Automated Height Based Box Sorting System Using PLC: Project On
Automated Height Based Box Sorting System Using PLC: Project On
Automated Height Based Box Sorting System Using PLC: Project On
by
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)
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Approval sheet
Vidya Prasarak Mandal, Thane’s
Maharshi Parshuram Collage Of Engineering
District: Ratnagiri, Pin-415729
Approval Sheet
Submitted by
1. Sagar Santosh Bhosale (I 801)
2. Suraj Ramesh Bhosale (I 802)
3. Ishtiyaq Abdul-Karim Patait (I 806)
4. Sairaj Sanjay Shinde (I 807)
Guide Examiner
Ms. Pradnya Gokhale
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Declaration
We declare that this written submission represents our idea in our own
words and where other idea or word have been included. We are adequately
cited and referenced the original source. We also declare that, We are ad-
hered to all principles of academic honesty, integrity and have not misrepre-
sented, fabricated or falsified any idea/data/fact/source in our submission.
We understand that any violation of the above will be cause for disciplinary
action by the Institute and can also evoke penal action from the source which
have thus not been properly cited or from whom proper permission has not
been taken when needed.
Date:
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Ackowledgement
We take this opportunity to express our sincere gratitude towards our guide
Ms.Pradnya Gokhale from Department of Instrumentation Engineering,
VPM’s Maharshi Parshuram College of Engineering, Velneshwar,
(affiliated to University of Mumbai), for their encouraging and inspiring
guidance. We also wish to thank staff members of our college for their
support.
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Abstract
The drinking water crisis in Asia is reaching alarming proportions. It
might may very soon attain the nature of global crisis. Water is one of the
most essential nature’s gifts to the manhood and without water no one can
imagine their lives. Now, man recognized the water significance, particu-
larly where water is not easily available. Now this is being achieved in an
appropriate manner in city areas where the use of water is more than its
availability. Hence, it is of atmost important to preserve water for human
beings. There are several problems of electricity in rural area. Also, the
small towns are incapable to use electricity based level sensors in small in-
dustries or domestic tanks. In many agricultural fields and domestics there
is the problem of water scarcity. The water level indication can provide a
solution to this problem. In this project, the water level indication works
on the principle of diaphragm deformation. It will provide a water level in-
dication mechanism without power supply. The sensor consists of low cost
materials. Hence, sensor is cost effective, reliable and could be made easily
available in rural area.
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List of Tables
3.1 Technical Specification . . . . . . . . . . . . . . . . . . . . . 14
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List of Figures
2.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Proposed system . . . . . . . . . . . . . . . . . . . . . . . . 6
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Contents
Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Approval Sheet . . . . . . . . . . . . . . . . . . . . . . . . ii
Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Acknowledgement . . . . . . . . . . . . . . . . . . . . . . iv
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
1 Introduction 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Aim and objectives . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Problem statement . . . . . . . . . . . . . . . . . . . . . . . 2
2 Literature Review 3
2.1 Literature review . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Theoretical Analysis 7
3.1 Programmable Logic Controller . . . . . . . . . . . . . . . . 7
3.1.1 PLC Hardware: . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 How does PLC works? . . . . . . . . . . . . . . . . . 10
3.1.3 Communication: . . . . . . . . . . . . . . . . . . . . 11
3.1.4 Programming Languages in PLC: . . . . . . . . . . . 11
3.1.5 Timers and Counters in PLC : . . . . . . . . . . . . . 12
3.2 Siemens S7-200 PLC . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Technical Specifications: . . . . . . . . . . . . . . . . 14
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3.2.2 Input Output Port: . . . . . . . . . . . . . . . . . . . 15
3.2.3 Features: . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Technical Details: . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.2 IR Sensor . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.3 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Block Diagram: . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Experimental Setup 23
4.1 Schematic Diagram: . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 FlowChart: . . . . . . . . . . . . . . . . . . . . . . . 24
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 1
Introduction
1.1 Introduction
Sorting is very important in any type of industry such as manufacturing
industry to improve the efficiency of system. In this project, we have devel-
oped a Low Cost Automation System for sorting the light weight boxes on
the basis of height variation. It will save the man power as well as increase
the consistency and flexibility. This will not only reduce manual efforts and
time consumed, but also prevents danger which might occur when human
beings work in hazardous environments such as chemical industries.
