BHM4704 INDUSTRIAL AUTOMATION

SEMESTER 1 SESSION 2017/2018

LAB REPORT 3

PROF DR ZAHARI TAHA

MR FAEIZ AZIZI ADNAN

PICK & PLACE AND CONVEYOR BELT SYSTEM

DANIAL HARIS BIN LIMI HAWARI HA15006

MUNIRAH BINTI NAWI HA15013
NOR HANIM SOFIAH BINTI PISHAL HA15017
ALIAA NABILA BINTI ABDUL MUTA’ALI HA15025

Faculty of Manufacturing Engineering

UNIVERSITI MALAYSIA PAHANG

DECEMBER 2017
Table of Contents

1.0 INTRODUCTION.................................................................................................................. 1

2.0 OBJECTIVES....................................................................................................................... 1

3.0 PROCEDURE ...................................................................................................................... 2

4.0 RESULT ............................................................................................................................... 5

5.0 DISCUSSION......................................................................................................................19

6.0 CONCLUSION ....................................................................................................................20

List of Figures

Figure 1 Pick and place system control module ......................................................................... 3

Figure 2 Conveyor belt system control module........................................................................... 3
Figure 3 PLC connections .......................................................................................................... 3
Figure 4 Object1 (outer) and object2 (inner) ............................................................................... 4
Figure 5 P&P circuit 0 to 5 ......................................................................................................... 5
Figure 6 P&P circuit 6 to 10........................................................................................................ 6
Figure 7 P&P circuit 11 to 15...................................................................................................... 7
Figure 8 P&P circuit 16 to 20...................................................................................................... 8
Figure 9 P&P circuit 21 to 25...................................................................................................... 9
Figure 10 P&P circuit 26 to 30...................................................................................................10
Figure 11 P&P circuit 31 to 35...................................................................................................11
Figure 12 P&P circuit 36 to 40...................................................................................................12
Figure 13 P&P circuit 41 to 46...................................................................................................13
Figure 14 P&P circuit 46 to 50...................................................................................................14
Figure 15 P&P circuit 51 to 55...................................................................................................15
Figure 16 P&P circuit 56 to 58...................................................................................................16
Figure 17 Conveyor circuit 0 to 4 ..............................................................................................17
Figure 18 Conveyor circuit 5 to 7 ..............................................................................................18
Figure 19 Broken tube inside connector ....................................................................................19
Figure 20 Broken connector inside cylinder V7 .........................................................................19
Figure 21 The old (left) and new (right) objects .........................................................................20

List of Table

Table 1 Address table ................................................................................................................ 2

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1.0 INTRODUCTION

A programmable logic control (PLC) is an industrial digital computer which has been adapted for
the control of manufacturing processes. PLC can range from small building brick devices with
tens of inputs and outputs, in a housing integral with the processor, to large rack-mounted modular
devices with a count of thousands of I/O.
Pneumatic system is a system that uses compressed air to transmit and control energy. There
are various applications of pneumatic system in the real world. It is widely use due to its high
durability and reliability, simplicity, safety and high adaptability to harsh environment.
In Lab 3 for this course, we are required to apply the simulation for pneumatics with PLC done in
Lab 1 and Lab 2 into an actual mechanism. The mechanism is already set up, however there
were a few parts that needed to be changed as they have come to the end of their lifetime.
From the simulation done in Automation Studio software, the ladder diagrams are then modified
to better suit the actual mechanisms using the CX-Programmer software.

2.0 OBJECTIVES

 To put simulation into real applications

 To apply the ladder diagram system done in Lab 1 and 2 to real systems

 To learn application of ladder diagram in system using CX-Programmer software

 To successfully run a full system using ladder diagram programming

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3.0 PROCEDURE

From the ladder diagrams designed in the two labs before, it is recreated in the CX-Programmer
software and changes were made according to needs of the software. There were some
differences in term of setting up the timer but overall the system is convertible to the new software.

The system consist of a pick and place section and a conveyor belt section. The pick and place
section have 10 pneumatic valves and 23 sensors while the conveyor belt has two sensors and
two pneumatic valves. Pictures of the labelled components are included in the appendices.

