T211-07 CONVEYOR TRANSFER SYSTEM

HUD BIN OMAR 50124209089

FATHI DANIAL BIN SHABARUDDIN 50124209403

Report submitted to fulfill the partial requirement for the Diploma of Engineering Technology in Automated System and Maintenance Universiti Kuala Lumpur Malaysia France Institute July 2011
i

DECLARATION PAGE

We declare that this report is my/our original work and all references have been cited adequately as required by the University.

Date: 11 November 2011

Signature:...... Full Name: Hud Bin Omar ID No: 50124209089

Date: 11NOVEMBER 2011

Signatue: Full Name: Fathi Danial Bin Shabaruddin ID No: 50124209403

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APPROVAL PAGE

We examined this report and verify that it meets the program and Universitys requirement for the Diploma of Engineering in Automated System and Maintenance.

Date: 11 November 2011

Signature: . Supervisor Name: Madame Siti Khadijah Binti Ismail Official Stamp:

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ACKNOWLEDGEMENT

First of all, Alhamdulillah we would like to thank to Allah because give us his strength and health to finish this final year project. Thanks to personal individual that involved directly and indirectly in this project especially to our supervisor, Madam Siti Khadijah binti Ismail and to the other lecturers that give us a guidance and moral support to finish this final year project. Secondly, thank to our family and friend especially to other groups because give us idea and help us to finish this project. They always give us moral support and help when needed and their honest comments or advices our project. Lastly we hope this project can lead us and my friends as a student to enhance our management skills, communication skills and practical skills and excellent student that UniKL MFI has produced. We also hope this project can give us advantages and more experience when we go out for industrial training.

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ABSTRACT

By following project schedule the project is finally complete on this time. The division of work areas also helps the work to be more effective and running smoothly. Students of Automated system and Maintenance Technology 092S1, group final project T21107 invents a study of new system of programming and wiring conveyor system for Final Year Project. The new system for programming and wiring conveyor system has been successfully been demo on 25th November 2011. The progress of project is about 15 weeks. The ideas for creating this project is want to show the conveyor system application in industries in small scale that we can study and learn about the whole system for programming and wiring conveyor system. This design of conveyor system came out after discussion to our project coordinator Mr. Amirsharizam Bin Ismail at the beginning of semester. We are group of 8 started this project and finished it on datelines. The conveyor system use pneumatic air and electrical supply to run the machine. It uses PLC Telemechanique TSX-17 for its controller. In this report we show all the design and implementation phase for this project including diagram, Gantt chart, drawing and program.

TABLE OF CONTENTS

DECLARATION PAGE....................................................................................ii APPROVAL PAGE.........................................................................................iii ABSTRACT...................................................................................................v LIST OF FIGURES.......................................................................................viii CHAPTER 1: INTRODUCTION........................................................................1 1.1 Group Task........................................................................................3 1.2 Objective...........................................................................................4 CHAPTER 2: LITERATURE REVIEW................................................................1 2.1 History of conveyor............................................................................1 A conveyor is a horizontal, inclined, or vertical device for moving or transporting bulk material, packages, or objects in a path predetermined by the design of the device, and having points of loading and discharge, fixed or selective. Conveyors can be either gravity powered or live. .......1 Conveyor Classification............................................................................2 Benefits of Conveyors..............................................................................2 Types of Conveyors.................................................................................3 CHAPTER 3 : METHODOLOGY...................................................................4 3.1 Project Planning and Organization......................................................4 3.1.1 Task Area.....................................................................................5 3.2 Analysis and problem solving.............................................................9 3.2.1 Introduction.................................................................................9 ................................................................................................................. 12 CHAPTER 4: PRODUCT DEVELOPMENT......................................................15 4.1 Programming Part............................................................................15 4.2 Electrical Part...................................................................................20 4.2.1 Wiring System............................................................................20 4.2.2 Input and output wiring..............................................................21 4.2.3 Pneumatic Wiring.......................................................................23 CHAPTER 5: TESTING RESULT....................................................................25 5.1 Introduction.....................................................................................25 5.2 Testing method................................................................................25 5.2.1 Used the Multimeter...........................................................25 vi

