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PLC CONTROLLED CONVEYOR SYSTEM II
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CERTIFICATION OF APPROVAL,PLC CONTROLLED CONVEYOR SYSTEM II. Ahmad Hazwan syahmi Bin Waginoh,A project dissertation submitted to the. Department of Electrical Electronic Engineering,Universiti Teknologi PETRONAS. in partial fulfilment of the requirement for the,Bachelor of Engineering Hons. Electrical Electronic Engineering,Assoc Prof Dr Nordin Saad.
Project Supervisor,UNIVERSITI TEKNOLOGI PETRONAS,TRONOH PERAK. CERTIFICATION OF ORIGINALITY, This is to certify that I am responsible for the work submitted in this project that the. original work is my own except as specified in the references and. acknowledgements and that the original work contained herein have not been. undertaken or done by unspecified sources or persons. Ahmad Hazwan Syahmi Bin Waginoh, Automation Controller in Flexible Manufacturing System FMS plays a significant. role to increase productivity and flexibility in an industry Programmable Logic. Controller PLC is an industrial computer controlled by a program having input and. output unit memory arithmetic logic unit and control unit that is superior to past. relay logic in terms of robustness and flexibility The objective of this project is to. operate FMS using a structured method of programming routine via PLC The. project is to provide appropriate programming routine for the integration of. Automation Laboratory in Block 22 Universiti Teknologi PETRONAS which is. combination of 3 systems vision system conveyor system and robotic system. Currently the laboratory is not in use and its function is limited only for. demonstration purposes This makes it difficult for Research Development R D. work to be conducted Scope of study for this project is more on the familiarization. of the FMS using the software and hardware approach The Automation Studio is. used to create design and simulate the conveyor systems The sequence of the whole. process need to be understood prior to work on the programming routine For the. hardware the FMS system in the laboratory is divided into 3 sub categories which. are Omron Vision Sensor Conveyor Systems and KUKA Robotic Arm KR 15. System Methodology used in this project is on study to get overview of FMS. system learning on the software Automation studio and training by the vendor on the. PLC Siemens S7 200 before interfacing the designed programming routine to the. PLC Besides that understanding the configuration of the hardware in the. laboratories such as I O of PLC timer sensor at the conveyor can help designing the. programming routine The objective of this project to develop new programming. routine has been achieved Besides that planning to integrate with all the systems. which are vision system conveyor system and also robotic system has been. ACKNOWLEDGEMENTS,Name of Allah Most Gracious Most Merciful. First of all author would like to express a gratitude to God almighty for all His. blessing in everything author has accomplished completing this project The author. also would like to thank Assoc Prof Dr Nordin Saad the author s supervisor for all. his guidance and moral support given to author Not to forget the author would like. to thank Mr Azhar the laboratories technologies that really co operated well with. author in understanding the existing Flexible Manufacturing System in Universiti. Teknologi PETRONAS, A Special thanks to author s friends especially Adrien Muhammad Bin and Lim Chin.
Yong for giving full support to finish the project given since early stage of the. project Last but not least my deepest gratitude goes to my beloved mother and siblings. Mrs Noor Hayati Bte Yacob Noor Hazwani Bte Waginoh and Nurul Zawanah Bte. Waginoh for their endless love prayers and encouragement author greatest gratitude. goes to those who have assisted his directly or indirectly starting from the beginning. of the project All the cooperation is highly appreciated and only God can repay the. CHAPTER 1 1,INTRODUCTION 1,1 1 Background Study 1,1 2 Problem Statement 3. 1 3 Objectives and Scope of Study 3,1 4 Significant and Feasibility of the Project 4. CHAPTER 2 5,LITERATURE REVIEW 5,2 1 Flexible Manufacturing Systems 5. 2 1 1 The Definition of FMS 5,2 2 Programmable Logic Controller 6. 2 2 1 Central Processing Unit CPU 7,2 2 2 Memory 8.
2 2 3 Input Modules 8,2 2 4 Output Modules 8,2 3 Programming Language 9. 2 4 Description of the System 10,CHAPTER 3 11,METHODOLOGY 11. 3 1 Introduction 11,3 2 Project Activities 14,3 2 1 Project Activities FYP I 14. 3 2 2 Project Activities of FYP II 16,3 3 Gantt Chart and Milestone 18. 3 4 Key Milestone 18,3 5 Tools Required 19,CHAPTER 4 21.
