Automated packaging machine using plc

IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 2 Issue 5, May 2015.
www.ijiset.com
ISSN 2348 – 7968
Automated Packaging Machine Using PLC
Alhade A. Algitta 1
, Mustafa S.2
, Ibrahim F.3
, Abdalruof N.4
and Yousef M. 5
1,2,3,4,5
Control Engineering Dep., College of Electronic Technology,
Bani Walid 38645, Libya
yousef.yaqa@gmail.com
Abstract
This paper presents final year project prototype with the use of
programmable logic controller in automation industry for
packaging process. The main idea of the project is to design and
fabricate a small and simple conveyor belt system, and automate
the process for packaging small cubic pieces (2 × 1.4 × 1) cm3
of
wood into small paper box (3 × 2 × 3) cm3
. Inductive sensor and
photoelectric sensor were used to provide the information to the
controller. Electrical DC motors used as output actuators for the
system to move the conveyor belts after get the orders from the
control system. Programmable logic controller Mitsubishi FX2n-
32MT was used to control and automate the system by ladder
logic diagram software. The experimental result of the prototype
was able to fully automate the packaging system. This results
show that the machine were done to package 21 boxes in one
minute. In addition, the results obtained show that the system
able to decreases product time, and increase product rate as
compared with traditional manual system.
Keywords: Packaging Machine, Automated, PLC, Switches,
Inductive Sensor, Photoelectric Sensor.
1. Introduction
Industry automation becomes the global trend in
manufacturing, packaging process is one of the most uses
in industry; more and more companies are switching to
automation. This project is devoted to the use of automatic
control system in process machine system; the control
system will play a major role in control on all parts of the
project. This project report is about design and fabricate
an automated packaging machine system. Electrical DC
motors control were used as actuators for the entire
process to move the upper and lower conveyor belts, and
the sensors used to feed the control system by system
information.
Conveyor belt used for transporting samples from
location to another one, which would be packaged into a
specific paper boxes later. The control system for the
hardware project is to be controlled by the Mitsubishi
FX2n-32MT programmable logic controller (PLC) device.
Ladder logic diagram for programmable logic controller
were used for control the actual prototype for the
experimentation. The whole system executes to package 4
wood samples (2 cm × 1.4 cm × 1 cm) into paper boxes (3
cm × 2 cm × 3 cm). Finally, the prototype with system
controller were successfully done to package 21 boxes in
one minute, every box include 4 samples.
1.1 Conveyor Belt
A conveyor belt is one of many types of conveyor
systems. The belt is a loop of flexible material as shown in
Figure 1(a) used to mechanically link two or more
rotating shafts, most often parallel. A belt conveyor
system consists of two or more pulleys (sometimes
referred to
as drums), with an endless loop of carrying medium that
rotates about them as shown in Figure 1 (b). 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 pulley.
There are two main industrial classes of belt conveyors;
Those in general material handling such as those moving
boxes along inside a factory and bulk material handling
such as those used to transport large volumes of resources
and agricultural materials, such as grain, salt, coal, ore,
sand, overburden and more [6].
Fig. 1 (a) Belt Type, (b) Conveyor Belt with Pulley.
1.3. Packaging
Packaging is the technology of using conveyor belts for
enclosing or protecting products (food, wood, and
material) for storage, pack objects together into containers,
sale, and use. Packaging also refers to the process of
design, evaluation, and production of packages. Packaging
can be described as a coordinated system of preparing
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ISSN 2348 – 7968
goods for transport, warehousing, logistics, sale, and end
use. Packaging contains, protects, preserves, transports,
informs, and sells [7].
2. Components Selection and Hardware
Structure
The Automatic Packaging Machine system is a
combination of electronic, electrical and mechanical parts,
Figure 2 shows the whole system proposed.
• Input Devices are devices used to gather information
about the system, which consists switches (toggle
switch) and sensors (photo and inductive sensor), in
order to feed the controller (PLC) by an information
about the belts status and objects.
• The controller, which is the main element that operate
the whole system, by using the information from the
sensors to take the counting and movement decision
before sending the orders to the output devices by the
actuators and the relays.
• Output Devices are the actuators that converts an
electrical signal into mechanical movement; the
principle types of actuators are relay, solenoid, and
motors.
.
Fig. 2 Automated Packaging System.