5.2.2 Used the Plc Console..................................................................26 5.3 Result..............................................................................................27 CHAPTER 6: CONCLUSION AND RECOMMENDATION..................................34 6.1 Conclusion.......................................................................................34 6.2 Recommendation.............................................................................35 REFERENCES.............................................................................................36 APPENDIX A: PROCESS FLOW CHART FOR PROJECT REGISTRATION...........37 APPENDIX B: PROCESS FLOW CHART FOR IMPLEMENTATION.....................38 APPENDIX C: SAFETY OPERATING PROCEDURE..........................................40

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LIST OF FIGURES

Figure 1: Conveyor system..........................................................................1 Figure 2: Conveyor system..........................................................................2 Figure 3: Conveyor system..........................................................................2 Figure 4: Control panel................................................................................3 Figure 5: WBS 1..........................................................................................4 Figure 6: WBS 2..........................................................................................6 Figure 7: WBS 3..........................................................................................7 Figure 8: Gantt chart...................................................................................8 Figure 9: WBS 4..........................................................................................9 Figure 10: PLC TELEMECHANIQUE TSX-17.................................................20 Figure 11: PLC TELEMECHANIQUE TSX-17.................................................20 Figure 12: Multimeter................................................................................26 Figure 13: Programmable console.............................................................26

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CHAPTER 1: INTRODUCTION

In order to make the better project, many ways were going through the analysis and research from this project. When the analysis were made on the system, the problem will come out which given the difficulty to finalize the task. From the observation and analysis we were going through fix the outcome of the problems by resolving in order to successes full the project task. In this project, there have various of the group were divide into the three mechanical parts and one group concentrate to the electrical and programming part. The base of conveyor group known as Loader conveyor, Stack conveyor, and Unloader conveyor. Loader and Stack conveyor represent by group Mohd Ezzazafran and Mohd Syafiq , Pick and Place conveyor represent by group Muhammad Aqram and Muhammad Bazil , Transfer conveyor represent by group Muhammad Khazin and Muhammad Fadhli and Unloader conveyor represent by group Hud and Fathi Danial. Assuming this project as the big project for UNIKL MFI in AI industry. Figure 4 show about our project. First team, figure 1 is Loader conveyor function to loading the product. Stack conveyor function receive the product from the loader then after enough to five products it will turn the conveyor to 90 degree by pass to the transfer conveyor. Third team, figure 3 is Transfers conveyor by functional to collect and arrange the product and transfer to unloader conveyor. Fourth team, figure 4 is Unloader conveyor as functional to collect and arrange to the magazine.

Figure 1: Conveyor system

Magazine

Unloader conveyor

S1 S S11 0 9 Cylinder C

S 8

Cylinder A

Cylinder B S 1 S 2

Figure 2: Conveyor system 3:

S 4 S 5 S 7

Produc t Loader conveyor

S 3

S 6 Stack conveyor 2

Gree n

Orang e

Red

Conveyor run

Selector switch

Start (auto)

Step by step (manual)

Rese t

Emergency button

Figure 4: Control panel

1.1

Group Task This project we create for make system in our industry more simple and it can save money for maintenance only use small space than other machine in our industry right now. As we know, technologies are very important for human
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life. Knowing important of technologies, many innovation and new ideas were carried out to make any work become easier. The technologies are built for any condition and purpose to support human need.

Our task for this conveyor system is to do programming and wiring for whole of the conveyor that consists of Loader conveyor, Stack conveyor and Unloader conveyor. For this conveyor system, we used PLC model Telemechanique TSX-17. This PLC consists of 20 discrete I/O.

To install the wiring system all the mechanical part must done by other group. If the mechanical part not complete with their task we cant create and design the wiring system. Based on figure 5, this conveyor system control by control panel that consists of lights, emergency button, selector switch to select auto or manual mode, step by step, start and reset. For this conveyor we can choose to operate the conveyor system using auto mode or manual mode. For the manual mode we must pressed the step by step button to

1.2

Objective The aim of this project is to provide the opportunity for us to apply and integrate theoretical knowledge and principles, taught in the course in solving technical problems. It also provides the opportunity for us to demonstrate independence and originality, as well as to plan and organize a project every certain period of time. Throughout this course, we should be able to:

1. To develop programming for conveyor system. 2. To create, design and install wiring system. 3. To install and test run the PLC for the system. 4

Our project is interrelated with other group because without our task that is programming and wiring, the mechanical part cant run as we plan. Our task or project is dependent project because when mechanical group not complete their task that fabricate and assembly the conveyor system, our objective three that is to install and test run the PLC for the system will not achieve.

