XVI. HARDWARE IMPLEMENTATION The hardware setup of the automatic storage and retrieval system is shown below. The stack crane moves in X axis Y axis and Z axis. It moves in forward axis to store the ream and in the reverse direction to retrieve the reams.

X fwd -- Y fwd -- Z fwd -- X rev -- Y rev -- Z rev

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

Fig. 7: hardware setup of the automatic storage and retrieval system

XVII. SIMULATION RESULTS

Fig. 8 (A): Start Operation

Fig. 8 (B): Storing Operation

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

Fig. 8 (C): Retrieving Operation

Fig. 8 (D): Loading Operation

Fig. 8 (E): Unloading Operation

XVIII. CONCLUSION The PLC being an effective tool in automated can automate any process logically along with the usage of i/o’ s. The main advantage in this regard is that, Even if one PLC fails, the another PLC connected in the same network will retake the process without causing any interruption or malfunction. This kind of cheaper and well efficient design if installed can create perfect sequence of operation.

The main aim is to provide smooth and precise handling of paper storage. Since everything is automated the storage and retrieval process is quick and more efficient than manual handling. Our project ensures the same similarly in case of production expansion the system needs some small changes in program generally in timer circuit. Thus a separate setup is not required such that the this proposed system will be sufficient to meet the maximum production.

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Automatic Ream Handling System (Automatic Storage and Retrieval System) by using PLC (GRDJE/ Volume 3 / Issue 5 / 002)

REFERENCES [1] [2] [3] [4] [5] [6]

Swathi S P , M G Vasundhra, Dr B Yogesh, 2013“PLC based Automatic Racking System” in International Journal of Engineering Research Technology. pp 805-810 A. Albagul, K. Alsharef, M. Saad, Y. Abujeela, "Design and Fabrication of an Automated Multi-level Car Parking System", in Manufacturing Engineering, Automatic Control and Robotics, 2013.

Kees Jan Roodbergen, 2009, “A survey of literature on ASRS”. European Journal of Operational Research. pp 343-362 Rashid, M.M; Kasemi, B; Rahman, M., 2001, “New ASRS using wireless communication”, International conference on Mechatronics IEEE. pp 1-7 We-Min Chow, 1989,” Development of an Automated Storage and Retrieval System for manufacturing assembly lines”. Proceedings of international conference on Robotics and Automation, IEEE. pp 490-491 H. karnataka, "PLC controlled low cost automatic packing” International Journal of advanced mechanical engineering vol . 4, no .7, PP.803-811, 2014.

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