2.1Sensors
A sensor is a device that measures a particular
characteristic of an object or system. Some sensors are
purely mechanical, but most sensors are electronic,
returning a voltage signal that can be converted into a
useful engineering unit. Sensors are used in everyday
objects such as touch-sensitive elevator buttons (tactile
sensor) and lamps, which dim or brighten by touching the
base. There are also innumerable applications for sensors,
which include cars, machines, aerospace, medicine,
manufacturing and robotics [3].
2.1.1 Photoelectric Sensor
A photoelectric sensor, or photo eye, is a device used to
detect absence, or presence of an objects by using a light
transmitter, often infrared, and a photoelectric receiver.
They are used extensively in industrial manufacturing.
There are three different functional types: opposed
(through beam), retro-reflective, and proximity sensing
(diffused), figure 3 shows one of Photo types [8].
Fig. 3 Photoelectric Sensor Sample.
In the project prototype, the photoelectric sensor is
placed at the upper belt to sense and count the samples
before dropping them in the box as shown in Figure 4
below.
Fig. 4 Photoelectric Sensor Setup on the Project.
2.1.2. Inductive Proximity Sensors
Inductive sensors use currents induced by magnetic
fields to detect nearby metal objects. All of inductive
sensors consists of four basic elements; the oscillator,
which produces the electromagnetic field, the coil, which
generates the magnetic field, the detection circuit, which
detects changes in the field when an object enters it and
the output circuit which produces the output signal as
shown in figure 5 [1].
Fig. 5 Inductive Proximity Sensor Structure [9].
The inductive sensor was installed above the lower
conveyor belt (about 3 cm) and in front of the particular
upper belt to sense the coming boxes of the samples for
packaging. This sensor can be able to sense from (0.5 mm
to 5 mm) and it sense iron only (so that metal sheets were
used to cover the boxes) as shown in Fig. 6 below.
PLC
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Fig. 6 Inductive Sensor Setup on the Project.
2.2. Switches
Switches are electrical or electronic contact devices used
to turn (ON) or (OFF) the flow of electricity through a
circuit. Switches are essential components in almost all the
electronic devices used today. Switches require another
device or action (Force) to change their state from open to
close or close to open. Switches might operate manually or
mechanically.
• Manually Operated referred to types operated by hand,
which the operator must do an action, in order to start,
stop or reverse the state. Manually switches such as
(toggle and pushbutton switches).
• Mechanically Operated referred to switches those
controlled automatically (Mechanically) by factors such
as pressure, position, flow, or temperature. These
include (limit switch, inductive limit switch) [1].
2.2.1 Toggle Switch
Toggle switch is operated manually by external action
(force) and come in two types:
• Momentary: where the contacts are operated only
while the actuator is operated. Sometimes referred to
as spring return.
• Non-Momentary (Latching): sometimes called on-off
or, with a button actuator, where the contacts lock in
one position when the button is pressed then released
and only change back when the button is pressed a
second time. [4][5]. In the project, the switch is used
for starting up and shutting down the system by the
designer as shown in figure 7 below.
Fig. 7 Toggle Switch Used.
2.3. Actuators
Actuation defines as the result of a direct physical action
on the process, such as drilling a work piece or rotate the
object from side to another side by rotating the upper
rotary disk.
2.3.1 DC Motor
DC motors have been used in industrial applications for
years. Coupled with a DC drive, DC motors provide very
precise control. DC motors can be used with conveyors,
elevators, extruders, marine applications, material
handling, paper, plastics, rubber, steel, and textile
applications [2,3].
As shown below Figure 8, two DC motors were
installed on the project; one of them mounted with a
pulley to rotate the upper belt (Y1), and the other one,
mounted with a pulley to rotate the lower belt (Y0). The
two motors used to do next tasks:
1. The lower DC motor starts first to bring empty boxes
at desired position.
2. The upper DC motor starts after the box reach desired
position, to bring some samples for packaging into the
box.
Fig. 8 Upper and Lower DC Motors Installation.
2.4 Relays
Relays are simple switches operated both electrically and
mechanically . Relays consists of an electromagnet and set
of contacts .There are also other operating principles for
its working which differ according to their applications,
Figure 9 shows type of electro-mecanical relays used in
the project [3].
Fig. 9 Type of Relays.
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Figure 10 shows the mechanical relays used on the project
as interface between the PLC outputs and DC motors
inputs.
Fig. 10 Relay's Setup on the Project.
