PICK AND PLACE MECHANISM USING PLC

Submitted in the partial fulfillment of the requirement for the award

DIPLOMA

IN MACHINE TOOL MAINTENANCE AND REPAIRS

SUBMITTED BY:

1. V.GANESAN
2. G.BALAN
3. K.BHARATHI

4. C.ANSAR BASHA
5. K.BALAJI

Under guidance of
Mr.V.K.RAJENDRAN M.E

NOVEMBER 2004
DEPARTMENT OF MACHINE TOOL MAINTENANCE AND REPAIRS.

C.M. KOTHARI TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI 602103

C.M. KOTHARI TECHNOLOGICAL POLYTECHNIC

COLLEGE
CHENNAI- BANGALORE ROAD
SEMBARAMBAKKAM
CHENNAI 602103

BONAFIDE CERTIFICATE

This is to certify that this Project work on

PICK AND PLACE MECHANISM USING PLC

submitted by . Reg. No.

in partial fulfillment for the award of
DIPLOMA IN MACHINE TOOL MAINTENANCE AND REPAIRS
This is the bonafide record of work carried out by him under our supervision
during the year 2004-2005
Submitted for the Viva-voce exam held on ..

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. R.J. KUMAR, M.E.F.I.E, M.I.S.T.E for encouragement and
valuable advice.

We are also thankful to Mr. V.K. RAJENDRAN, M.E. for his

guidance and full attention towards the project and kind help in completing
the same.

We also owe our sincere thanks to all staff members of the MTMR
and foundry department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CHAPTER NO.

TITLE

1.

SYNOPSIS

2.

CONSTRUCTION

3.

WORKING PRINCIPLE

4.

INTRODUCTION TO PLC

5.

SOFTWARE DETAILS

6.

LADDER DIAGRAM

7.

PNEUMATIC CIRCUIT DIAGRAM

8.

MECHANICAL ASSEMBLY DIAGRAM

9.

ELECTRICAL WIRING DIAGRAM

10.

COST ESTIMATION

11.

CONCLUSION

12.

BIBILOGRAPHY

PICK AND PLACE MECHANISM USING PLC

SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select this Project work is to acquire practical knowledge in the
field of
We selected PICK AND PLACE MECHANISM USING PLC as
our Project work and we used principles of mechatronics in developing this
Project work. The stepper motor used in this model is being driven using
PLC. PLC is a solid state equipment, designed to perform the function of
Logical decision making in industrial control applications.

This has

motivated us to do the project through PLC.

This mechanism basically consists of two operations:
(a) The rotating arm with vacuum gripper mechanism for pick and
place the object.
(b) The up and down feed control mechanism for transporting the
object from one place to another..
The first operation is performed using stepper motor which rotates for
a specified angle with instantaneous starting and stopping.The vacuum

gripper pick the object by the action of 3/2 solenoid operated directional
control valve which is controlled through the PLC. The second operation is
performed by a 5/2 DCsolenoid valve. The stepper motor and solenoid
valve are controlled through PLC.

CONSTRUCTION DETAILS
This project consists of following four units
1.PLC
2.HORIZONTAL ROTATING ARM
3.UP AND DOWN UNIT
4.GRIPPER

The above units have the following components

1.PLC
2.DOUBLE ACTING CYLINDER
3.SOLENOID OPERATED 5/2 WAY DC VALVE
4. SOLENOID OPERATED 3/2 WAY VALVE
5.FLOW CONTROL VALVE
6.VACCUM GRIPPER
7.NOVOPAN BOARD
8.STEPPER MOTOR
9.SWITCH BOARD

1.PLC
Here keyencee PLC is used to control all the mechanism .It has 10 inputs
and 6 outputs. The operating voltage of the PLC is 24V DC.Switches and
sensors are connected to the input of the PLC and the stepper motor,
solenoid valves are connected to the output of the PLC.

