PLC, SCADA & PIC Based Adaptable Automated Product Weighing Conveyor System - 5th Year Project

Product weight consistency monitoring conveyor system with SCADA | Tafadzwa Mhambure
FACULTY OF INDUSTRIAL TECHNOLOGY
DEPARTMENT OF ELECTRONICS ENGINEERING
FINAL YEAR PROJECT
PRODUCT WEIGHT CONSITENCY MONITORING

CONVEYOR SYSTEM WITH SCADA
MHAMBURE TAFADZWA – N*******
Submitted in partial fulfilment of the requirements of the Bachelor

of Engineering Honours Degree in Electronics
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PRODUCT WEIGHT CONSISTENCY MONITORING

CONVEYOR SYSTEM WITH SCADA
By
Mhambure Tafadzwa
Dr. B Mtunzi
Department of Electronic Engineering
Faculty of Industrial Technology
National University of Science and Technology
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DEDICATION
This report is dedicated to the author’s parents, brothers and fellow colleagues who always
encouraged and motivated him to keep soldiering on in pursuit of his dream to be a proficient
professional Electronics & Control Engineer and a successful entrepreneur.
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ACKNOWLEDGMENTS
The author gives utmost thanks to Almighty God for His presence and guidance through his
entire life; His mercy endures forever. Special thanks to the author’s parents and family for all
their financial and moral support. The author would want to recognize the support of his
supervisors Dr. B Mtunzi and Eng. R Gonye, who through thick and thin situations were there
to assist and advise. The author would also like to thank Mutare Bottling Company for the
support and assistance they gave him in procuring some of the material and components used
for this design project. The author would also want to salute the immense help that he received
from his friends just to name a few; T. Mangena and P. Chiwundo. Special mention to all
NUST 2014 - 2015 Part V Electronic Engineering students and members of staff.
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ABSTRACT
This is a complete report on the final year project undertaken by Mhambure Tafadzwa in partial
fulfilment of the requirements of the Bachelor of Engineering Honours Degree in Electronics
at the National University of Science and Technology (NUST).
The project involved the design and submission of a working prototype to illustrate a product
weight consistency monitoring conveyor system with SCADA. This report describes the work
undertaken as well as followed procedures that resulted in the successful completion of the
project.
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DEDICATION........................................................................................................................ iii
ACKNOWLEDGMENTS ...................................................................................................... iv
ABSTRACT .............................................................................................................................. v
CHAPTER 1: INTRODUCTION ........................................................................................... 1
1.0 INTRODUCTION .................................................................................................................. 1
1.1 PROBLEM STATEMENT ........................................................................................................... 3
1.2 AIM ............................................................................................................................................... 3
1.3 OBJECTIVES ............................................................................................................................... 3
1.4 IMPORTANCE OF STUDY ........................................................................................................ 3
1.5 LIMITATIONS OF THE STUDY ................................................................................................ 4
1.6 DEFINITIONS .............................................................................................................................. 4
1.7 ASSUMPTIONS ........................................................................................................................... 4
1.8 JUSTIFICATION ......................................................................................................................... 4
1.9 CHAPTER OVERVIEWS ............................................................................................................ 5
1.10 CONCLUSION ........................................................................................................................... 5
CHAPTER 2: LITERATURE REVIEW .............................................................................. 6
2.0 INTRODUCTION .................................................................................................................. 6
2.1 MASS AND WEIGHT ................................................................................................................. 6
2.1.1 Mass ....................................................................................................................................... 6
2.1.2 Weight .................................................................................................................................... 6
2.2 AUTOMATED WEIGHING TECHNIQUES .............................................................................. 7
2.2.1 Radiation based weighing technology ................................................................................... 7
2.2.2 Gravimetric based weighing technology ................................................................................ 8
2.2.3 Other designs ......................................................................................................................... 8
2.2.4 Quality Assurance .................................................................................................................. 9
2.2.5 Weight and mass sensing transducers .................................................................................... 9
2.2.5.1 Strain gauge .................................................................................................................... 9
2.2.5.2 Load cell........................................................................................................................ 10
2.2.5.3 Resistive Load Cell ....................................................................................................... 11
2.2.5.4 Capacitive Load Cell ..................................................................................................... 11
2.2.5.5 Force sensitive resistors ................................................................................................ 12
2.2.5.6 Flex sensor .................................................................................................................... 12
2.2.6 Weight signal conditioning .................................................................................................. 13
2.2.6.1 Instrumentation Amplifier............................................................................................. 13
2.2.7 PIC Microcontroller ............................................................................................................. 15
2.2.8 Programmable Logic Controller (PLC) ............................................................................... 16
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2.2.8.1 CPU ............................................................................................................................... 17

