report fyp repaired)

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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

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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 T211-

07 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 25thNovember 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.

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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 ................................................................................. 3CHAPTER 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 ................................................................................ 255.2.1 Used the Multimeter ........................................................... 25

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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 4: Control panel................................................................................3

Figure 5: WBS 1..........................................................................................4

Figure 6: WBS 2..........................................................................................6

Figure 7: WBS 3..........................................................................................7

Figure 8: Gantt chart...................................................................................8Figure 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.

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Figure 1: Conveyor system

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Produc

t

Loaderconveyor Stackconveyor

Unloader

conveyor

Cylinder

A

Cylinder

C

Cylinder

B

S

6

S

2

S

4

S

5

S

3

S11

S

7

S

8

S

9

S

1

S1

0

Magazine

2

Figure 2: Conveyor systemFigure 3: Conveyor system


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Gree

n

Orang

e

Red

Conveyor

run

Selector

switch

Start

(auto)

Step by

step

(manual)

Rese

t

Emergency

button

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

3

Figure 4: Control panel


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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.

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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.

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CHAPTER 2: LITERATURE REVIEW

2.1 History of conveyor

A conveyor is a horizontal, inclined, or vertical device for

moving or transporting bulkmaterial, 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 bulkyitems. 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

conveyorin 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 materialswithin manufacturing facilities.

1
http://www.wikimheda.org/wiki/Bulkhttp://www.wikimheda.org/wiki/Gravity_conveyorhttp://www.wikimheda.org/wiki/Gravity_conveyorhttp://www.wikimheda.org/wiki/Powered_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/Powered_and_free_conveyorhttp://www.wikimheda.org/wiki/Image:Powered_Roller_Conveyor.gifhttp://www.wikimheda.org/wiki/Bulkhttp://www.wikimheda.org/wiki/Gravity_conveyorhttp://www.wikimheda.org/wiki/Gravity_conveyorhttp://www.wikimheda.org/wiki/Powered_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/Powered_and_free_conveyor


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Powered roller conveyor, courtesy ofCICMHE/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 usedin 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 in-

floor)

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

2
http://www.cirrelt.ca/mhmultimediabankhttp://ezinearticles.com/?History-of-Conveyor-Belts&id=353910http://www.wikimheda.org/wiki/Unit_load_conveyorhttp://www.wikimheda.org/wiki/Overhead_conveyorhttp://www.wikimheda.org/wiki/Accumulation_conveyorhttp://www.wikimheda.org/wiki/Warehousehttp://www.cirrelt.ca/mhmultimediabankhttp://ezinearticles.com/?History-of-Conveyor-Belts&id=353910http://www.wikimheda.org/wiki/Unit_load_conveyorhttp://www.wikimheda.org/wiki/Overhead_conveyorhttp://www.wikimheda.org/wiki/Accumulation_conveyorhttp://www.wikimheda.org/wiki/Warehouse


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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 locationsthroughout 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 qualitycontrol 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