HORIZONTAL ROTATING ARM;

The rotating arm is screwed to the aluminium bush which is mounted on the
stepper motor shaft as shown in figure. One end of the arm carries the
vacuum gripper and the other end carries a piece of magnet.The stepper
motor can be lifted up and down by the action of double acting cylinder

UP AND DOWN FEEDING UNIT;

In this unit the stepper motor is mounted on a rod end of the double acting
cylinder. Double acting cylinder is actuated by the 5/2 way directional
control solenoid valve which is mounted on a Novopan board. When the
solenoid valve is ON, the stepper motor will be lifted up by the movement
of piston rod in the double acting cylinder. The arrangement of up and down
Feeding unit is shown in figure.

GRIPPER;
GRIPPER is used to grip the job with the the suction pad and the job is
placed under the suction pad at the loading station. Gripper is fitted to the
rotating arm. This gripper works under the principle of vaccum and is
actuated by the 3/2 way directional control solenoid valve.

WORKING PRICIPLE
PLC controls the stepper motor,5/2 way DC valve and 3/2 DC valve to load
and unload the job.To start the operation, the object is placed under the
gripper and the ON switch is pressed in the switch board.This switch sends
the 24v dc signal to the input of the PLC.PLC gives the output signal as per
the ladder logic program.PLC actuates the 3/2 way directional control
solenoid valve.
This 3/2way solenoid valve actuate the gripper to pick the job .After
picking,the 5/2 way solenoid valve becomes ON.This 5/2 way solenoid
valve directs the air supply to the double acting cylinder which lifts the
rotating arm upwards.

After allowing a time delay of few seconds , the stepper motor rotates with
the gripper arm and stops at the unloading station by the control of magnetic
sensor which is placed at unloading point.When the rotating arm unit
crosses the magnetic sensor, it sends the signal to the PLC. The PLC
switches OFF the stepper motor and actuates the 5/2 way solenoid valve to
move the gripper downward for unloading the job. After

unloading , the

double acting cylinder and the rotating arm unit returns to the original
position.

INTRODUCTION TO PROGRAMMABLE LOGIC

CONTROLLER
It is a Solid state equipment designed to perform the function of
logical decision making industrial control application.
It acts as a total replacement for hard wired relay logic with an
effective reduction in wiring and panel size and of course, with increase in
flexibility and reliability.
It has been experienced that majority of the faults with system using
PLCs are due to external cause like, malfunctioning of field or external
devices such as sensors, limit switches, push button etc.
The KEYENCEE PLC is a unique product by itself offering the most
advance features in compact size. It finds application in areas like small
SMPs, conveyors, Industrial Washing M/c, Welding machine, Screen
Printing Machine, Generator Control, small automation process etc.
Features of KEYENCEE PLC.
Compact
Economical
Easy mountable
Choice of selecting either AC or DC powered PLC
High speed counter input upto 4 KHz.

Pulse catch inputs 500 s or more variety of function blocks and

powerful instruction set.
Availability in 4 modules 8/60, 12/80, and 16/120
Source or sink type inputs
Relay outputs
Sink type DC output

POWER SUPPLY
I
N
P
U
T

PROCESSOR

PROGRAMMING
DEVICE

O
U
T
P
U
T

The block diagram of PLC is shown in fig. The PLC is designed to

replace relays, timers, counters, etc. The necessary voltage and current
requirement for the internal working of the PLC are given by power supply.
The field elements are interfaced to the input or output sections.
Typical input elements are push buttons, limit switches, proximity switches,
relay contacts etc. typical output elements are solenoid valves, relay coils

indicator lights, LED displays etc. These field elements are selected by the
end user.
The necessary power supply the input and output elements provided
externally to the PLC. The power supply for PLC is provided to operate
only the internal electronics and not to power the field elements.