RESULT AND DISCUSSION 21,4 1 Simulation in Automation Studio 5 0 21. 4 1 1 Description of Sequence 22,4 1 2 Timing Sequence 24. 4 1 3 Boolean Logic Expression 25,4 1 4 Ladder Diagram 27. 4 2 Designing FMS System for Conveyor System II 29. 4 2 1 Layout of Section 3 and 4 30,4 2 2 Description sequence of the system 33. 4 2 3 Timing Diagram 34,4 2 4 Boolean Sequence 36,4 2 5 Ladder Diagram 37.
4 3 Discussion of system 3 and 4 38,CHAPTER 5 41,CONCLUSION AND RECOMMENDATION 41. 5 1 Conclusion 41,5 2 Recommendation 41,REFERENCES 42. APPENDICES 44, 3 3 1 Gantt Chart for Final Year Project I FYP I 45. 3 3 2 Gantt Chart for Final Year Project II FYP II 46. List of Figures, Figure 1 Automation Laboratory Universiti Teknologi PETRONAS 1. Figure 2 Reject Side 2,Figure 3 OMRON Vision Sensor 2.
Figure 4 Lifting Valve and Limit Switch 2,Figure 5 Conveyor Belt System 2. Figure 6 Programmable Logic Controller PLC 7,Figure 7 Rung of the ladder diagram 9. Figure 8 The methodology of the project 13,Figure 9 Project Activities for FYP I 14. Figure 10 Weekly Activities for FYP II 16,Figure 11 Stopper valve 19. Figure 12 Conveyor Belt system 19,Figure 13 Automation Studio 5 0 software 19.
Figure 14 OMRON Limit Switch 20,Figure 15 Stopper valve 20. Figure 16 Robotic Arm System 22,Figure 17 Timing Sequence for Robotic System 24. Figure 18 shows all valves A B and C in Automation Studio 27. Figure 19 Ladder Diagram for Robotic Arm 28,Figure 20 Conveyor in Section 3 30. Figure 21 Conveyor in Section 4 32, Figure 22 Timing Diagram for Both Sections input and output 35. Figure 23 Ladder Diagram for System Conveyor II 38. Figure 24 Conveyor System 3 39,Figure 25 Conveyor system 4 39.
Figure 26 Maximum Pallet that cans Support Conveyor System 4 40. LIST OF TABLES, Table 1 Gantt chart and Key Milestone for FYP I 44. Table 2 Gantt chart and Key Milestone for FYP II 45. Table 3 Table of input of conveyor 3 31,Table 4 Table of Output of conveyor 3 31. Table 5 Table of input of conveyor 4 32,Table 6 Table of Output of conveyor 4 33. LIST OF ABBREVIATIONS,CIM Computer Integrated Manufacturing. FMS Flexible Manufacturing System,FBD Function Block Diagram.
PLC Programmable Logic controller,R D Research Development. ST Structured Text,UTP Universiti Teknologi PETRONAS. INTRODUCTION,1 1 Background Study, Automation is a technology concerned with the application of mechanical. electronic and computer based systems used to operate and control production. systems One of the most important types of automation is flexible automation. Productivity cost quality and utilization are concepts of concern in most industries. Flexible Manufacturing Systems FMS can promote the integration of these. concepts and many more which are important to the manufacturer 1 FMS consists. of a group of processing work stations interconnected by means of an automated. material handling and storage system and controlled by integrated computer control. A study has shown that FMS is used in industries increase from year to year. and because of that Universiti Teknologi PETRONAS Figure 1 setup one. laboratory special to give students exposure to study on FMS system same with. industrial robotic systems which is used in factories. Figure 1 Automation Laboratory Universiti Teknologi. The laboratory consists of material handlings which are OMRON Vision Sensor. System Conveyor System and KUKA robot The integration of these three systems. is essential for the whole systems to be successfully run The FMS system in the. laboratory is based on SIEMENS S7 200 PLC, First system in the laboratory is OMRON Vision Sensor System Figure 2. The function of this system is to check the orientation of the product and coding that. programmed decide to reject or accept the product based on similarities of image. processing in early stage If the object is rejected it will be lifted by pneumatic. handling system and moved to separate section Figure 3. Figure 3 OMRON Vision Figure 2 Reject Side, Meanwhile second system is the Conveyor Belt System Figure 4 which.