Reciprocating vertical conveyor

Roller conveyor

Screw conveyor

3

Chain conveyor Chute conveyor

Screw

conveyor Vibrating

conveyor
http://www.wikimheda.org/wiki/Dockhttp://www.wikimheda.org/wiki/Quality_controlhttp://www.wikimheda.org/wiki/Storagehttp://www.wikimheda.org/wiki/Belt_conveyorhttp://www.wikimheda.org/wiki/Bucket_conveyorhttp://www.wikimheda.org/wiki/Cart-on-track_conveyorhttp://www.wikimheda.org/wiki/Chain_conveyorhttp://www.wikimheda.org/wiki/Chute_conveyorhttp://www.wikimheda.org/wiki/Gravity_wheel_conveyorhttp://www.wikimheda.org/wiki/Incline_conveyorhttp://www.wikimheda.org/wiki/Magnetic_belt_conveyorhttp://www.wikimheda.org/wiki/Monorailhttp://www.wikimheda.org/wiki/Pneumatic_conveyorhttp://www.wikimheda.org/wiki/Power-and-free_conveyorhttp://www.wikimheda.org/wiki/Reciprocating_vertical_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/Screw_conveyorhttp://www.wikimheda.org/wiki/Chain_conveyorhttp://www.wikimheda.org/wiki/Chute_conveyorhttp://www.wikimheda.org/wiki/Screw_conveyorhttp://www.wikimheda.org/wiki/Screw_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Image:Vibrating_Conveyor.gifhttp://www.wikimheda.org/wiki/Image:Screw_Conveyor.gifhttp://www.wikimheda.org/wiki/Image:Chute_Conveyor.gifhttp://www.wikimheda.org/wiki/Image:Chain_Conveyor.gifhttp://www.wikimheda.org/wiki/Dockhttp://www.wikimheda.org/wiki/Quality_controlhttp://www.wikimheda.org/wiki/Storagehttp://www.wikimheda.org/wiki/Chain_conveyorhttp://www.wikimheda.org/wiki/Chute_conveyorhttp://www.wikimheda.org/wiki/Screw_conveyorhttp://www.wikimheda.org/wiki/Screw_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Belt_conveyorhttp://www.wikimheda.org/wiki/Bucket_conveyorhttp://www.wikimheda.org/wiki/Cart-on-track_conveyorhttp://www.wikimheda.org/wiki/Chain_conveyorhttp://www.wikimheda.org/wiki/Chute_conveyorhttp://www.wikimheda.org/wiki/Gravity_wheel_conveyorhttp://www.wikimheda.org/wiki/Incline_conveyorhttp://www.wikimheda.org/wiki/Magnetic_belt_conveyorhttp://www.wikimheda.org/wiki/Monorailhttp://www.wikimheda.org/wiki/Pneumatic_conveyorhttp://www.wikimheda.org/wiki/Power-and-free_conveyorhttp://www.wikimheda.org/wiki/Reciprocating_vertical_conveyorhttp://www.wikimheda.org/wiki/Roller_conveyorhttp://www.wikimheda.org/wiki/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.

4

Figure 5: WBS 1
http://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Slat_conveyorhttp://www.wikimheda.org/wiki/Sortation_conveyorhttp://www.wikimheda.org/wiki/Tow_conveyorhttp://www.wikimheda.org/wiki/Trolley_conveyorhttp://www.wikimheda.org/wiki/Troughed_belt_conveyorhttp://www.wikimheda.org/wiki/Vertical_lift_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyorhttp://www.wikimheda.org/wiki/Slat_conveyorhttp://www.wikimheda.org/wiki/Sortation_conveyorhttp://www.wikimheda.org/wiki/Tow_conveyorhttp://www.wikimheda.org/wiki/Trolley_conveyorhttp://www.wikimheda.org/wiki/Troughed_belt_conveyorhttp://www.wikimheda.org/wiki/Vertical_lift_conveyorhttp://www.wikimheda.org/wiki/Vibrating_conveyor


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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.

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6

Figure 6: WBS 2


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Figure 7: WBS 3

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1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

Sketches and de sign

R o u g h s k e t c h e s

F r e e s k e t c h e s

Technical d esign

M e c h a n i c a l

P ro gram m ing

E lec t r i ca l

Purchasing

Fabrication

M e c h a n i c a l

T a b le

Program m ing

Electrical

W ir ing

Assem bly and w iring

M e c h a n i c a l

E lec t r i ca l

P ro gram m ing

Test run

T ro u b le sh o o t in gPresentation

Dem ostration

SE P T EM B ER O CT O B ER

T A SK

J U N E J U LY A U G U ST

8

Figure 8: Gantt chart


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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.