2.2.8.2 Input modules................................................................................................................ 17
2.2.8.3 Output modules ............................................................................................................. 18
2.2.8.4 Communication in a PLC .............................................................................................. 18
2.2.8.5 PLC operation ............................................................................................................... 18
2.2.9 Motor protection .................................................................................................................. 19
2.2.9.1 Thermal overload protection ......................................................................................... 19
2.3 CONCLUSION ........................................................................................................................... 20
CHAPTER 3: DESIGN ......................................................................................................... 21
3.0 INTRODUCTION ...................................................................................................................... 21
3.1 INTELIGENT WEIGHT INPUT CARD DESIGN .................................................................... 24
3.1.1 Weight detection circuit design............................................................................................ 27
3.1.1.1 INA125P based amplifier circuit design ....................................................................... 28
3.1.1.2 AD623 based amplifier circuit design........................................................................... 30
3.1.1.3 AD620 based amplifier circuit design........................................................................... 31
3.1.2 Calibration of the load cell ................................................................................................... 34
3.1.3 Analog to digital conversion of the weight signal ............................................................... 37
3.1.4 PLC system and HMI design ............................................................................................... 42
3.1.4.1 S7 200 PLC system ....................................................................................................... 42
3.1.4.2 Why a PLC? .................................................................................................................. 43
3.1.4.3 Remote I/O .................................................................................................................... 44
3.1.5 PLC setup ............................................................................................................................. 45
3.1.5.1 Connecting the PLC ...................................................................................................... 45
3.1.5.2 Programming the PLC .................................................................................................. 48
3.1.5.3 Motor wiring ................................................................................................................. 48
3.1.5.4 Rejecter arm .................................................................................................................. 49
3.1.5.4 Counting the units ......................................................................................................... 50
3.1.6 SCADA HMI TD 200 design............................................................................................... 51
3.1.6.1 Process tags ................................................................................................................... 53
3.1.6.2 Configuring alarms ....................................................................................................... 54
3.2 METHODOLOGY ..................................................................................................................... 56
3.2.1 Instruments ........................................................................................................................... 57
3.2.2 Data ...................................................................................................................................... 57
3.2.3 Analysis................................................................................................................................ 58
3.2.4 Limitations ........................................................................................................................... 58
3.3 CONCLUSION ........................................................................................................................... 58
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CHAPTER 4: RESULTS AND DISCUSSION ................................................................... 59

