B.

Sc project, July 2010

ASSUIT UNIVERSITY
FACULTY OF ENGINEERING
MECHATRONICS AND ROBOTICS DEP.

Design and manufacturing of

HMI & PLC Controlled Conveyor

System for Factory Automation
 Team Work

1. Ahmed Mohamed Ahmed Abo El-Soud.

2. Dalia Mohsen Fayez El Malakh.
3. Roweis El komos Beshoy. 
4. Sarah Alaa El Din Abd-Elhameed.

Supervised By

5. Prof. Dr. / Abo El Makarem A. Khalil.

6. Prof. Dr. / Abo Bakr A. Nasr.
7. Dr. / Amer Abd El Fatah.
8. Dr. / Moumen Taha El Meligy.
Mechatronics Definition
• Many technical process and products in the area of mechanical and electrical
engineering show an increasing integration of machines with electronics and
information proccesing this integration is between the components(hardware) and
the information driven function (software) integration resulting in integration
systems called mechatronic system.
Design procedures for mechatronic system:
 
Project objective:

The weight value of the packaged goods is capture and compared to a reference
value. This enables to check whether all components are complete. It must be
possible to apply the check for completeness of the packaged goods also to other
products with different content without extra work. The packaging system is to be
operated and maintained exclusively via an HMI device.
The main aim of our project:

To apply the mechatronics approach on the project of PLC Controlled Conveyor System for
Factory Automation. The system is considered a good example of mechatronics as we use
combination sciences that we have studying it, like Machine design, engineering control,
Transducer and sensor, Electric circuit, electronic circuit, and plc programming.
In a packaging system, a check for completeness of the packaged goods is required before
delivery. In the course of this quality assurance measure the goods are to be uniquely
identified. This project is suitable for many industrial applications in which cost-effective.
Weight measurements have to be performed with little engineering overhead.
This set is particularly suitable if additionally automated logging functions are required in the
framework of the measurement.
System block diagram
Conveyor System
System description
 
1- Enter the desired weight value on HMI, then press start button,
motor1, motor2 ON.
2- When (S1) ON motor1 OFF, motor2 OFF for 3 secs.
3- When (S2) ON delay 5 secs then motor 1 ON:
- If accepted nothing happen
- If rejected motor 3 ON
4- Start from the beginning again.
Flowchart
System components
1. The system is designed to control crossing an object to the final stage in process. The
system consists of:
2. Conveyer1 (bringing objects from the previous process).
3. Conveyer2 (the main part that the object measured on it).
4. Motors.
5. Load cell to measure the object weight.
6. Approximate sensors.
7. Limit switch.
8. The plant controller (PLC).
9. The HMI (human machine interface).
10. Power supply.
• 1-BELT:

Material: rubber
Thickness: 3 mm
Dimension:
- Belt 1: 200cm*10 cm
- Belt2: 100cm * 10cm
2 -PULLEY:
Material: Aluminum
Dimension:
- Inlet diameter: 5cm
- Outlet diameter: 7cm
-No. of pulleys: 4
3-load cell
The heart of any weighing system is the load cell. Load cells are designed to sense force
or weight.
• TECHNICAL SPECIFICATION:

Measuring ranges 0-60 Kg

sensitivity 2 mv V/V FS

Analog output voltage 0-5 V

Out put current 4-20 mA

4- Photoelectric sensor

A photoelectric sensor is used for detecting the presence of an object in a detection

region, the position of the object, the color of the object….etc .

•We use 2 approximate sensors in our system:

S1: to detect if the object delivered to the next conveyer or not
S2: to detect if the object arrived in front of the rejection hand
5-limit switch:
A mechanical device which, when activated, opens or closes contacts to alter the control
circuit.
We used two limit switches in our project to control rejection mechanism.
6-Motors

Specifications :

Nominal Voltage 22 v
Condition pulled
Weight 588 grams
Power 55 watt
Velocity 110 rpm
7 Bearing:
Type: Ball bearing
Number: we used 8 in our project
Inner diameter: 20 mm
8-rack and penion:
The rejection mechanism
9-Programmable Logic Controller: [PLC]
A programmable logic controller (plc) is especial form of microprocessor based
controller that uses a programmable memory to store instructions and implement
functions such as logic, sequencing, timing, counting and arithmetic in order to control
machines and processes and are designed to be operated by engineers with perhaps a
limited knowledge of computers and computing languages

LS® product called MASTER-K120S

Standard type K7M-DR20U AC220V,
DC24V 12-input/8-relay output
The PLC system
I/O used in system:
10-Analog module
The ADHA Module is an analog to digital – digital to analog module that
connected to the PLC so it can deal with the analog world
Specification:

The ADHA Module is an analog to digital – digital to analog module that

connected to the PLC so it can deal with the analog world.

Input range Dc 0-10 v, dc 0-20mA or

dc 4-20mA

Digital output 12bit (o-4000)

power DC 24v
Analog module with PLC
 11-Human Machine Interface(HMI):
HMI is the system that presents process data to the operator and through which the
human operator controls the process.
Today there exists many Human Machine Interface soft wares that could be used to
monitor, supervise and control process. What we are presenting here is just an overview
of what could be achieved with most of these soft wares.
Main functionality of HMI system
1- Recording and trending of measured process variables. This allows the operator to view time-domain
trajectories of recorded process variables.
 
 
2- Configuration of controller parameters. This allows the operator to modify controller parameters and then
communicate them down to the actual process controller.
 
 
3- Display mimic of the actual process. This allows the operator to see in real-time a schematic
representation of the plant being controlled.
 
Advantages
1-High quality graphics for realistic representations of machinery and processes.
2-Viewing alarms.
3- Communication.
4- Recipe Manager.
5- Simulation.
6- Messaging.
7-Animate equipments and instrument based on operator standards
8- Reduce the cost of hardware.
 
Specifications:
The XGT Panel programming:

• Before talking about The XGT Panel programming you must remember that
control action could not be applied with XGT Panel alone it must be
connected with PLC to apply actions on the process.
• Main role of The XGT Panel is to control and display the process using
graphs and charts and made alarm and messages to the user.
Operation of touch tag:
Lamp tag
Base screen no.1
It is Contains project, university and faculty information when NEXT button
pressed screen no. 2 appears.
Base screen no. 2:
Its contains three touch buttons everyone leads to another screen (screenchange switch)

a) Team work
b) Supervisors
c) Project
Base Screen no.3:
It is contains team work names (from toolbox Text)
 Base Screen 4:
It is contains project supervisors names.
Base Screen no. 5:
• It is contains applied on the process the user is allowed to select only one of
them.
• Screen 5 appears when START button in screen 2 pressed.
Calibration Of Load Cell

WEIGHT VOLT(V) load cell calibration

(g)
0.8
0 0.429 0.7
y = 0.0002x + 0.4303

analog output (v)

0.6

250 0.479 0.5

0.4
0.3
500 0.517 0.2
0.1
0
1000 0.625 0 200 400 600 800 1000 1200 1400 1600
load (gm)
1500 0.703
THANX