PLC based Segregation of Scrap Material

Mangesh B. Nagapure Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 4, ( Part -3) April 2017, pp.06-10
www.ijera.com DOI: 10.9790/9622-0704030610 6 | P a g e
PLC based Segregation of Scrap Material
Mangesh B. Nagapure*, Dr. R. M. Deshmukh**
*(Student, Dept. of Electronics & Telecommunication Engineering, SGBAU University, Amravati, India
** (HOD, Dept. of Electronics & Telecommunication Engineering, SGBAU University, Amravati, India
ABSTRACT
This paper describe segregation of scrap materials using automation system. With the growing population rate,
the amount of waste being produced is also increasing at a very faster rate. It is also posing a very serious
problem at the industrial and domestic level to manage the wastes being dumped everywhere as landfill waste.
So, it is very crucial to have some system to manage waste automatically which is currently not there. Prime
Minister Modi’s mission of Swaccha Bharat Abhiyan can also be successfully implemented by the proposed
system. The paper proposes a novel method where the provision is given to separate out metal and nonmetal
waste into respective bins by the sensing of different sensors incorporated along the conveyor belt. Pieces of
glass, paper, wood and metallic materials are separated out from proposed work. Using the segregation, most of
the metal and nonmetal components like paper, glass, plastic increases the economic value of the waste to its
best. For every scrap separation system, a higher level of automation demands more and more accurate
programming device. So, we are using programmable logic controller (PLC) as main component.
Keywords: Programmable Logic Controller (PLC), Sensors, Robotic arm, Conveyor Belt, Relays.
I. INTRODUCTION
The purpose of this project is to segregate
the metal and nonmetal waste for the industrial and
domestic use. Due to the environmental aspect as
well as increasing prices for raw materials, scrap
separation is a global topic and also the business
model of the future. The advantages of scrap
separation system are to improve the results in
energy savings, better environmental performance,
minimize raw materials wastage and reduce
manufacturing costs. These benefits also categorized
as to improved scrap management systems. The
advantage of PLC is the automation with a relatively
small amount of cabling and a low error rate.
Productivity, flexibility and efficiency with using
only a few contactors specify the controller. The
whole system is completed by modifications and
extensions of functions as well as by communication
with other devices via analog, digital and serial
interfaces.
Automation or automatic control is the use
of various control systems for operating equipment
such as machinery, processes in factories, boilers
and heat treating ovens, switching on telephone
networks, steering and stabilization of ships, aircraft
and other applications with minimal or reduced
human intervention. Some processes have been
completely automated. The biggest benefit of
automation is that it saves labor; however, it is also
used to save energy and materials and to improve
quality, accuracy and precision.
The main advantages of automation are:-
 Increased throughput or productivity.
 Improved quality or increased predictability of
quality.
 Improved robustness (consistency), of processes
or product.
 Increased consistency of output.
 Reduced direct human labor costs and expenses.
II. PLC SYSTEM
A PLC is a digitally operating electronic
device which uses a programmable memory for
internal storage of instructions for implementing
specific functions, such as logic sequencing, timing,
counting and control through digital or analog
input/output modules. A programmable logic
controller, also called a PLC or programmable
controller, is a computer- type device that is used to
control equipment in an industrial facility. PLC’s are
real-time controllers with cyclic behavior. Each
cycle consists of three steps. The first step scans the
inputs to the controller and maps a picture of the
input status into the controller memory. After that a
program stored in the controller memory is
processed, taking into account the memory image of
the inputs. As a result, an image of the outputs is
produced. In the third step the image of the output
variables is mapped to the actual outputs.
RESEARCH ARTICLE OPEN ACCESS

Fig. 2.1 Block diagram of PLC system
There are three basic components in a PLC
system: 2.1.1 The PLC processor - It stores the
control program and data in its memory. Reads the
status of connected input devices & executes the
control program. Commands connected outputs to
change state based on program execution For
example: Turn a light on, start a fan, adjust a speed,
or temperature and Comes in various physical forms.
2.1.2 I/O Modules - They physically
connect to field devices. Input modules convert
electrical signals coming in from input field devices
such as pushbuttons, to electrical signals that the
PLC can understand. Output modules take
information coming from the PLC and convert it to
electrical signals the output field devices can
understand, such as a motor starter, or a hydraulic
solenoid valve. I/O comes in various forms.
2.1.3 Power Supply - A power supply is needed to
provide power to the PLC and any other modules.
Power supplies come in various forms:
 Power supply modules that fit into one of the
slots in a chassis.
 External power supplies that mount to the
outside of a chassis.
 Stand alone power supplies that connect to the
PLC or I/O through a power cable.
 Embedded power supplies that come as part of
the PLC block.
III. HARDWARE CONFIGURATION
Fig. 3.1 Block diagram of Segregation of Scrap materials with PLC
Fig. 2 shows the block diagram which consists of
three units- sensing units, controlling units,
segregation units.
3.1.1 Sensors
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.
3.1.1.1 Photoelectric Sensor - A photoelectric
sensor, or photo eye, is a device used to detect
absence, or presence of an object 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.
Fig.3.1.1.1 Photoelectric Sensor Sample.
3.1.1.2 Inductive Proximity Sensors - Inductive
sensors use currents induced by magnetic fields to
detect nearby metal objects. All of inductive sensors
consist 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
Fig. 3.1.1.2 Inductive Proximity Sensor Structure
1.1.2 Conveyor Belt
A conveyor belt is one of the main
important types of conveyor systems. The belt is a
loop of flexible material 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.
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.
1.1.3 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