4.0 INTRODUCTION ...................................................................................................................... 59
4.1 RESULTS OF PRACTICAL TESTING OF WEIGHING SYSTEM ........................................ 59
4.2 CIRCUIT SIMULATION ........................................................................................................... 60
4.3 PROTOTYPE ............................................................................................................................. 62
4.4 SCADA ....................................................................................................................................... 64
4.5 ANALYSIS OF RESULTS ........................................................................................................ 66
4.6 CONCLUSION ........................................................................................................................... 66
CHAPTER 5: CONCLUSION.............................................................................................. 67
5.0 INTRODUCTION ...................................................................................................................... 67
5.1 SUMMARY OF FINDINGS ...................................................................................................... 67
5.2 POSSIBLE IMPROVEMENTS ON THE DESIGN................................................................... 68
5.3 CHALLENGES ENCOUNTERED ............................................................................................ 69
5.4 SUMMARY OF CONTRIBUTIONS ......................................................................................... 70
5.5 CONCLUSIONS......................................................................................................................... 70
REFERENCES ....................................................................................................................... 71
APPENDIX A: DATASHEETS ............................................................................................ 73
APPENDIX B: PIC 16F877 ASSEMBLY PROGRAM ..................................................... 77
APPENDIX C: PLC STL PROGRAM ................................................................................ 97
APPENDIX D: BUDGET .................................................................................................... 106
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CHAPTER 1: INTRODUCTION
1.0 INTRODUCTION
Almost each and every company especially in the manufacturing industry has a department or
office dedicated specifically to quality assurance or quality management. In the generality of
sense, the way consumers or customers and manufacturers or producers define the term
“quality” is different. Customers define quality based upon the satisfaction derived from
consumption of a commodity or service while manufacturers can index quality by the
timeliness and efficiency of a production run for a particular product or commodity.
In most countries there are statutory requirements that must be fulfilled or complied with by
manufacturers for their products to be regarded as being of acceptable quality. In Zimbabwe,
organizations like the Standards Association of Zimbabwe [17] and The Consumer Council of
Zimbabwe [18] serve to safeguard of many other things, the right of consumers by setting and
enforcing both qualitative and quantitative acceptable measures of “quality” within which any
product sold on the market should lie. The Trade Measures Act Chapter 14:23 22/2001 [19] of
the constitution of Zimbabwe makes it mandatory for any article sold on the market to conform
to the set said mass or weight
Quality Assurance (QA) can thus be defined as the continuous process of ensuring that
produced goods satisfy the customers’ needs and expectations as well as satisfying the legal
and statutory requirements prevailing in the country. For any business to succeed, a balance
should be struck between customer satisfaction and optimization of the production process.
Production losses and wastes (Muda) should be minimized. Many local Zimbabwean
companies as well as many foreign companies are ISO 9001 Certified. This is a recognition of
a company’s conformance to a set of international expected standards of quality. In the food
processing and handling industry, companies also thrive to be FSSC 22001 Certified. This also
is an example of a measure of the degree of quality of a company’s products.
To assess the quality of products or goods produced by a certain manufacturing company

usually the quantitative measure used is either volume or mass while qualitative assessment
involves visual inspection of the packaging or container, labels and closures of packaged
products. Local companies which manufacture petroleum jelly for example Unilever (Pvt) Ltd
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and Tsatsa (Pvt) Ltd are supposed to package their product within a stipulated mass leeway.
Failure to do so is regarded as a non-conformance and selling of non-conforming products is
regarded as a violation of consumer rights which makes the responsible company liable to legal
action [19], [20]. As a result, non-conforming product is usually destroyed or recycled at the
expense of the company resulting in heavy loses.
Companies like Dairyboard Zimbabwe Limited and Dendairy which produce consumable
products like yoghurt and margarine whose quantity is usually expressed in grams must also
conform to packaging requirements. Goods like baked beans and tinned jam are also packed
by mass not volume only.
Due to economic challenges as well as lagging technological and industrial automation