• To save the time for inspection and reduce the efforts of the workers.
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1.3 Motivation
• Manual sorting is the conventional approach that is preferred by indus-
tries which involves visual observation performed by human beings.
• The problem statement for the project is to create the electronic system
which can reduce the efforts of workers as well as to reduce the time
spent in inspection of components.
• In old days it was possible to implement manual labor for sorting similar
objects. But nowadays due to increased production and for minimizing
the labor expenditure for such unskilled task, industries cant afford
human errors for sorting these products. This forced industry to tend
towards atomizing the sorting process.
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Chapter 2
Literature Review
2.1 Literature review
1. Kadiyam Sasidhar, Shaik Faiz Hussain, Syed Ali Safdar, Mohd Aleem
Uddin, published paper entitled as ”Design and Development of a PLC Based
Automatic Object Sorting”.
In this project they have sorted the objects as metallic and non-
metallic by using two DVD drives. The DVD drives acts accordingly to the
signals based on the sensing module. If the object is a metal then the first
drive pushes the object out of conveyor according to the program given in
the ladder programming and if the object is a non-metal then the second
drive pushes the object. And they both get to their initial position after
some time delay.
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Figure 2.3:
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Chapter 3
Theoretical Analysis
3.1 Programmable Logic Controller
A Programmable Logic Controller, or Programmable Controller is a dig-
ital computer used for automation of typically industrial electromechanical
processes, such as control of machinery on factory, or light fixtures. PLCs
are used in many machines, in many industries. PLCs are designed for
multiple arrangements of digital and analog inputs and outputs, extended
temperature ranges, immunity to electrical noise, and resistance to vibration
and impact. Programs to control machine operation are typically stored in
battery-backed-up or non-volatile memory. 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 unintended operation will result.
A Programmable Logic Controller is a specialized computer like device
used to replace bank of electromagnetic relays in industrial process control.
The PLC is also known as a programmable Logic Controller (PLC). The tile
PC for Programmable Controller could be confuse in common usage with
PC used to mean personal computer. To avoid this confusion, we shall refer
to the programmable controller as a programmable logic controller or PLC.
A Programmable Logic Controller (PLC) is an industrial computer con-
trol system that continuously monitor the state of input device and make
decision based upon a custom program to control the state of output de-
vices. Before the PLC, control, sequencing, and safety interlock logic
for manufacturing automobiles was mainly composed of relays, timers, and
dedicated closed-loop controllers. Since these could number in the hundreds
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or even thousands, the process for updating such facilities for the yearly
model change-over was very time consuming and expensive, as electricians
needed to individually rewire the relays to change their operational charac-
teristics.
• CPU:
It keeps checking the PLC controller to avoid errors. They perform
functions including logic operations, arithmatic operations, computer
interface and many more. It has three subparts : memory system,
processor and power supply.
• Memory:
Fixed data is used by the CPU. System (ROM) stores the data per-
manantly for the operating system. RAM stores the information of the
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status of input and output device, and the values of timers, counters
and other internal devices.
• I/P Section :
Input keeps a track on field devices which includes sensors and switches.
Various input devices are connected to input module. Input module
gives signal to the controller and then controller takes the action based
on input signals. It acts as the interface between physical devices in the
real world outside the PLC and digital arena inside the PLC.
• O/P Section : Output has a control over the other devices which in-
cludes motors, pumps, lights and solenoids. The I/O ports are based
on Reduced Instruction Set Computer (RISC). The role of an output
module is to translate signals from the PLC’s CPU into a form that the
output device can use.
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Since some programming can be done while running, while some PLC
programming functions require it to be stopped. Putting a PLC into Stop
mode also turns off all the outputs. Handy for checking inputs with causing
anything to happen out of sequence. In Reset mode, it resets the PLC from
operating conditions back to switch on position. When this is done without
resetting any data memory registers, this is called a warm reset. If the reset
performed is full, for example resetting all I/O and data registers, it’s called
a cold reset.