9

Figure 9: WBS 4


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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-complexapplications. The brick style models include AC inputs/relay outputs, DCinputs/transistor or relay outputs to meet your design requirements. The base I/Ofor the CPUs ranges from 10, 20, 30, and 40 I/O points with maximum expansion to100 I/O. Specialized expansion modules include mixed analog I/O, temperaturesensor 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 expansionmodules 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 ITEM PRICE (RM) QUANTITY(RM)

TOTAL (RM)

1 DCGEARED(24V

)

58 1 58

2 DOUBLEACTING

CYLINDER

400 1 400

3 PROXIMITYSENSOR

300 1 300

4 5/2 WAYVALVE

100 1 100

5 TIMINGPULLEY

120 2 240

6 BEARING 10 4 40

7 BELTING 50 1 508 ALUMINIUM

PROFILE- 1 -

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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

NO

YES

16

START

ALL MOTORS

CONVEYOR RUNNING

SENSOR

DETECT

OBJECT

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 themanual 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 SYMBOL DESCRIPTION

I0 ST1 Start Button

I1 SP Stop Button

I2 PB1 Emergency Stop Button

I3 PB2 Auto/Manual Push Button

I4 PB3 Step By Step operation

I5 S1 Cylinder A extend

I6 S2 Cylinder A retract

I7 S3 Proximity Sensor

Output List

ADDRESS SYMBOL DESCRIPTION

O0 EV1 Solenoid Valve 1

O1 EV2 Solenoid Valve 2

O2 KA Relay

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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.

20

Figure 10: PLC TELEMECHANIQUE

TSX-17

Figure 11: PLC TELEMECHANIQUE TSX-

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24VC0

00V C1 C6 C7C2

C

3C8

C

4

C

9

C5

5

co

m

TELEMECHANIQUE TSX-17

C10 C11

L

1

L

2

L

3

KA

1

KA

2

EV

1

EV

2

0V 024V 1 6 72 3 84 95 com1

0

1

1

ST

1SP

PB

Auto/

manu

al

Step

by

step

S1

4.2.2 Input and output wiring

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S

1

S

2

Loader

Cylinder

Y1 Y2

Star

t

Sto

p

RS

1

RS

2

Y

1

Y

2

4.2.3 Pneumatic Wiring

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4.3 PROBLEM STATEMENTS

Bearings

Those bearings stuck at pulley plate at first time assembly.

SolverApply some lubricant at bearings and pulley plate

Belting

Difficult to take measure on length of belt

SolverWe 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

SolverMake 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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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

26

Figure 12: Multimeter

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 wastee) 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

36
http://www.telemechanique.com/http://www.telemechanique.com/


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Student brainstorm the

project and prepare the

project proposal

Start

Project proposal

presentation

Project proposal

agreed by project

supervisor

Supervisor given the project

title and student had to make

the new project proposal on

the title

Fill in title form

and submit at FYP

coordinator

FYP coordinator

publishesgroup andtitle

End

APPENDIX A: PROCESS FLOW CHART FOR PROJECT REGISTRATION

SEMESTER 4

Week 4-11

Week 12

No

Yes

Week 13

Week 14

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Start

Meeting with

supervisor

Implementation ofwork and report

writing

Presentation &

demonstration

Correction + binding and

submission of project

report

End

APPENDIX B: PROCESS FLOW CHART FOR IMPLEMENTATION

SEMESTER 5

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APPENDIX C: SAFETY OPERATING PROCEDURE

General Safety Tips

1) Do not wear

fabric shoes, sandals, open-toed shoes, and high-heeled shoes.

2) Do not wear

loose clothing, loose neckwear or exposed jewelry while operating machine.

3) Long sleeves

on shirts should be rolled up above the elbows.

4) Always wear

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

place.

5) Pull back and

secure long hair.

6) Wear good

strong shoes. Training shoes are not suitable.

7) Always be

patient, never rush in the workshop.

8) Always use a

guard when working on a machine.

9) Keep hands

away from moving/rotating machinery.

10) Use hand

tools carefully, keeping both hands behind the cutting edge.

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11) Report any

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

report fyp repaired)

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