progress in Zimbabwe, most of the surviving companies in the manufacturing industry are still
using outdated, fully manual techniques for ensuring the consistence of the mass of their
products. The commonly used technique in many local companies is periodic random sampling
of the products for manual weighing using mass balances. The production process will be
stopped for the duration of the sampling process.
This project seeks to help address the problem of quality assurance by automatically checking
the weight of each unit as it passes the weighing point on the conveyor belt. This project is to
remove or reject any underweight or overweight units from the main conveyor belt. The design
also consists of SCADA (supervisory control and data acquisition). It is used to monitor and
control the plant or equipment in industries.
This system facilitates the transfer of data between a SCADA Human Machine Interface
(HMI), a remote intelligent analog input weighing module and a PLC. The SCADA system
gathers information back to the central site, then alerts the home station that a rejected has been
detected, or an overload has been detected and the like and then carries out necessary analysis
and control. It consists of:
 One or more field data interface devices for example a PLC which interfaces field
sensing devices (load cell, diffusion sensors) and actuators (motors, solenoids, buzzers)
 A communication system (PPI Master Cable) used to transfer data interface devices
and control units and the SCADA HMI.
 The SCADA HMI called TD 200 device.
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1.1 PROBLEM STATEMENT
It has been observed that in many packaging lines in local Zimbabwean companies, the
products produced have weight or mass discrepancies which compromise the quality of the
companies’ products. This leads to losses in monetary value, time and at times reputation
of the company.
1.2 AIM
To design a cheap weight consistency monitoring conveyor belt system with SCADA.
1.3 OBJECTIVES
 Design an operational intelligent weight sensing circuit

 Display on the LCD whether a unit is a reject or not
 Display on a separate screen the mass of each unit
 Reject detected underweight and overweight units
 Description of the sequence of events occurring in the system
 Produce the PLC ladder or wiring diagram
 Wiring the PLC and field instruments
 Develop a SCADA system which provide electronic data interface with the PLC
 Run the control signals on a model plant
1.4 IMPORTANCE OF STUDY
If the system is implemented in the local manufacturing industry, it can be modified to suit
specific requirements of a particular company resulting in improved productivity,
efficiency and profitability. This falls in-line with the Zimbabwe Agenda for Sustainable
Socio-Economic Transformation (ZIMASSET).
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This increase in productiveness and efficiency of the local manufacturing sector will help
improve the economic sustainability of Zimbabwe.
This project will also stimulate interest in students in the department of Electronics
Engineering at NUST to venture more into the field of industrial automation, process
control and application of Programmable Logic Controllers in process automation with the
aim of process optimisation in mind.
1.5 LIMITATIONS OF THE STUDY
This system is intended for use and application in heavy manufacturing industrial setups
thus components and sensors which are robust and suitable enough for use in such
conditions are necessary if a fully, perfectly functional prototype is to be constructed. The
scope of this project focuses on the automation of the quality control and packaging process
on a packaging or filling line.
1.6 DEFINITIONS
i. PLC – Programmable logic controller

ii. PIC – Programmable interrupt controller
1.7 ASSUMPTIONS
In this design and project it is assumed that the acceleration due to gravity, g, at NUST is
10ms-2. It is also assumed that the terms mass and weight can be used interchangeably in
this document unless specified otherwise.
1.8 JUSTIFICATION
The design is relevant to the course of electronic engineering as it incorporates Process