CHAPTER 2: LITERATURE REVIEW

2.1 History of conveyor A conveyor is a horizontal, inclined, or vertical device for moving or transporting bulk material, packages, or objects in a path predetermined by the design of the device, and having points of loading and discharge, fixed or selective. Conveyors can be either gravity powered or live.

Though it is suggested that ancient civilizations such as the Egyptians used conveyors in major construction projects, the history of the modern conveyor dates back to the late 17th century. These early conveyor systems were typically composed of a belt that traveled over a flat wooden bed. The belt was usually made from leather, canvas or rubber and was used for transporting large bulky items. It wasn't until the end of the Industrial Revolution that conveyors came to be used for a broader range of applications. Hymle Goddard of Logan Company patented the first roller conveyor in 1908. Its initial applications were not very popular, and it wasn't until it was introduced in the automotive industry that it was able to prosper. In 1919, the first powered and free conveyors were introduced into the mass production of automobiles. The conveyor quickly became a popular means of transporting heavy materials within manufacturing facilities.

Powered roller conveyor, courtesy of CICMHE/MHIA Multimedia Bank The application of the conveyor branched out to coal mining in the 1920s, where the technology underwent considerable changes. Conveyor belts were designed made of layers of cotton and rubber coverings. During the manufacturing increase of World War II, manufacturers created synthetic materials to make belting because of the scarcity of natural components. Today's conveyor belting is made from an almost endless list of synthetic polymers and fabrics and can be tailored to any requirements. Possible uses of conveyors have broadened considerably since the early days and they are used in almost any industry where materials have to be handled, stored or dispensed. The longest conveyor belt currently in use operates in the phosphate mines of the Western Sahara and is over 60 miles long.[2] Conveyor Classification Conveyors can be classified using the following criteria: Load: The type of product being handled (unit load or bulk load)

Location: Location of the conveyor (overhead, on-floor or infloor)

Accumulation: Whether or not loads can accumulate on the conveyor

Benefits of Conveyors Conveyors offer a wide range of benefits, many of which are readily apparent. Before the invention and implementation of conveyors, warehouse and factory workers needed to physically travel with an object from place to place. Not only was this cumbersome for the employee, it was inefficient for the company and, essentially, a huge waste of time. The conveyor brings a project
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to the worker, rather than a worker having to travel to a project. Conveyors can be used to transport parts to workers or locations throughout a plant or warehouse and, eventually, to the shipping dock for delivery. Besides the obvious benefits of increased efficiency, conveyors can serve to increase quality control at a manufacturing or storage location. The use of automated production lines allows individual parts to be moved to and from automated machinery, allowing workers who were once designated to transporting parts to perform tasks that cannot as easily be automated, such as quality control or or supervision/management processes. In addition, conveyors can increase the safety of a facility. Specialty conveyors are designed to transport heavy or hazardous products, keeping workers out of harm's way.

Types of Conveyors

Belt conveyor Bucket conveyor Cart-on-track conveyor Chain conveyor Chute conveyor Gravity wheel conveyor Incline conveyor Magnetic belt conveyor Monorail Pneumatic conveyor Power-and-free conveyor

Chain conveyor Chute conveyor

Screw conveyor

Vibrating conveyor

Reciprocating vertical conveyor Roller conveyor Screw conveyor

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Slat conveyor Sortation conveyor Tow conveyor Trolley conveyor Troughed belt conveyor Vertical lift conveyor Vibrating conveyor

CHAPTER 3 : METHODOLOGY

3.1

Project Planning and Organization Organization is so important in order to manage the time and divide the task into a few departments that conduct by the specialist. From the organization created, the projects will more effective manage and manpower know the area of the job that need to be done. The job also easy to be arranged and planning the job time limitation. This project will more efficient with this organization.