The connections are labelled by their addresses accordingly:

Table 1 Address table

Pick and Place Conveyor Belt

Components Address Components Address
V1 100.00 V1 101.02
V2 100.01 V2 101.01
V3 101.01 S1 0.03
V4 100.02 S2 0.04
V5 100.04 SS2 0.01
V6 100.03 SS4 0.02
V7 100.05
V8 101.00
V9 100.07
V10 100.06
S1 0.03
S2 0.08
S3 0.09
SS2 0.04
SS3 1.03
SS4 0.05
SS5 1.00
SS6 1.02
SS10 0.06
SS13 0.10
SS20 0.11

The programming for the two sections are done separately, as the labs before. To transfer the
ladder diagram to system, a computer is connected to the PLC and it is uploaded using a cable
that connects it to the computer. A few test run were done by parts to ensure the smoothness of
the systems.
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As the system has not been used for quite some time, it required some twitching up for the
mechanical parts. Some of the problem that occurs were not of the programming but of the
mechanical components.

Figure 1 Pick and place system control module

Figure 2 Conveyor belt system control module

Figure 3 PLC connections

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The pick and place mechanism carries two object where one of it will be inserted to the other
using the arms. The object is as in Figure 4.

Figure 4 Object1 (outer) and object2 (inner)

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4.0 RESULT
The ladder diagrams from the labs before undergoes a few changes to fit the current
mechanism of the system and are drawn in the CX-Programmer are as follows. Included are the
explanation by each circuit (rung).

For pick and place system:

Figure 5 P&P circuit 0 to 5

Circuit 0: When START button is pressed, it energize R1 as long as STOP is open.

Circuit 1: Sensor S1 energize relay R2.
Circuit 2: If arm1 is at initial position when R1 and R2 are energize, cylinder V1 will
operate, pushing object1 to position.
Circuit 3: Sensor SS2 detects extension of V1 and signal cylinder V2, causing movement
of arm1 to left.
Circuit 4: Sensor SS4 open, energizes relay R3 when relay R30 and R31 are closed.
Circuit 5: Relay R3 activates timer1 and timer2.
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Figure 6 P&P circuit 6 to 10

Circuit 6: Cylinder V4 operates by for different set of instructions, lowering the height of
arm1.
Circuit 7: Cylinder V6 operates, enabling gripping of arm1 when timer2 or relay R17 is
open while relay R5, R23 and R31 remains close.
Circuit 8: Timer2 activates timer3.
Circuit 9: Relay R4 is energize when timer3 is open while relay R30 and R31 is close.
Circuit 10: Relay R4 activates timer4.
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Figure 7 P&P circuit 11 to 15

Circuit 11: Cylinder V5 operates when timer4 is open, extending arm1 forward.
Circuit 12: Sensor SS10 will start timer5.
Circuit 13: Relay R5 energizes when timer5 ends.
Circuit 14: R5 starts timer6.
Circuit 15: Relay R6 energizes when timer6 ends.
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Figure 8 P&P circuit 16 to 20

Circuit 16: Relay R6 starts timer7.

Circuit 17: Relay R7 is energized when timer7 ends.
Circuit 18: Relay R8 energizes to an open R7 and S2.
Circuit 19: R8 operates V7 as long as R9 and R31 are closed, pushing object2 into place to
be picked up.
Circuit 20: Sensor SS13 will activated V10, lowering arm2 to pick up object2 from the
pushed position. R12 will also activates V10. As long as relay R10, R14 and R31
are close.
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Figure 9 P&P circuit 21 to 25

Circuit 21: Sensor SS20 energizes R9, while R30 and R31 are closed.
Circuit 22: Relay R9 allow V9 to operate, gripping object2.
Circuit 23: V9 activates timer8.
Circuit 24: Timer8 energizes R10, but R30 and R31 must remain close for this.
Circuit 25: Relay R10 starts timer9
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Figure 10 P&P circuit 26 to 30

Circuit 26: Timer9 energizes relay R11.