Control and Industrial Automation. It plays a major role in defining the student as an
Engineer who can apply the knowledge gained from both study and experience gained from
working in the industry during industrial attachment. It shows the ability of the student to
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effectively use and apply available, cheaper resources to design alternative engineering
solutions for the benefit of the society as a whole.
1.9 CHAPTER OVERVIEWS
Chapter two mainly outlines the theory behind the design project. It details both the work
related to the design project that was done before and the relevant literature review
necessary for a complete comprehension of the design project and the rest of this document.
Chapter three gives a detailed chronological description of the steps followed and
experimental procedures performed in order to come up with a properly working design.
Chapter four contains the results obtained from the experiments and simulations performed
during the design stage as well as during the system integration and testing phase. An
analysis and comparison of the results against expected or standard results is done.
Chapter five is the conclusion of the design project. It shows a summary of the findings
made during the course of the project. It also contains the challenges that were met during
the design process and proposed suggestions for future improvements on the system.
1.10 CONCLUSION
The background information to the problem was given in the introductory section. The aim and
objectives of the project have also been outlined. The relevant theoretical and background
information for a full comprehension of the project is detailed out in the next chapter.
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CHAPTER 2: LITERATURE REVIEW
2.0 INTRODUCTION
This chapter outlines the basic underlying relationships between mass and weight. It also
outlines some existing automated weighing techniques that are in use as well the attempts that
were made earlier by other scholars to design gravimetric based weighing systems. The chapter
also explains some fundamentals of quality assurance. The operation of force sensing
transducers, PICs and PLCs is detailed out.
2.1 MASS AND WEIGHT
Mass and weight are two terms which are frequently used interchangeably but are different
strictly speaking in scientific or physics terms.
2.1.1 Mass
It is the quantity of matter in a body regardless of its volume or any forces acting on it. It can
also be defined as a numerical measure of its inertia [1].
M = V * D where M is mass, V is the volume of the body of the object and D is the density.
2.1.2 Weight
On the other hand, weight is defined as the force with which a body is attracted toward the
earth [1].
W = M * g where M is mass of the object and g is the acceleration due to gravity.
In other words, technically speaking mass is a scalar and weight is a vector quantity. To
determine weight, various instruments ranging from fully mechanical, electro-mechanical to
fully electronic instruments have been designed and are in use depending on the requirements
or intended application.
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Electro-mechanical and electronic instruments employ transducers for force measurement.

Various methods which can be broadly classified as being either contact or contactless are used
for determining or inspecting the mass or weight of products on packaging lines worldwide.
Contact weight measuring methods employ transducers which convert force to some
corresponding variable electrical parameter, usually voltage or current. These contact methods
are mainly gravity based. On the other hand, contactless weighing and inspection techniques
employ the use of electromagnetic waves of a suitable wavelength and frequency in
conjunction with some specialised transceivers and algorithms.
2.2 AUTOMATED WEIGHING TECHNIQUES
Various technologies have been used in different parts of the world by different manufacturers and
designers to try and perform real time mass tracking and inspection on packaging line conveyor belts.
The common ones are weight sensing full conveyor belts. However, some weigh-checkers based on
various radiation technologies are now in use. Attempts have also been made to design and construct
single point weighing conveyor systems.
2.2.1 Radiation based weighing technology
This weighing technology uses electromagnetic radiation usually X-rays. The X-ray system
beams X-rays through the body of the substance which is to be inspected [3]. The X-ray system
converts the cross sectional absorption of these rays into a mass proportional signal [3] [4].
Advantages of radiation based weight inspection technologies
 It is faster
 Vibrations do not introduce errors
Disadvantages of radiation based weight inspection technologies
 They face acceptability challenges

 They are presumed to be health hazards because electromagnetic radiation can be very
harmful if prolonged exposure occurs
 The machines tend to be too fragile and not suitable for heavy industrial undertakings
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2.2.2 Gravimetric based weighing technology
This weighing technology mainly uses force sensitive transducers like strain gauges, strain
gauge based load cells and force sensitive resistors to detect the weight of objects. Usually
gravimetric based weighing systems are implemented as stand-alone units like mass balances.
Most weight sensitive conveyor belts in use are usually only capable of sensing weight on the
whole conveyor length.
Advantages of gravimetric based weight inspection technologies
 They are more acceptable to the society