Figure 5: WBS 1

3.1.1

Task Area The tasks have been divided into 4 areas which are programming,

purchasing, assembly and wiring and test run. All of these tasks in figure 7 .From this section, the work also divided into a few small sub sections to make it easier to manage and more quickly to settle the job.

Figure 6: WBS 2
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Figure 7: WBS 3

T A SK Sketches and design R o u gh ske tch e s Fre e sk e t ch e s Techn ical design M e ch an ica l P r o gr am m in g Ele ct rical Purchasing Fabricatio n M e ch an ica l T a b le Pro gram m ing Electrical W ir in g A ssem bly and w iring M e ch an ica l Ele ct rical P r o gr am m in g Test run T ro u b le sh o o t in g Presentation D em o stratio n

JU NE 3

J U LY 4 5 6 7 8 9

A U G U ST 10 11

12

13

SE P T EM B ER 14 15 16

17

O CT O B ER 18 19

20

Figure 8: Gantt chart

3.2

Analysis and problem solving 3.2.1 Introduction In order to make the problem solving more efficiently, the analysis can help to reduce time taken to solve any problem arise. Each problem will divide to each group. Each group is responsibility to the problem which had given to them. With this method or way, the task will be easy and any problem can settle with smoothly and effectively. For this programming and wiring conveyor system, the problem solving part has been divided into several areas. The details of problem and how to solve the problem are shown at figure 10.

Figure 9: WBS 4

LIST OF THE HARDWARE OF THE PROJECT

PLC TELEMECHANIQUE TSX-17

20 discrete I/O, 24VDC inputs, relay outputs. AC power supply. This system comprises: a 110/240VAC power supply 1 that provides a 24VDC, 250mA sensor supply output 2. a processor unit with a programming port 3 and a status display 4, 8K bytes of internal RAM program memory, that can be battery backed-up. The battery is located in 5 and has a 1 year service life, a location 6 for a plug-in EEPROM or EPROM memory cartridge for saving user programs, 12 isolated 24VDC inputs 7, 8 relay outputs8 with a front panel status display 9, 2 removable terminal blocks with protected screws &, a ground connector.

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DOUBLE ACTING CYLINDER (SCPD2-L-LS-6-60-M2V-D)

Capacitive proximity sensor (cr18-8dp)

Capacitive Proximity Sensor Supply Voltage Range DC:12V to 24V Frequency Response Max:50Hz Sensing Range Max:8mm Sensor Input:Capacitive Supply Voltage DC, Max:24V

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DC12V Output Power: 3.4 Watt Rated Speed: 56RPM Rated Current: 0.9A Rated Torque: 588mN.m More power compared to SPG30 series

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The CPM1A series micro controllers solve both basic and semi-complex applications. The brick style models include AC inputs/relay outputs, DC inputs/transistor or relay outputs to meet your design requirements. The base I/O for the CPUs ranges from 10, 20, 30, and 40 I/O points with maximum expansion to 100 I/O. Specialized expansion modules include mixed analog I/O, temperature sensor inputs and serial communications

_ _ _ _ _ _

10, 20, 30 and 40 point I/O CPUs Expandable up to 100 I/O points Peripheral communications port built in AC or DC input models Analog expansion modules available Temperature sensor input expansion modules available _ Auxiliary 24 VDC supply (AC type only) _ Relay or Transistor outputs _ UL, CSA, CE approvals

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COSTING BUDGET OF PROJECT

NO 1

ITEM DC GEARED(24V ) DOUBLE ACTING CYLINDER PROXIMITY SENSOR 5/2 WAY VALVE TIMING PULLEY BEARING BELTING ALUMINIUM PROFILE

PRICE (RM) 58

QUANTITY (RM) 1

TOTAL (RM) 58

400

400

3 4 5 6 7 8

300 100 120 10 50 -

1 1 2 4 1 1

300 100 240 40 50 -

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CHAPTER 4: PRODUCT DEVELOPMENT

4.1

Programming Part Programming part is the most important component that gives the support to function some of the automation system. We do the programming using Telemechanique console then we testing using programmable controller testing kit before final transfer to the PLC TSX-17 The first step before we do the programming we came out with the flow chart. We meets lecturer programming fundamental to teach us about the flow chart because our programming so complicated. After we the flow chart, we gave to our supervisor to check. After the flow chart was verify by our supervisor we go to the next step. The next step is we convert the flow chart to the ladder diagram. About a month we to the ladder diagram until the program run. We install the program to the Telemechanique console for the testing and after that, we test run to the programmable controller training kit.

