PSG COLLEGE OF

(Autonomous
and an ISO 9001 certified
TECHNOLOGY
Institution)
COIMBATORE 641
004

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING

BE EEE (SANDWICH)

10 AMPS STAGE ASSEMBLY

SEMI-AUTOMATION MACHINE
Presented
By
YUVASHREE S
DEEPIKA T
MADHAN KUMAR M
12/6/16

Guided By
10E654
11E902
11E905

Mr.A.MAHABOOB SUBAHANI

Assistant Professor

CONTENTS

Introduction

Cam Operated Rotary Switches

Parts

Assembly Process

Stage Assembly

Semi Automation Machine

System Design

Process flow

Block Diagram

Description

Software Details

Ladder diagram

Advantages

Future Enhancement

NTRODUCTION

COMPANY PROFILE
Salzer electronics are the manufacturers o world class cam
operated rotary switches
Its currently worth $ 32 billion and according to industry
estimates it has the potential to reach $150 billion
PRODUCTS
1. DC switches
2. Relays
3. Cam Operated Switces
4. Changeover switches
5. Proximity switches
6. Modular switches
7. Sensors

M OPERATED ROTARY SWITCHES

A cam switch is one that employs the rotation of a cam
shaft to operate a number of switching elements
simultaneously
The main areas of operation are in making , breaking
and isolation of power circuits

CAM switch

PARTS

Knob
Front pad
Stage
Latch

ASSEMBLY PROCESS

TAGE ASSEMBLY

Fixed
contacts

Stage

Stage

EMI AUTOMATION MACHINE

This machine is to assemble selected parts of

10 amps

rotary switches by
semi-automation machine i.e. fixed contacts within stage
It is designed to control the industrial process using PLC to
withstand

in

rough

surface,

handle

high

temperature,

vibration , to reduce man power and increase production rate

A Programmable Logic Controller is a digital computer used
for automation of electromechanical process

YSTEM DESIGN

XISTING METHOD
Contacts are assembled within stages manually
100 stages are assembled in one hour and hence
the production rate is less

ROPOSED METHOD
The project is aimed to control the industrial process using PLC
By using PLC it is possible to add or remove the input and output
modules, which is useful for future enhancement
Targeted for 500 stages to be assembled per hour

PROCESS FLOW
Stage
insertion

Fixed contacts
insertion

Allower

Feeding solenoid

Junction

Pressing solenoid

chamber

BLOCK DIAGRAM

POWER
SUPPLY

Feeder
solenoi
ds

START

Reed switch
1
Reed switch
2
Reed switch
3
Reed switch
4

Programm
able Logic
Controller

Allower
Solenoids

Pressing
Solenoids

LOCK DIAGRAM DESCRIPTION

Input
section
Start complete ON and OFF control
Reed switch1, Reed switch 2, Reed switch3 are used
to sense the
status of feeder 1, feeder 2, feeder
3 solenoids
Input 4 is used to sense the status of
pressing solenoid
Output
section
Feeder solenoids
Pressing solenoids

OFTWARE DETAILS

PLC programs are typically written in a special application on a

personal computer and then downloaded by a direct-connection
cable to the PLC.
IEC 61131-3 currently defines five programming languages for
programmable control systems:
Function block diagram
Ladder diagram
Structured text
Instruction list and sequential function chart

DDER DIAGRAM DESCRIPTION

Rung 1

When the start button is pressed, the contact change its

condition from normally open to normally close
So the current flow will take place on the rung and energize
the output coils (Feeder 1, Feeder 2, Feeder 3) which are
actually solenoids
If we want energize more than one coil(output) in a single
rung, then connect the outputs in parallel form

Rung 2

When the coil feeder 1 is energized, the contact will close

When the sensors sense the coils feeder 1, feeder 2 and
feeder 3 that reaches the maximum position, the contact
read1, read2 and read3 will close then the stage and
Rungfixed
3
contact coil are set.(i.e.,) Gate is open

When the stage coil set, Timer is ON and produce the

delayed output signal according to the preset time period
Here two seconds time delay is given as preset time, so
after two seconds the stage and fixed contact will be reset

Rung 4

When read 1, read 2 and read 3 is ON , and the stage is OFF, the
TIMER2 is ON

When the timer2 produces the delayed signal then the pressing
Rung 5
solenoid will SET

Whenever the pressing solenoid is SET (ON), the contact will

change its condition from normally close to normally open
So that, the coils feeder1, feeder2 and feeder3 will deenergized

Rung 6

When the read 4 is sense pressing solenoid reaches its

maximum level, it will be RESET (OFF)

ADVANTAGES

Withstand in rough surface

Handle high temperature and vibrations

Easy to troubleshoot

Faster response time

Serial communication capability

Less wiring

Easier and faster to make changes

More flexibility

Re-programmable

Add or move the input and output modules

FUTURE ENHANCEMENT

Since the PLC is used as processing unit of the machine, there is a

flexibility to add or remove the input modules as well as output
modules

In future it is possible to remove the existing input/output and

replace by new input/output as per user requirement

THANK YOU