Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-2, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Regulated Material Handling System Using PLC And HMI Kavyashree S & Suma S Electrical and Electronics Engineering, VVIET, Mysuru, India. Abstract — Material handling is the overall taking care and control of materials, goods or product throughout the manufacturing process as well as distribution and disposal process. Also the movement and storage of product is controlled. The focus is on different types of methods, mechanical equipment’s used, controlling systems and related controlling mechanisms are used to get these functions. The material handling system is covered maximum working area in present industrial environments. For example simple pallet rack and shelves to different complex conveyor belt, it also includes the automated storage and retrieval system. It also called as AR/RS system. It also consist of packing and sorting, as well as automated guided vehicles.
87% of production or lead time 18-72% of the total cost of a manufactured product or goods 4-6% of all material handled becomes damaged So considering all of these factors which creates huge amount of effect on the total cost and manufacturing time. As a result many industries are trying to adopt the automation in there processing operations. Along with the material handling system and the newly invented software’s like SCADA and PLC. The main advantage is that it prevents the damaging of the product while transporting or shipping that goods or product. Hence the material handling system is needed.
Keywords — SCADA, Material Handling, Human machine interface (HMI), Programmable logic controller (PLC), hardware component
DESCRIPTON & BLOCK DAGRAM
Introduction:
The present day industrial environment is such most of the companies are trying to reduce their man power so as a result of this the industries are trying to automate and as much as possible their process.
In recent days in industrial environment most of the companies are trying to cut down their man power as much as possible. So that they are trying to automate their industrial processes. In view of adopting the automation with material handling system using PLC and SCADA software. These systems are found in several stages as follow: This system are Integrated at the input end from where raw materials are supply to the industry
At house manufacturing process level
Assembly process
At the end of the process line where finished products are packaged safely according to the predefined order
moved onto the transporting section or on conveyor belts for shipping out the product or materials There are some statistics studied to understand to see how much effect made by material handling accounts for in industries. 25% of all employees 55% of all factory space
Imperial Journal of Interdisciplinary Research (IJIR)
In the view of the material handling is most probably used as the input to the industry with respect to raw materials which are using in process. As well as at the manufacturing process also at the end of the finished product where packaging and transporting of the materials or goods are done at different machining level. To accomplish these processes the huge amount of man power is needed, so that to eliminate this process of using labour and also to get a hi-tech facility status industrial environment they will go for the material handling system. Material handling system using PLC and HMI with three in process mechanism’s namely:1. 2. 3.
Stamping operation Sorting operation Stacking operation
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-2, 2017 ISSN: 2454-1362, http://www.onlinejournal.in cylindrical belt type conveyor is used and the width of the conveyor is depending upon the product size. For the automatic retrieval and automatic storage system the stepper motor is used. The stepper motor is inbuilt with the driver circuitry so that is doesn’t required the additional driver circuit to drive the motor. SOFTWARE FLOW: The most important part of programming a microcontroller is to design the flowchart with complete flow of the control action, inputs and outputs. The flow chart of project is as shown below
Figure 1.1: Block diagram of the project The main controlling part of the material handling system is PLC (programmable logical device). Which can control all the mechanical system and monitoring all the operating parameters. Here in this project the all pneumatic system and electronics system are integrated with the mechanical unit and all the sensor inputs and outputs are monitor and control by the PLC. This PLC is also consisting with 64 counters and 128 timers for counting operation of the product which flow continuously on the conveyor belt. The implemented part in my project is the human machine interface (HMI) panel is integrated with the PLC. Because of this feature the operating and monitoring system is done easily. It is human friendly unit from this we can control all the controlling and monitoring parameters. It is a touch screen panel where with the help of simple touch we can easily operate it. The HMI panel is used to count the no of metallic parts as well as the non- metallic parts which are flowing on the conveyor belt. If we want stop the conveyor we can use the “STOP” button which is indicated on the HMI panel. For restarting the following operation we can use the “RE-START” button. The all different type of sensors like infrared sensor(IR SENSOR) which are used to detect the object or product which are transporting on conveyor belt. Another one sensor is used is Proximity capacitive sensor which also used to avoid the obstacles. The sensor output is given to the PLC through the relay driver and relay mechanism. To accomplish the sorting and stamping operation two double acting cylinders are used. The pneumatic air compressor with 2 to 4 bar pressure is used. The signal is provided through the relay driver and mechanism. The Ac motor and DC motors are used to provide the rotating movement to the conveyor belt. Here the
Imperial Journal of Interdisciplinary Research (IJIR)
CONCLUSION AND FUTURE SCOPE A. Conclusion: The project is helped to bringing tomorrows feature integrated system with the help of some automation technologies like flexible manufacturing system. Page 15
Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-2, 2017 ISSN: 2454-1362, http://www.onlinejournal.in The project is helpful to learning different aspects like time management and teamwork with guide. Through this project the automation in industrial environment with its functioning which are listed below:
Programming of PLC controller by using some software like schematic manager and wincc flexible. Mechanical integration with some pneumatic and electronics aspect. Working characteristics of some sensors and there connectivity with controller in material handling system. Overall the project has given me to learn the overall planning, designing and execution of the complete project. Even though this kind of small academic projects helped to personal as well as the academics growth.
[3] "Automated Storage and Retrieval System". The University of Chicago Library.Retrieved 9 January 2013. [4] Process automation, retrieved on 20.02.2010 Menzies, Thomas. R. National Automated Highway System Research Program [5] Ouellette, Robert (1983), Automation Impacts on Industry, Ann Arbor, MI, USA: Ann Arbor Science Publishers [6] Dunlop, John T. (ed.) (1962), Automation and Technological Change: Report of the Twenty-first American Assembly, Englewood Cliffs, NJ, USA: Prentice-Hall.
future scope:
[7] Trevathan, Vernon L. (ed.) (2006), A Guide to the Automation Body of Knowledge (2nd ed.), Research Triangle Park, NC, USA: International Society of Automation
This projects does three operation which can be controlled by HMI panel, that can be replaced other newly developed automated devices or controlling units. The result tends to adopting many industrial
[8] Javed, O, & Shah, M. (2008). Automated multicamera surveillance. City of Publication: SpringerVerlag New York Inc.
applications and also the human activities. The computer aided technologies are using to developed the complex system with the help of some different mathematical and industrial tools. The numerical system is also implemented to improve the design analysis by which can the manufacturing product will be beneficial for the automated industries. Following are the different areas where we can improve in feature for industrial automation, they are listed below:
[9] Menzies, Thomas. R. National Automated Highway System Research Program A review. 253. Washington D.C.: Transportation Research Board [10] Kolawa, Adam; Huizinga, Dorota (2007). Automated Defect Prevention: Best Practices in Software Management.Wiley-IEEE Computer Society Press. [11]Automation - Definitions from Dictionary.com". dictionary.reference.com. Archived from the original on 29 April 2008.
Addition of other controlling operations like colure code detector technologies for easy data management and storage system The overall speed of execution of the system can be improve The pick and place type robotic arms can be integrated with this kind of technologies. This system can be implement into a fault redundant system to achieve higher efficiency
REFERENCES: [1] Yam, K. L., "Encyclopedia of Packaging Technology", John Wiley & Sons, 2009 [2] Frazelle, E. (2001), World-class Warehousing and Material Handling, McGraw-Hill, New York, NY
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