Monday, July 27, 2015

Application Programmable Logic Controller on Conveyor Control System

Background the use of the Conveyor Control System
Manufacturing industry demanded can produce goods (production result) with excellent quality criteria, low cost and fast delivery. The key to successful fulfillment of production with these criteria is the use of appropriate control system. One of the popular control system used is a Programmable Logic Controller which controls automatically conveyor to the process of moving any part of the production process to the next process.
Conveyors are widely used in manufacturing industries as conveyance to transfer of industrial materials in the solid form into the next stage of the production process. Conveyor consists of a round tire which resembles belt works by rotating and driven by a induction motor. Some types of conveyors are widely used in manufacturing industry are Belt Conveyor, Chain Conveyor, Screw Conveyor.
The key to successful manufacturing is the appropriate control systems to produce products with good quality, low cost and quick delivery

Powered roller conveyor
Powered roller conveyor via

How PLC works on a conveyor?
At a manufacturing industry that uses PLC as a control machine works based on input data from sensors mounted on each conveyor point. The data is processed in a computer program within the Central Processing Unit then produces an input as required. Several applications used to determine when a conveyor on the “ON” or “OFF” position and how many the amount of production results that have passed the conveyor.
How PLC works on a conveyor
How PLC works on a conveyor

Other article about conveyor control using PLC
A control device such as PLC is equipped with several internal functions such as timers, counters and shift registers to support the good performance of the machine. This control tool will change the input data and then processing logic based on instructions programmed into memory. The PLC advantage compared to conventional control device is to have an interface that can be connected directly to the actuator or transducer without requiring the relay so that it can produce output more quickly and efficiently.
Several main supporting components in the control system are:
  • Input interface
  • interface output
  • CPU-Central Processing Unit
  • Memory Unit
PLC output signal is produced in accordance with a program created by the user based on the input data analysis.
There are two types of output card, namely:
  • analog output card
  • digital output card
On the conveyor control process, each output cards are distinguished by a specific address. Each of the output data before exit to conveyor machine was processed by a microprocessor according to the address. The more output in the setting requires proper PLC type according to their needs. Results of the data program from the microprocessor will emit an electric signal through the output card that will control the induction motor on the conveyor to perform automatic work such as condition “on”, “off” and count the number of objects passing through the panel timer.
Each PLC also features internal input and output, and a timer that can be created in the configuration on the delay, the delay off, on a timer, off timers and others in accordance with the program. The process of calculating process time on, off and count the number of objects passing, PLC works based by address each of the data recorded in the microprocessor. To produce a reliable control system performance, the PLC is powered by software that is an essential part in the form of ladder diagram and basic instruction diagram which is the core of the programming in the central processing unit.
The essential parts of central processing unit is source code program namely ladder diagram and basic instruction diagram

Conveyor control applications in the manufacturing industry
Almost all manufacturers use the conveyor in the production process. Conveyors are controlled by the PLC is usually connected to the induction motor and the timer at any point you want to control. Several applications of the PLC control system as follows:
  • Electronics manufacturing industry

  • At the electronics manufacturing industry, PLC control system controls the conveyor working to move electronic components mounted in a printed circuit board using the machine SMT (Surface Mounting Technology). Automatic control system is absolutely necessary in order process Printed Circuit Board Assembly is going well to minimize the occurrence of process or component defect. Sensors to record data input PLC program is put on each control point specified.

  • Vehicle assembly manufacturing industry

  • In the vehicle assembly industry, PLC control applications found in many assembly lines for example the distribution of raw materials to be processed by the machine and brought along a conveyor entrance to the next production process into parts assembly.
    Some assembly modeling applications with automated control systems such as below:
    • Model Assembly line to achieve production cost low
    • Assembly line balancing
    Both of the above types of models used by based on the type of product to be produced. Appropriate control process will produce a corresponding output production targets, and reduce risk of product defect.


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