A solid-state relay is an ON-OFF control device in which
the load current is conducted by one or more semi
conductors. Like all relays, the SSR requires relatively low
control circuit energy to switch the output state from OFF
to ON. Since this control, energy is very much lower than
the output power controllable by the relay at full load [7].
In this prototype, since the photoelectric output voltage is
very small, we used them as interface between the output
of the sensors and the input of PLC. Figure 11 shows the
SSR positions on the prototype.
Fig. 11 Solid State Relay Installation.
2.5 Indicators
Indicators are used to monitor the system operation or
condition and the telecommunication and electrical circuit
for indicator signal, accident signal, fault signal and other
indicator signals [4].
In our project as shown in Figure 12, we have chosen
three types of indicators in order to monitor different
operations, this indicators are:
• Green indicator: To indicate and show system running
state.
• Yellow indicator: To indicate lower belt moving state.
• Red indicator: To indicate upper belt moving state.
Fig. 12 Indicators.
2.6 Mechanical Structure and Design
The project prototype designed and fabricated with
metal rods by dimensions 80cm × 80cm (length x width)
as shown in
Figure 13
below in order
to carry the
completely
packaging
components.
Fig. 13 Project Prototype Main Base.
Conveyors are a strip of belt mounted on pulley at two
ends, driven by one or two of the pulleys. In the prototype
as shown in Figure 14, two belts were used as upper and
lower belts; the upper belt is 67 cm length with 4.6 cm
width installed on the 67 cm rod. The other belt with is 72
cm length with 4.6 cm too, installed on the 72 cm rod
Fig. 14 Upper and Lower Belts Setup on the Project.
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Two DC motors (12 volts) mounted with main pulley
for each to derive and rotate the belts (Upper and Lower
belts) as shown in Figure 15, Red arrows indicate belt
direction moving.
Fig. 15 DC motors with pulley Installation.
Figure 16 below shows the pulleys and motors dimensions
on the prototype.
Fig. 16 Pulley and DC Motor in the Prototype.
Figure 17 below shows the size and dimensions of the
boxes and samples which used in the prototype.
Fig. 17 Size of Boxes and Samples.
3. Block Diagram and Wiring the System
The block diagram of the proposed system is shown in
figure 18, which consists of three inputs (toggle switch ,
photo sensor, inductive sensor) to provide the control by
system state. Also the system consist of three output (the
dc motor, indicators)
Fig. 18 Block Diagram of the System.
 Toggle Switch: It have two wires connected as
sourcing to the PLC one of the wirers is connected to
24 V DC, while the other wire is connected to 0VDC.
 Inductive Proximity Sensors: The first wire of
inductive proximity sensor is connected to X0 at the
PLC and the other wire is connected to 0 VDC.
 Photoelectric Sensor: The first wire of photoelectric
sensor is connected to X1 at the PLC and the other
wire is connected to 0 VDC.
 Lower DC Motor: Since the DC motor works under
5V and the PLC gives 24VDC, then 24VDC relay
used. The lower DC motor is connected to (Y1) in the
PLC.
 Upper DC Motor: since the DC motor works under
5V and PLC gives 24VDC, then 24VDC relay is used.
The upper DC motor is connected to (Y2) in the PLC.
Figure 19 below shows the wiring of the whole component
of the prototype with the PLC
Fig. 19 Wiring of PLC.
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3.1 Programmable Logic Controllers (PLC)
Technical specifications of PLC Mitsubishi FX2n-
32MT on the Table 1 [2].
Table 1: Technical Specifications of Mitsubishi PLC
4. Experimental Results and Discussions
Figure 20 shows the whole system prototype for the
automated packaging machine, as shown in the figure, it
consists of sensors (inductive and photoelectric), actuators
(two DC motors, two mechanical relays and solid-state
relay), and indicators (red, green, yellow), PLC, power
supply, boxes, samples.
Each component have a specific function to perform,
which can be explained as follows:
Toggle Switch: was use as main switch to start up, and
turn off the Packaging system.
Lower Motor (Y0): it is responsible for the movement of
the lower conveyor belt, to bring empty boxes in sequence
to the desire location.
Inductive Sensor (X0):This sensor has two main
missions, the first one is to detect the empty boxes as
arrival at the desired location, the second one is to stop the
lower belt and activate the upper belt to drop the samples
into the box.