1.1.4 Robotic Arm
A Robotic Arm attached to the system
delivers fast, accurate and repeatable movement.
When metal is detected by the metal detector, the
conveyor belt stops and control signal given to the
Robotic arm by PLC is drop/push the metal particles
into its respective bin.
IV. PROPOSED WORK & OBJECTIVES
We are developing a prototype for
separating out metal and nonmetal particles using
Programmable Logic Controller (PLC) for the
domestic and industrial use. In this system the scrap
materials (i.e. metal and nonmetal waste) will be fed
onto the conveyor belt, object sensors will detect the
particles on the conveyor belt and start the rotation
of the conveyor belt. Then, metal sensors which are
clamped to the conveyor belt will sense the metal
waste and stop the conveyor belt. A segregator
attached to the system will push the metal waste into
its respective bin, which will be carried for further
operations and the nonmetal waste are automatically
fed into the waste dust bin.
The objectives are:-
* Designing of the Industrial/Home automation
systems.
* PLC works as the core of the system which
controls the whole setup.
* Controlling robotic arm by using Ladder diagram.
* Sensor is used to detect the presence of the object
on the conveyor belt.
* To take action on input and output as per program,
the logic feed to PLC.
* Inputs suitable for switches and proximity
switches.
* Outputs capable of driving solenoid valves or
indicator lights.
* By producing such system, the scope is in the field
of Manufacturing Industries.
* Interlocks for Safety purpose and for high
production rate.
V. ADVANTAGES
 Increases in production capacity and quality.
 Decreases in total manufacturing cost.
 Less manual work.
 Easy analysis.
 Improves productivity.
 Time saving and efficient
VI. DISADVANTAGES
 Costly for small scale industries.
 Segregation mechanism is time based hence
Frequent monitoring is required.
 PLC devices are proprietary.
VII. CONCLUSION
The soft wiring advantage provided by
programmable controllers is Tremendous. In fact, it
is one of the most important features of PLCs. Soft
wiring makes changes in the control system easy and
cheap. If it want a device in a PLC system to behave
differently or to control a different process element,
all have to do is change the control Program. In a
traditional system, making this type of change would
involve physically changing the wiring between the
devices, a costly and time-consuming endeavor.
REFERENCES
[1] M Nidhi Mishra1, Rakhi T. Waghmare2,
Rani B. Phulpagar3, Pooja A. Londhe4 ,
“Plc Based Scrap Management
System”,Rani B. Phulpagar et al Int.
Journal of Engineering Research and
Applications ISSN : 2248- 9622, Vol. 4,
Issue 3( Version 1), March 2014.
[2] S.M .Dudhal1, B. S. Jonwal2, Prof. H. P.
Chaudhari3, “Waste Segregation Using
Programmable Logic Controller”,
International Journal For Technological
Research In Engineering Volume 1, Issue 8,
April-2014 ISSN.
[3] Joanna Marie M. Baroro, Melchizedek I.
Alipio, Michael Lawrence T.
Huang,Teodoro M. Ricamara, Angelo A.
Beltran Jr..,” Automation of Packaging and
Material HandlingUsing Programmable
Logic Controller”,(ISSN: 2277 –
1581),Volume No. 3, Issue No. 6, pp: 767 –
770. 1 June 2014.
[4] Joice Johny1, Abin Joy2, Della Sunny3,
Basil M Joseph4 & Shaji M Jamal5 ,
“Automatic Plastic Separating Technology
For Solid Waste Disposal”, International
Journal of Civil, Structural, Environmental
and Infrastructure Engineering Research
and Development (IJCSEIERD)ISSN 2249-
6866Vol. 3, Issue 2, Jun 2013, 99-108 ©
TJPRC Pvt. Ltd
[5] John W. Webb, Ronald A. Reis,
“Programmable Logic Controllers:
Principles and Application”, Edition 5th
,
Publisher- Eastern Economy Edition.
[6] Guo, L., Pecen, R., “Design Projects in a
Programmable Logic Controller (PLC)
Course in Electrical Engineering
Technology”, ASEE Annual Conference &
Exposition, 2008.
[7] Prof. Mr. P. Balramdu, Prof. Mr. Manoj
Kumar, Mr. Chape Laxman Murlidhar,
Mr.Wankhade Sachin Sudamrao,
Mr.Phalke Ulhas,Mr.Kotkar Narhari
Ramkrushna, “ Remote Monitoring and
Sorting System for Waste Material

Management Using RFID”,International
Journal of Advanced Research in Computer
Engineering & Technology (IJARCET)
Volume 3 Issue 10, October 2014.
[8] Subhasini Dwivedi, Michael Fernandes,
Rohit D’souza, “A Review on PLC based
Automatic Waste Segregator”, International
Journal of Advanced Research in Computer
Engineering & Technology (IJARCET)
Volume 5 Issue 2, February 2016.
Books:
[1]. W. Bolton, Programmable Logic
Controllers, (Fifth Edition, Newnes, 2009
ISBN 978-1- 85617-751-1, Chapter 1)
[2]. Johnson, C. D., Process Control
Instrumentation Technology, (Prentice
Hall, 2006).
[3]. Petruzella, F. D., Programmable Logic
Controllers, (McGraw Hill, 2005).

PLC based Segregation of Scrap Material

More Related Content

What's hot (20)

Similar to PLC based Segregation of Scrap Material (20)

Recently uploaded (20)

PLC based Segregation of Scrap Material