ADVANTAGES OF USING PLC CONVENTIONAL ELECTRICAL RELAY PANELS

1. Maximum Reliability
2. Logic easily changeable
3. Single PLC can be used in multiple application by mere change of
program.
4. Indicator lights provided at the major diagnostic point to simplify
trouble shooting.
5. Powerful software features like timers, counters, table operations etc.
in conjunction with optional display to assist trouble shooting.
6. Availability of unlimited number of NI/NL contracts for input and
output internal logic coils.
7. Very compact and rugged design leading to less down loading time.
8. Easy installation
9. Low Cost

WORKING PRINCIPLE

PLC control the stepper motor,5/2 way DC valve and 3/2 DC valve to load
and unload the job.To start the operation,switch the start button which sends
the 24V supply to the input of the PLC which drives the signal to the 5/2
way solenoid valve This valve actuate the double acting cylinder which
pushes the gripper to downward. After few seconds delay,3/2way solenoid
valve activates and actuate gripper to pic the job .After picking,5/2 way
solenoid valve becomes OFF.

After allowing few seconds delay , the stepper motor moves the feeding unit
through the belt drives up to the unloading station .A magnet is placed at
unloading point in order to stop the stepper motor.

When the feeding unit crosses the magnetic sensor , sends the signal to the
PLC

which switch OFF the stepper motor and activate 5/2 way solenoid

valve to move the gripper downward for unloading job.After

the double acting cylinder and the feeding unit return to home.

unloading ,

ELECTRICAL CIRCUIT FOR INPUT & OUTPUT

I/O circuit configuration
IN
3K 4.3
51

24v DL COM
+

Valves in ( ) used only for terminals connected to relays other than 0000
through 0005.
Input from both NPN [(C+) connected to (OM)]
Output circuit (relay contact)

INTERNAL
CIRCUIT

Power supply for operate relay

24DC Power is internally
supplied

OUT

COM

~
+
-

Applications only to the Kv-80, Kv-40, Kv-24RW, Kv-16Rw, Kv-10Rw.

A separate power supply is required for the load.

ELECTRICAL WIRING DIAGRAM

6/4 6 inputs 4 outputs
+24V
SOLENOID
+
-

KEYENCEE

0004

503

PLC

0003
0002

0001
500
0000
C
ON

O
C
+ 24V

BLOCK DIAGRAM

POSITION
START / STOP

INPUT
POWER SUPPLY
(0 TO 24V)

PLC
OUTPUT

5/2 SOLENOID

3/2
3/2
SOLENOID
STEPPER DC VALVE
MOTOR

VALVE
GRIPPER
COMPRESSED
AIR

FRL

DOUBLE
ACTING
CYLINDER

PNEUMATIC CIRCUIT DIAGRAM FOR

PICK AND PLACE MECHANISM
WITH PLC

COST ESTIMATION

NAME OF THE PARTS

1. Double acting cyclinder
(Festomake )

Cost in Rs
400/-

2. Stepper Motor (6 volt)

400/-

3. Single solenoid 5/2 wayDC Valve

900/-

4. Gripper

550/-

5. Novopan board

200/-

6. single solenoid 3/2 way DC valve

800/-

7. Valve Connectors(10 Nos. x 40.00)

400/-

8. Plastic tube (5 metres) 40/metre

200/-

9. Wires,screws&nuts

50/-

10. Flow control valve

200/-

12. Manual ON/OFF switch

100/-

13. Report

700/-

14. 24v Relay (6 nos)

600/-

TOTAL

CONCLUSION

5500.00

We have made this project entirely different from other projects.

Since concepts involved in our project is entirely different that a single unit
is used to various purposes which is not developed by any of other team
members.
By doing this project we gained the knowledge of PLC programming .
and also how automation can be effectively done with the help of pneumatic
system.
By doing this project work, we understood the working
principle and uses of various sensors, switches, relays etc.
It will be of no doubt that PLC will be an integrated part of any
process in industry in the near future and we developed a through knowledge
in programming of PLC.
Once again we express our sincere thanks to our staff members.

BIBILOGRAPHY
1. Programmable Logic Controller

Messung Manual

2. Programmable Logic controller

Keyence Manual

3. Hydraulic & pneumatics for Power Production -

Harry L Stewart

4. Programmable Logic Controller

Omron Manual