 They are presumed non-health hazard by many people who use
 Full length sensitive conveyors are usefully in heavy industrial and mining setups
Disadvantages of gravimetric based weight inspection technologies
 Vibrations introduce noise where accurate and precise measurements are wanted
 Single point weighing machines need frequent recalibration
 Resistance based weight transducers are prone and susceptible to hysteresis thus they
end up giving false readings
2.2.3 Other designs
Numerous attempts have been made by several hobbyists and scholars to adapt digital or
electronic weighing scales and digital mass balances to perform particular desired additional
functionality. Jorge (2012) did three different projects with different scales. He started out with
the Fagor BB-90, which is a cheap and simple scale with an LCD screen [2]. The goal of his
project was to store the data on an SD card and then further add more advanced features to the
scale. The new features included time and date and multi-user support.
He modified the original scale by removing the original LCD screen and replaced it with
another LCD screen. He also incorporated a microcontroller (LPC2103) which he could easily
control. The microcontroller fetched data from the SD card and did multiple calculations before
outputting it on the LCD screen. Jorge (2012) further improved the scale to give it Bluetooth
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connectivity [2]. The scale communicated with his Android mobile phone via a Bluetooth link.
He used the Android application Smart Weight Chart to show the data as a graph.
His second work was related to his prior work but using a different scale. Thirdly, he
manipulated the Beurer BG 16 scale which measures weight, percentage of fat, percentage of
water, and percentage of muscle (Jorge, 2012b) in beef. He made the same modifications as
with the other scales. Though the scale was very sophisticated, it was however expensive and
not affordable by most people. Of his attempts, Jorge never managed to install the
modifications directly onto any production line.
2.2.4 Quality Assurance
Quality Assurance can thus be defined as the continuous process of ensuring that produced
goods satisfy the customers’ needs and expectations as well as satisfying the legal and statutory
requirements set by the regulatory boards in the country.
Reasons for quality assurance
 Satisfy consumer expectations

 Comply with set standards and requirements
 Reduce losses (production) incurred by the company
 Improve company’s reputation
2.2.5 Weight and mass sensing transducers
There are several transducers that can be used to measure weight or force. These include strain
gauges, load cells and force resistor strips or force resistor pads.
2.2.5.1 Strain gauge
A strain gauge is a sensor which is used for measuring physical quantities like force. The
resistance of a strain gauge varies with the change in applied force. If a stain gauge is bonded
to a solid or surface, this characteristic can be manipulated to measure physical quantities like
acceleration, pressure, tension and force [5].Figure 2.0 shows a strain gauge and the qualitative
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relationship between the various forces that can be applied and the corresponding changes in
resistance that will result.
Figure 2.0 Strain gauge [5]
Four strain gauges can be connected together in a full Wheatstone bridge circuit configuration
to measure resistance as shown in figure 2.1. The voltage measured at the output relates to the
resistance by ohm’s law and will be proportional to the force applied on the strain gauges.
Figure 2.1 Strain gauges in Wheatstone bridge configuration [5]
2.2.5.2 Load cell
A load cell is a transducer that converts a force acting on it into an electrical signal [5]. This
signal is usually referred to as the load. There are various types as well as classification of load
cells. They can be classified as either capacitive, inductive or resistive load cells. Resistive load
cell design and functionality is based on the full bridge strain gauge circuit shown in figure 2.1.
In all load cell types, the electronic signal can either be a current change, frequency change or
more commonly a voltage change depending on the load cell as well as signal conditioning
circuitry used.
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2.2.5.3 Resistive Load Cell
These load cells are usually made using resistive bonded foil strain gauges connected in a
Wheatstone bridge configuration. Generally the strain gauges are built using standard
semiconductor etching techniques and are bonded to some solid surface like an aluminium
cantilever beam also called the spring element or to a diaphragm [6]. The spring element
becomes slightly distorted when a weight or force is applied. The degree of distortion of the
spring is proportional to the applied force, however the relationship between the distortion and
the applied force depends on the properties of the material used to make the spring element or
the cantilever beam.
Figure 2.2 Load cell [6]
The movement of the spring element depicts a general parallelogram configuration indicating
the phenomenon of the Roberval mechanism (typical mechanical movement in beam balances).
The sensitivity of a load cell is usually expressed in mV/V and it is defined as the corresponding
change in output voltage of the load cell in response to the applied force when it is excited by
1V. Physically a load cell has 3 or 4 wires, one for supply voltage (and one for ground) and the
other two for signal.
2.2.5.4 Capacitive Load Cell
Capacitive load cells are built on the principle that capacitance of the dielectric between the
charged plates of a capacitor changes when a force is applied on the plates. The capacitance or
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ability to store charge is proportional to the area between the parallel plates. Capacitive load
cells are usually more sensitive than resistive load cells and are thus applicable in situations
where higher sensitivity is required for example measuring tilt, proximity or fluid quantity [7].
However strain gauge based load cells are the most prevalent ones due to the following reasons
 Highly precise and linear measurements

