PLC Controlled Electropneumatic Sorting Process
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In this thesis, a design and development, then implementation of an automated sorting system on the FESTO Modular Production System (MPS) platform based on Programmable Logic Controller (PLC) is to addressed. Its primary objective was the implementation of an integrated electropneumatic control system that facilitates sorting the workpieces through the use of PLC programming and sensors and actuators. The coordinated system of three main functional components, the detection subsystem (detection unit and gas capture unit), handling mechanism, and sorting module, under centralized control logic in Beckhoff TwinCAT 3 software based on Structured Text (ST), form the core/administration of the system. Hardware setup was constituted by the use of a Beckhoff C6030 industrial PC in EtherCAT master mode in combination with sensors and actuators via the EK1100 EtherCAT coupler and I/O modules. Specifically, a set of various types of sensors (capacitive and inductive proximity sensors) were used for the detection of the presence, position, and type of objects found at various stages of the process. The PLC processed the input signals from these sensors to control pneumatic actuators to lift, transfer and also position the workpieces for the sorting. The system also included a pneumatic gripper by which the object on the slide could be picked up and placed into one of the defined sorting stations in accordance with control logic. The first part of the control sequence is detecting an object at the input station. When the object is detected, the lifter takes the object and raises it to a pneumatic slide which sends the object under the gripper that is aligned initially at the left side. It is checked if the object is located under the gripper by a sensor. If confirmed, the gripper picks up an object, moves it to the proper sorting place. The sorting station is then preselected according to fixed material criteria, the number of sorted objects in each station is counted by a counter. Once each station gets to a specified, the process stops automatically.