Tracking & Sorting Application.pdf
- 1. Conveyor Applications Automatic sorting machine using conveyor belt on automobile industry Objective: Is to sorting of vehicle engines according to their type moving on the conveyor. Purpose is of intelligent tracking. The engine (for our application we will have 3 different cartons depicting 3 types of engines) is fed on to the conveyor at head pulley. Each engine is having an identification tag, mounted on it. Now the conveyor will start. The objects get identified using RFID system. The unit consists of the conveyor belt which is driven by servo motor, servo drive system. For the pushing and sorting purpose, the pushing mechanisms are mounted on the frame. After sorting, the provision is made for automatic switching off the conveyor belt. The car engines based on size,capacity etc are moving in bulk on the conveyor from one station to other. The RFID Reader (usually short range) is mounted fixed on workstation. The engine carrying tags gets identified by the reader, and the stored information like type, capacity etc. Will be displays on HMI/ PC. At the final stage the counting of objects/engines will be performed by photoelectric sensor, the counting will be displayed on HMI/ SCADA There is a flap at the segregation point, which opens and allows the engine to move to their respective conveyor line for further processing. The system stops automitically with an indication as soon as the counter hits the desired no. of products expected per shift. System can be stopped and also be reset.
- 2. Sn. Inputs to PLC/ Outputs Required Soft Input & Output Hardware Connetced Input Signals to PLC 1. Signal to set the conveyor in run mode - Selector Switch S1 on IN1 2. Write the expected no. of product per shift Soft Keypad 3. Signal to start the conveyor Start Button on HMI PB1 on IN1 4. Engine counting by sensor By sensor Photo Sensor ML100-8-H-350- RT/103/115 5. Engine 1 detected by RFID Identification of Tag 1 RFID Reader- F116 & Tag 6. Engine 2 detected by RFID Identification of Tag 2 RFID Reader- F116 & Tag 7. Engine 3 detected by RFID Identification of Tag 3 RFID Reader- F116 & Tag 8. Signal to stop the conveyor Stop Button on HMI PB2 on IN2 9. Signal to reset the conveyor - Selector Switch S1 on IN1 10. Emergency Stop Emergency Stop Button ES1 on IN1 Output signals from PLC 1. To conveyor motor to start the conveyor Indication for Plant start on HMI L1 on IN1 2. Engine counting on counter Soft Counter on HMI via PLC - 3. Identification & displaying stored information for Engine 1 Displaying stored information of tag 1 on SCADA & HMI - 4. Identification & displaying stored information for Engine 2 Displaying stored information of tag 2 on SCADA & HMI - 5. Identification & displaying stored information for Engine 3 Displaying stored information of tag 3 on SCADA & HMI - 6. Output to flap 1 for segregation of Engine 1 Movement of Object to track 1 to be simulated on SCADA Actuation of Solenoid valve 1 with cylinder 1 7. Output to flap 2 for segregation of Engine 2 Movement of Object to track 2 to be simulated on SCADA Actuation of Solenoid valve 2 with cylinder 2 8. Output to flap 3 for segregation of Engine 3 Movement of Object to track 3 to be simulated on SCADA Actuation of Solenoid valve 3 with cylinder 3
- 3. 9. Alarm on completion of 1 cycle and system should stop automatically Prompt with cycle complete on SCADA Annunciator 10. To conveyor motor to stop the conveyor Stop indication on HMI L2 on IN1 11. To conveyor motor to reset (to move motor to home location) the conveyor Reset indication on HMI L3 on IN2 12. Emergency Stop Prompt for Emergency Revolving Light and Buzzer I/O List SCADA & HMI Simulation SCADA screen to be designed as per the following design Data Loging ● Engine Model no. ● Engine type ● Transmission: Manual/ Automatic ● Engine Power (kW) ● Engine 1: 205 kW ● Engine 2: 250 kW
- 4. ● Engine 3: 120kW ● Engine Capacity ● Manufacturing Date ● Engine Cost ● Cost for Engine 1,20,000 ● Cost for Engine 2,20,000 ● Cost for Engine 2,50,000 Reports ● For number of cycles ● For no. of types of product produced in the cycle ● Total cost calculation based on different types of engine Trends ● No. of types of engine produced vs No. of Cycle ● Cost of different engines vs total produce Security Writing window for tags via SCADA should only be accessible after a password protected security layer. Alarms & Alarm History Safety warning and line slowdown below a decided speed be built in the PLC software and reported to HMI or SCADA Expected Features ● User Administration ● Energy Monitoring Future Add Ons ● Identification based on following different ● Heights ● Sizes ● Vehicle identification, controlling of barrier ● Warehouse applications using RFID (asset tracking) ● Weighbridge application using RFID