Circuit 27: With relay R10 and R11 now energized, V8 operates, moving arm2 horizontally
to the left. R15 and R31 are closed.
Circuit 28: Upon reaching the far left, sensor SS15 detects arm2 and energizes relay R12,
given R30 and R31 are closed.
Circuit 29: Sensor SS20 and with R12 energized, R13 is also energized.
Circuit 30: R13 activates timer10
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Figure 11 P&P circuit 31 to 35

Circuit 31: Timer10 energizes relay R14, given R30 and R31 remains closed.
Circuit 32: Relay R14 activates timer11.
Circuit 33: Timer11 energizes relay R15, given R30 and R31 remain closed.
Circuit 34: Relay R15 activates timer12.
Circuit 35: Timer12 energizes relay R16, given R30 and R31 are closed too.
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Figure 12 P&P circuit 36 to 40

Circuit 36: Sensor SS10 and relay R16 activate timer13.

Circuit 37: Timer13 energizes relay R17.
Circuit 38: Relay R17 activates timer14.
Circuit 39: Timer14 energizes relay R18.
Circuit 40: Relay R18 activates timer15.
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Figure 13 P&P circuit 41 to 46

Circuit 41: Timer15 energizes R19.

Circuit 42: Relay R19 activates timer16.
Circuit 43: Timer16 energizes relay R20.
Circuit 44: Relay R20 activates V3, rotating arm1 90 degrees clockwise, facing the
conveyor belt on its right.
Circuit 45: Sensor SS5 detects changes in the angle of arm1 and energizes relay R21.
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Figure 14 P&P circuit 46 to 50

Circuit 46: Relay R22 is energized.

Circuit 47: Relay R22 starts timer17.
Circuit 48: Relay R23 is energized.
Circuit 49: Relay R23 starts timer18.
Circuit 50: Relay R24 is energized.
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Figure 15 P&P circuit 51 to 55

Circuit 51: Relay R24 starts timer9.

Circuit 52: Relay R25 is energized.
Circuit 53: Relay R25 starts timer20.
Circuit 54: Relay R26 is energized.
Circuit 55: Relay R30 is energized.
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Figure 16 P&P circuit 56 to 58

Circuit 56: Relay R31 energizes, when stop button is pressed.

Circuit 57: Relay R32 is energized.
Circuit 58: Relay R32 starts timer21.
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For conveyor belt system:

Figure 17 Conveyor circuit 0 to 4

Circuit 0: Relay R1 is energized.

Circuit 1: Motor starts.
Circuit 2: Relay R2 energizes, when sensor S1 detects object.
Circuit 3: Relay 2 starts timer0 and timer1.
Circuit 4: Timer1 activates V1 to push the object off the conveyor belt.
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Figure 18 Conveyor circuit 5 to 7

Circuit 5: Relay R3 energizes, when sensor S2 detects object.

Circuit 6: Relay R3 starts timer2 and timer3.
Circuit 7: V2 activated, pushing object off the conveyor belt.
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5.0 DISCUSSION

There are a few differences when it comes to the software used in Lab 1 and 2 compared to Lab
3. It requires changes in the PLC’s ladder diagram. In CX-programmer, we do not have to include
PLC wiring diagram. Only the ladder diagram is needed to be constructed. It is a little simpler as
the wiring is done physically and thus giving us a better understanding with hands on application
of it.

The mechanical parts had consumed some time also as we had to wait for the weekdays to have
some part changed. The tube connected to valve 7 had gone stiff and had the air leaked out
causing the pneumatic cylinder to not extend. The tubing was changed and made more secure.

Figure 19 Broken tube inside connector

Figure 20 Broken connector inside cylinder V7

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The mechanical parts of the pick and place system has gone through quite a lot of twitching to
ensure its functionality. The position of the extension of the first gripper was no longer intersecting
with the second gripper. However we managed to overcome this issue by adding masking tape
at the end of the bar to dampen its arrival. Besides that, the object to be picked also went through
a few changes. The housing metal was replaced by new ones that we had machined in the
machining lab. Its internal diameter is increased to give a bigger tolerance of the inner parts to
drop in, be it metal of rubber.

Figure 21 The old (left) and new (right) objects

6.0 CONCLUSION

The PLC for the system has been successfully programmed. There has been a couple of delays
due to waiting for parts but all in all the program was compiled well. Not all of the sensors within
the mechanisms are programmed with as some movement on the project is set by timer instead
of sensor detection.
The objectives of the lab are achieved. The use of CX-Programmer is a little simpler that
Automation studio from the labs before and having hands on application of the PLC is a great
approach for better understanding.