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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 output. This
scan time may be a few milliseconds for a small program or on a fast pro-
cessor, but older PLCs running very large programs could take much longer
to execute the program.
3.1.3 Communication:
PLCs have built-in communications ports, usually 9-pin RS-232, RS-
422, RS-485, Ethernet. Various protocols are usually included. Many of
these protocols are vendor specific.
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• Counters :
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Fig. 2.4 shows the I/O port of Siemens S7-200 CN. In I/O port, eight
inputs and eight outputs are present. Voltage of Input terminal is 24 V
and Ouput terminal is 5V. Addresing of input and output devices is given
in table 2.2 and 2.3. In this I/O port, we can connect external inputs and
outputs by giving the same addresses of inbuilt input devices.
The connections from inbuilt input devices are given to the I/O port
and hence we can use the same address to the external input devices. The
connections of inbuilt output devices are given to the I/O port and hence
we can use the same address of inbuilt output devices to the external output
devices. 16
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Types of PLC
• Based on size
1. Micro PLC or Small PLC
2. Medium PLC or Mini
3. Large PLC or Rack
3.2.3 Features:
1. High execution speed
2. Easy downloading of programs
3. Industrial feel look
4. Powerful instruction sets
5. PC based Ladder programming
6. High execution speed
7. Extremely easy and student friendly
8. Software to develop different programs
9. Several sample ladder programs
10. Choice of PLC and expansion modules
11. Easy downloading of programs
12. Practice troubleshooting skills
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3.3.1 DC Motor
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If an electric current flows through two copper wires that are between
the poles of a magnet, an upward force will move one wire up and a downward
force will move the other wire down. The loop can be made to spin by fixing
a half circle of copper which is known as commutator, to each end of the
loop. Current is passed into and out of the loop by brushes that press onto
the strips. The brushes do not go round so the wire do not get twisted. This
arrangement also makes sure that the current always passes down on the
right and back on the left so that the rotation continues.
3.3.2 IR Sensor
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The basic block diagram (as shown in fig.3.7 above)of the process and
its explanation is given below :
• Input Module : The input module consist of IR sensor and toggle switch.
There is one IR sensor whose output is given as an input to the PLC. The IR
sensor is used for detecting the boxes according to their height. The output
of IR sensor is given to PLC for running or stopping the conveyer. Toggle
switch is used to start the process.
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• Signal Conditioning :
The output of the sensors cannot be given directly to the PLC as the in-
put voltage to PLC is 24V. Hence they are given through signal conditioning
circuits which condition the input signals and in turn give it as an input to
PLC. For safety purpose the inputs are not given directly to the PLC. They
are given through relay circuits. The relay consist of 3 terminals common,
NO and NC. The 24V which is to be inputted into the PLC will be available
in the common terminal. Hence depending upon the necessary signals, the
circuit closes or opens thereby connecting to the PLC.
• PLC :
All control operations are done using the PLC. The entire box sorting
process is automated by feeding the necessary conditions into the PLC using
ladder logic. Ladder logic is one of the methods of programming a PLC.
Thus, depending on the logic developed the various operations take place
and the sorting of boxes are done.
Output Module:
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Chapter 4
Experimental Setup
4.1 Schematic Diagram:
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4.1.1 FlowChart:
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References
[1] Kadiyam Sasidhar, Shaik Faiz Hussain et. ”Design and Development of a PLC
Based Automatic Object Sorting”, in International Journal of Research and Scientfic
Innovation (IJRSI) Volume IV, Issue XII,December 2017..
[2] Sushrut Kulkarni, Sanjay Singh,et al. ””Object Sorting Automated System Using
Raspberry Pi”, in International Conference on Communication and Electronics Sys-
tem,2018..
[3] Rakhshan Zulfqar, Bushra Mehdi, Rumaisa Iftikhar, Tahmina Khan, et al. ”PLC
Based Automated Object Sorting System”, in 4th International Electrical Engineer-
ing Conference, 2019.
[4] R.Aravind, M.Arun Kumar, et al. ”Automatic Sorting In Process Industries Using
PLC”, in CONFERENCE, February 2018.
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