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4.1.1 Flow Chart

START

ALL MOTORS CONVEYOR RUNNING

SENSOR DETECT OBJECT

NO

YES

CYLINDER EJECT OBJECT TO UNLOADER CONVEYOR

END

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4.1.2

Function of the conveyor system To run the operation of the conveyor system, firstly select the selector

switch between manual mode and auto mode. If we selected the auto mode, we must push the start auto the conveyor will energize and either if we selected the manual mode we pushed the step by step button for conveyor energize. The movement of the conveyor system will start with the Loader conveyor that the initial position cylinder A at S1 and the cylinder will extend until the cylinder A reach at S2 to push the matches box every three seconds. The conveyor will move until the matches box reach at counter S3 that it will count until five and the matches box will move to the Stack conveyor. Cylinder B will extend until reach at S5. This cylinder functions to stop the matches box. After five matches box move to the Stack conveyor, the Stack conveyor will turn 90 until S7 detect and the Stack conveyor automatically will changed to the reverse condition. The initial position for Stack Conveyor is in forward condition. After that, the matches box will move to the Unloader conveyor. When all matches box reach at the Unloader conveyor, S8 will detect to count the matches box equal to five. After that, the Stack conveyor will turn back until S6 detect and automatically changed forward condition. Then, the Cylinder B as stopper will retract until reach at S4. Again, the matches box will count by S9. The cylinder C will extend until reach at S11 to pick and place the boxes to the transfer conveyor. After that, the cylinder C will retract until reach S10 . After the boxes pass through of two transfer conveyor, S. will detect the presence of the boxes and giv the signal to the cylinder E to extend push the boxes to unloader conveyor. The the unloader conveyor will moves the boxes to magazine. After that, the cylinder C will retract until reach S10

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4.1.3 Input and output list

Input List ADDRESS I0 I1 I2 I3 I4 I5 I6 I7 Output List ADDRESS O0 O1 O2 SYMBOL EV1 EV2 KA DESCRIPTION Solenoid Valve 1 Solenoid Valve 2 Relay SYMBOL ST1 SP PB1 PB2 PB3 S1 S2 S3 DESCRIPTION Start Button Stop Button Emergency Stop Button Auto/Manual Push Button Step By Step operation Cylinder A extend Cylinder A retract Proximity Sensor

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4.1.2

Grafcet

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4.2

Electrical Part The electrical part is one of the most important components in the conveyor

system. Electrical will give the energy supply for the system to give the movement in that system. Some of the problem on the conveyor system which involved in the electrical part is:4.2.1 Wiring System Some of the problem on the conveyor system, the wiring at the all

station does not systematic. Without the systematic wiring, the entire task will be difficult to do, especially when making the wiring. To solve this problem, the old wires should change to the new ones and labeling do to make sure all task be smoothly.

Figure 10: PLC TELEMECHANIQUE TSX-17

Figure 11: PLC TELEMECHANIQUE TSX17

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4.2.2

Input and output wiring

L 1

L 2

L 3

KA 1

KA 2

EV 1

EV 2

24V

0V

C0 C1 0

C2

C 3

C 4

C5 C C6 C7 C8 5 9

C10

C11

co m

TELEMECHANIQUE TSX-17

24V

0V

1 0

1 1

com

ST 1

SP

Auto/ S1 PB manu al Step by step

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22

4.2.3

Pneumatic Wiring

Loader SCylinderS 1 2

Y1

Y2

RS 1 Star t Sto p

RS 2

Y 1

Y 2

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4.3 PROBLEM STATEMENTS

Bearings Those bearings stuck at pulley plate at first time assembly. Solver Apply some lubricant at bearings and pulley plate Belting Difficult to take measure on length of belt Solver We use a rope to measure the belting of conveyor Magazine Difficult to make the product sliding into the magazine Solver Take many times design the slide of magazine Pusher cylinder Difficult to push the product exactly to the conveyor Solver Make the l-shaped pusher to push the product perfectly and make the pusher stable

