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IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

International Journal of Research in Information Technology (IJRIT) www.ijrit.com

ISSN 2001-5569

Automatically Controlled Scrap Conveyor Archana Rathod1, Manisha Sanap2, Prof.Swati Jagtap3, Mr. Yogesh Patil4 [email protected], [email protected], [email protected] Department Of Electronics & Telecommunication Engineering, PCCOE, Pune-411044,India 3 Assistant Professor in Department Of Electronics & Telecommunication Engineering, PCCOE, Pune 4 Gestamp Automotive India Pvt. Ltd. 1,2

Abstract The process of automation of conveyor system will play an important role in safety of workers as well as to save time for processes in industries. The industry consist of scrap conveyor system which is currently controlled manually from stamping press line. Operating of conveyor system is time consuming and create lots of stress on maintenance engineers and workers. Automation will make the industry safe, robust, cheap, highly efficient and maintenance free, and also minimizes work load on workers. Keywords – safety requirements, requirements at runtime, scrap conveyor system, stamping press line, Programmable logic controllers.

I. INTRODUCTION The field of automation has greater impact in a wide range of industries beyond manufacturing. Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provides human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy. One of the important applications of automation is in the conveyor system where a particular container is filled by a scrap automatically. For these kinds of applications, the trend is moving away from the individual device or machine toward continuous automation solutions. Totally Integrated Automation puts this continuity into consistent practice. This will provide safety requirements for the workers on the process plant. Totally Integrated Automation covers the complete production line, from receipt of goods, the production process, to shipment of goods with minimum requirement of time. Now application of automation is

Archana Rathod, IJRIT-384

IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

developed a logic for automatic controlling of conveyor system from stamping press line. The various processes are controlled using a PLC (Programmable logic controller).

II. BACKGROUND AND RELATED WORK The conventional method need to modernized and its various functions are required to be automated to achieve reduced cycle time, higher level of accuracy and more reliability. The age of automation has a brought a new meaning in electronics industries; it means the complete automatic operation of the machine without human brain intervention, implying automatic inspection and electronic integration and control of various machining operations. Modernization and automization of industrial machines generally comprise modification into a state of art programmable logic controllers(PLC) where in the conventional relay control is replaced with . Automation is the use of control system such as computers, microcontrollers or PLC to control industrial machinery and processes, replacing human operators. In the scope of industrialization, it is a step beyond mechanization. Automatic equipment is used in automation, instead of manual labour .This facilities the eliminations of human errors thereby increasing accuracy of manufacturing a desired product. PLC is designed for multiple inputs and output arrangements, 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[1]. PLC & SCADA software is mainly implemented for the control and monitoring between processing hardware and computer. It applies interfacing sever protocol when needed between the SCADA software and the hardware process. Filling process model has been designed with the help of hardware devices. It uses dc gear motor drivers, sensing devices, Limit switch, Programmable Logic Controller (PLC) device and serial port communication.[2]

III. PROBLEM DEFINITION The problems which are present in existing system is that it can be operated manually and not integrated with machine, if the fault arises in the conveyor then operator has to go at conveyor system and correct it manually. The time taken for doing all this process will become more in such condition. Sometimes in special environments which are dangerous and not conductive for human operation, the operator cannot go and see the fault. So the rate of production was affected due to the use of manual inspection systems.

Archana Rathod, IJRIT-385

IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

IV. METHODOLOGY The feedback is provided to stamping press line by conveyor. The press line is started only if the conveyor is in run condition otherwise it will not started. Also if the conveyor is running and traps selection is not done then warning to stop the conveyor is given to press line. The interlock for start or stop conveyor is provided on main press panel. To achieve this the logic for ladder program is made. The scrap conveyor system consist of two conveyor belts. Conveyor-1 is kept perpendicular to Conveyor-2. Conveyor-2 moves the scrap outside the process plant and Conveyor-1 is for filling two container present at left and right side from the axis of Conveyor-2.

V. PROCESS DESCRIPTION A. Block Diagram The basic block diagram (as shown in Fig.1) of the process and its explanation is given as follows :

Fig.1 Block Diagram I/P from conveyor block includes the input provided to main PLC that is feedback of scrap conveyor gives the status about functioning of conveyor whether it is working properly or not. HMI(Human Machine Interface) gives easy interface to user with machine. With the help of this unit, we will set all parameter for conveyor and also getting warning if the conveyor is in stop condition. The next block is press input through which gives start or stop command to conveyor system. After the press input is activated the Conveyor Motor Drive is running in forward or reverse biased as per requirements. The last block is PLC. All control operations are done using the PLC. The entire scrap conveyor control process is automated by feeding the necessary conditions into the PLC using ladder logic. Following flow chart shows details of automation.

Archana Rathod, IJRIT-386

IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

Fig. 2 Flow Chart B. Stamping Press Line Stamping press line is the system which cuts the huge metallic sheets into required size & shape with the help of dies. Die is the tool used to give different shapes to metal sheets with predetermined dimensions. These metal sheets are mainly used for the outer parts of vehicles like doors, handles, cabinets etc.

C. Scrap Conveyor Scrap conveyor is a piece of equipment used to collect metal chips or scraps resulting from manufacturing processes. These conveyors are often connected to manufacturing equipment, including metal lathes, milling machines, and other machinery used to cut metal. The scrap conveyor automatically collects and stores metal dust, scraps, and chips in a bin or vessel.

D. PLC PLC is a solid state device. They are well adapted to a range of automation tasks. All control operations are done using the PLC. The entire conveyor system is automated by giving 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 control conveyor is achieved. PLC consists of an I/O unit, central processing unit, and a memory unit. The input/output unit of the PLC acts as an interface to the real world. Inputs from real work are given to the input unit which is manipulated based on the

Archana Rathod, IJRIT-387

IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

programming, and the results are given back to the real world through the output unit of the PLC. All logic and control operations, data transfer and data manipulation operations are done by the central processing unit. The results and statuses are stored in the memory of the PLC. PLC’s are used for a wide range of applications especially in the field of control and automation.

VI. OPERATION The operation is starting from the stamping press line. From stamping press line the scrap is generated and go to the down where the conveyor is situated by the help of doors which are on the stamping press line , this scrap is carried out by the upper side of conveyor where the small conveyor is located and from that the scrap is put down on to the truck. in order to do this well there is an addition of interlocks to make all this system atomized.

CONCLUSION This project presents a automated controlled scrap conveyor system using PLC. A total control is made in a scrap conveyor is achieved. The present system will provides a great deal of applications in the field of automation, especially in mass production industries where there are large number of components to be processed and handled in a short period of time and there’s need for increased production. The programming to this system developed is flexible, quickly and easily. This will increase the total production output; this increase in production can yield significant financial benefits and savings. This concept can be used in product industries and manufacturing industries.

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Rishabh Das, S. Dutta, A. Sarkar, K. Samanta," Automation of Tank Level Using Plc and Establishment of Hmi by Scada " UIT, BU, India. IOSR, Volume 7, Issue 2 (Jul. - Aug. 2013), PP 61-67.

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Archana Rathod, IJRIT-388

IJRIT International Journal of Research in Information Technology, Volume 3, Issue 4, April 2015, Pg. 384-389

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[10] Joanna Marie M. Baroro, Melchizedek I. Alipio, Michael Lawrence T. Huang, Teodoro M. Ricamara, Angelo A. Beltran, "Automation of packaging and material handling using programmable logic controller", Jr 2013

Archana Rathod, IJRIT-389