also named as Conveyor System II The conveyor system is function to transfer. object from one sub location to another location in the lab such as from vision system. to Kuka robot Along the conveyor system it have 21 different sensors Figure 5. such as lifting sensor limit switch sensor and solenoid operated air valve. Figure 4 Lifting Valve and,Figure 5 Conveyor Belt System. Limit Switch, Lastly third system is KUKA Robotic Arm KR 15 The KUKA system is. independent system which function to load unload product depends on programming. that has been set,1 2 Problem Statement, A current facility in Flexible Manufacturing System FMS laboratory in Universiti. Teknologi PETRONAS usage is only limited for demonstration purpose only FMS. laboratory does not allow any programming routines conducted except using the. vendor made routine So in order to allow making this laboratory can be operate and. demonstrate this project of a PLC controlled conveyor system has been initiated The. study of capability of PLC has to be made to ensure it is working well The. laboratory will be upgraded to enable PLC used as a controller in this laboratory so. that the development of PLC conveyor system installed has better training learning. and teaching approach,1 3 Objectives and Scope of Study. The objectives for this project are, To do a study of Flexible Manufacturing System FMS.
To establish communication link between PLC and conveyor system. To integrate the capability of PLC as a controller in the FMS laboratory in. Universiti Teknologi PETRONAS UTP by developing programming. routine via ladder diagram using structure method, The scope of study start by familiarize with the Flexible Manufacturing System. FMS that to be upgraded in the laboratory to allow modification using PLC. program language The current arrangement of the FMS does not allow any. demonstration in the laboratory Second is to develop routine for controlling FMS via. PLC and to perform the experiments to verify the correctness of the developed. 1 4 Significant and Feasibility of the Project, The notion of the project is to design and developed programming routines for the. FMS system in Automation Laboratory in Block 22 The lab will be used for student. for study research and development for the FMS system in the future Nowadays. fact has been shown that FMS system is widely used using PLC as the main. controller So it is good point of view to expose student with the real technology used. in industries As we know PLC is widely used in industry to control manufacturing. process to increase reliability and flexibility reduce cost and increase. maintainability 3 6, This project can be done within the given two semesters In the end of the project. the programming routine will be successfully implemented PLC in the laboratory. using the structure method such as have the description of the process timing. diagram Boolean logic expression and ladder diagram The planning of doing this. project will be explained in the methodology and milestone that has been planned in. LITERATURE REVIEW,2 1 Flexible Manufacturing Systems. Increasing global competition has made many business leaders and policy. makes turn their attention to such critical issues as productivity and quality. Businesses seek new approaches to production process and manufacturing techniques. and explore new boundaries of technology Buzacott 7 present some important. features of today s manufacturing environment and speculates on their implications. for organizational changes More specifically technologies such as computer. integrated manufacturing CIM robotics and flexible manufacturing systems. FMSs are the focal point of much research and exploration Flexible manufacturing. technologies are a relatively recent addition to the portfolio of automated. manufacturing technologies To achieve strategic competitive benefits of FMSs. which are to improve quality greater flexibility and cost reduction firms must. carefully manage the implementation of these technologies 8. 2 1 1 The Definition of FMS, Despite all of the interest in Flexible Manufacturing Systems FMSs there is.
no uniformly agreed upon definition of the term FMS The main distinguishing. feature of FMS from traditional manufacturing system is the term flexibility 9. still does not have specific meaning One of the most cited definition of FMS is by. Ranky 10 who defines an FMS as a system dealing with high level of distributed. data processing and automated material flow using computer controlled machines. Programmable Logic Controller PLC is an industrial computer controlled by a program having input and output unit memory arithmetic logic unit and control unit that is superior to past relay logic in terms of robustness and flexibility The objective of this project is to operate FMS using a structured method of programming routine via PLC The project is to provide appropriate

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