Upper Motor (Y1): it is responsible for the movement of
the upper conveyor belt, to bring the cubic samples in
sequence to package them into the box.
Fig. 20 Packaging Machine Prototype.
Photoelectric Sensor (X1): It used to count the dropped
samples during packaging process.
Relays: the works as interface between the motors,
photoelectric sensor and the PLC.
Indicators: were used to light different colors to show
system states.
Power Supply: It feed the system with different voltages.
The prototype experimental testing and running divided
to next steps as following:
Step one:
When the toggle switch pressed ON, the system start
ruining by moving the lower belt by DC motor (Y0),
which carrying and bring the empty boxes, as the empty
box reach the inductive sensor (X1) as shown in Figure
21, that the inductive sensor will activate and send signal
back to the PLC to stop the lower belt moving. In the same
time when the system start running, the green indicator
lights ON, to inform the operator system states. Although,
the yellow indicators lights ON for lower belt moving.
Fig. 21 Inductive Sensor Activated as the box be in location.
Step two:
As the box, reach the desired location, the lower belt stop
moving and the upper belt start moving. Upper belt starts
to bring the samples one by one and drop them into the
box. This operation running until four samples.
Meanwhile, the red indicator lights on to show that the
system is packaging. Figure 22 show packaging operation
of the samples.
Fig. 22 Packaging Operation.
General features
Max .number inputs/outputs 16
Power supply 100-240 VAC
Output type Transistor
Power consumption [W] 30 V A
Weight [Kg] 0.65
Dimensions (WxHxD) [mm] 136x90x87
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The photoelectric sensor used to count the samples
while packaging, when the box fill by four samples, the
sensor give information back to the PLC to stop the upper
belt and bring another empty box to package it.
After the photoelectric sensor, count four samples, the
upper conveyor belt stop moving and the lower conveyor
start moving to carry the filled box away and bring another
empty box to package it with another four samples. Figure
23 below shows the final operation of the packaging.
Fig. 23 Carrying filled Box and Bring Another.
4.1 Product Rate of the System
The experimental results for the automatic and manual
operation shows different products rate as shown in Table
4.2 below.
Table 4.2: System Product Rate
Product Time
Manual
Packaging
Automatic
Packaging
One Minute 14 Boxes 21 Boxes
One Hour 840.00 1260.00
One Day ( 8
hours)
6720.00 10,080.00
One Week (5
working days)
33,600.00 50,400.00
One Month 134,400.00 201,600.00
5. Conclusion
An automated packaging machine prototype using PLC
Mitsubishi FX 2N has been successfully design,
constructed and implement based on control system
concepts. Mitsubishi ladder diagram applied for the
programming and operation of the presented prototype, in
which the operation is passes through two stages, carrying
empty boxes to desired location, and packaging the
samples into the boxes. The experimental prototype tested
to improve the automation processes with the use of the
PLC ladder diagram. The packaging prototype was done
to package four sample per a box in very short time. From
the experimental result, the automatic packaging machine
was able to package 1260 boxes per one hour, otherwise
the manual packaging able to package just 840 boxes at
the same time.
6. References
[1] Yousef M. Abueejela, A. Albagul, Ibrahim A. Mansour and
Obida M. Abdallah, " Automated Drilling Machine Based on
PLC", in International Journal of Innovative Science,
Engineering and Technology, Vol. 2 Issue 3, March 2015.
[2] 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.
[3] H . karnataka, "PLC controlled low cost automatic packing",
International Journal of advanced mechanical engineering,
vol . 4, no .7, PP.803-811,2014.
[4] Ibrahim M. and Obida A., "Automated Drilling
Machine Based on PLC" B.Sc. project, Dept. Control
Eng. College of Electronic Technology Bani Walid, 2015.
[5] D. Shetty and R. Kolk, Mechatronics System Design. India,
2004.
[6] Wikipedia. “Conveyor Belt”, Wikipedia.org. [Online].
Modified: 14 March 2015, at 11:21].
[7] Wikipedia. “Packaging and labeling”, Wikipedia.org.
[Online]. Available
http://en.wikipedia.org/wiki/Packaging_and_labeling
[8] (2015.feb.23)."photoelectric sensors theory of operation"
[online]. Available http://
www.enm.com/products/content/seimens/training/seimens_cou
rses. [Accessed: feb .29 ,2014].
[9] P. Frank ,Electric motors and control systems. USA,
McGraw-Hil, 2010.
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