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CHAPTER 5: TESTING RESULT

5.1

Introduction This section of the report explains our procedures for testing and results for this

project. Using the following tests we were able to verify our project. 5.2 Testing method We test the project by all the systems. Firstly we test all the pneumatic equipments to make it run smoothly and no any leakage. For wiring we connect all the wiring to take current from plc and test all the input and output at plc. When all the adjustment has been made we test the system by using programmable controller testing kit and give forces to all the output to make sure all the wiring system are perfectly correct. 5.2.1 Used the Multimeter

In order to ensure that we had sufficient voltage flowing from the power supply to the all system, we connected the ammeter and used the voltage on the ammeter to measure the voltage level. The voltage was found to be 24V, which was sufficient for our project. In addition, we were going to verify that the continuity also the ammeter.

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Figure 12: Multimeter 5.2.2 Used the Plc Console In order to used the old programming in the previous PLC, we were connected the console to the programmable controller training kit. After we connect to the programmable controller training kit, we test run the program. After the program and test run was verified, we transfer the program to the PLC Telemechanique TSX-17

Figure 13: Programmable console

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5.3

Result After we do some testing we confirm that all the wiring systems and pneumatic

circuit are correct. By using programmable controller training kit, we test all the output by give them forces to see whether it is function or not.

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CHAPTER 6: CONCLUSION AND RECOMMENDATION

6.1

Conclusion For the conclusion we conclude that building this project we use all the skills

and knowledge that we learn in ASMT. All the subjects like electrical, mechanical and plc programming are used to build this project. For mechanical structure we use a lot of mechanical skills. We measure all the measurement perfectly. For mechanical structure we use a lot of mechanical skills. We measure all the measurement perfectly. We applied the knowledge on designing all the brackets and joins. This process runs by electrical and pneumatic energy as the supply. It controlled by program that we set up in PLC. Besides, it gives us a lot of experience and knowledge about part, mechanism function and tool that used to produce the system. With this experience, we would be able to overcome such as problem and be able to work together as a group member, share everything of the knowledge and skill from the expert. Increase students creativity and also their competency in technology.

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6.2

Recommendation

With refer to the design, research and idea, this project have a potential to market. There is a part need to fabricate, modify and assembly. There is s few suggestions that gain from the experience and idea which can be realized:a) This prototype still needs improvements b) The design can be change for more like safety features c) The material can be upgrade for quality guaranteed d) The mechanical system can be change due to reliability and power waste e) The fabrication can be done better for more accuracy

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REFERENCES

www.telemechanique.com PLC TELEMECHANIQUE TSX-17 manual book

PLC cable and wiring guide book

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APPENDIX A: PROCESS FLOW CHART FOR PROJECT REGISTRATION SEMESTER 4

Start

Week 4-11
Student brainstorm the project and prepare the project proposal

Week 12
Project proposal presentation

No

Project proposal agreed by project supervisor Supervisor given the project title and student had to make the new project proposal on the title

Yes

Week 13
Fill in title form and submit at FYP coordinator

Week 14

FYP coordinator publishes group and title

End

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APPENDIX B: PROCESS FLOW CHART FOR IMPLEMENTATION SEMESTER 5

Start

Meeting with supervisor

Implementation of work and report writing

Presentation & demonstration

Correction + binding and submission of project report

End

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APPENDIX C: SAFETY OPERATING PROCEDURE General Safety Tips

1) fabric shoes, sandals, open-toed shoes, and high-heeled shoes. 2)

Do not wear

Do not wear

loose clothing, loose neckwear or exposed jewelry while operating machine. 3) on shirts should be rolled up above the elbows. 4) place. 5) secure long hair. 6) strong shoes. Training shoes are not suitable. 7) patient, never rush in the workshop. 8) guard when working on a machine. 9) away from moving/rotating machinery. 10) tools carefully, keeping both hands behind the cutting edge. Use hand Keep hands Always use a Always be Wear good Pull back and Always wear Long sleeves

an apron as it will protect your clothes and whole lose clothing such as ties in

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11) damage to machines/equipment as this could cause an accident.

Report any

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