 Little influence due to temperature changes
 Generally smaller size than other types of load cells
 Excellent fatigue characteristics
 Long operating life due to lack of moving parts or any parts that generate friction
2.2.5.5 Force sensitive resistors
These resistors vary their resistance depending on how much pressure is being applied to the
sensing area. Figure 2.3 shows a typical force sensitive resistor. The resistance is inversely
proportional to the applied force. Usually when no force is applied on the sensing part, the
resistance is in the order of MΩ whereas on full load the resistance can be as low as 2.5kΩ [8].
Force sensitive end
Figure 2.3 Force sensitive resistors [29]
2.2.5.6 Flex sensor
The resistance of a flex sensor changes when it is flexed or bent. As the sensor is flexed or
bent, the resistance across the sensor increases. Figure 2.4 shows a typical flex sensor which
can be used for force measurement.
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Figure 2.4 Flex Sensor [29]
2.2.6 Weight signal conditioning
The output signals from the above weight and force transducers usually need some form of
conditioning for example, the output of a typical load cell is in the range of millivolts (mV)
and it needs amplification to a more suitable range. For the load cell to be able to give
interpretable output to the controller, signal processing is needed. This mainly takes form of
signal amplification and filtering.
2.2.6.1 Instrumentation Amplifier
An instrumentation amplifier is a device that amplifies the difference between two input signal
voltages while rejecting any signals that are common to both inputs. The in-amp is therefore
the benchmark amplifier used for precision signal acquisition. Its symmetrical, high-impedance
inputs extract signals from common-mode errors and noise. Common-mode rejection (CMR),
the property of cancelling out any signals that are common (the same potential on both inputs),
while amplifying any signals that are differential (a potential difference between the inputs), is
the most important function an instrumentation amplifier provides [9].
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Figure 2.5 Three Op-Amp Instrumentation Amplifier [AD8698 Datasheet]
Figure 2.5 shows a three Op-Amp instrumentation amplifier. A typical three Op-Amp
instrumentation amplifier applicable for electronic weigh scales based on load cells is the
AD624 [10]. Amplifiers with bipolar input stages tend to achieve both higher CMR and lower
input offset voltage drift than FET input amplifiers.
Super beta bipolar input stages combine many of the benefits of FET and bipolar processes,
with even lower IB drift than FET devices. Higher gains or lower supply voltages will further
reduce the common-mode voltage range. Monolithic IC instrumentation amplifiers were
developed to satisfy the demand for in-amps that would be easier to apply and use. These
circuits incorporate variations in the 3-op amp and 2-op amp instrumentation amplifier circuits
while providing laser-trimmed resistors and other benefits of monolithic IC technology. In
addition, these components will stay matched over temperature, ensuring excellent
performance over a wide temperature range.
IC technologies such as laser wafer trimming allow monolithic integrated circuits to be tuned
up to very high accuracy and provide low cost, high volume manufacturing. An additional
advantage of monolithic devices is that they are available in very small, very low cost small
packages designed for use in high volume production.
Applications
 Pressure and strain transducers

 Thermocouples and RTDs
 Programmable instrumentation
 Industrial controls
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 Weigh scales
2.2.7 PIC Microcontroller
A microcontroller also known as MCU is a functional computer system on- a-chip usually with
integrated Central Processing Unit (CPU), memory and peripherals with capabilities of input
and output handling. PIC is an acronym for Peripheral Interrupt Controller.
Figure 2.6 Generic Internal Structure of a Microcontroller [10]
Figure 2.6 shows the generalised internal structure of a typical microcontroller. The memory
of microcontroller is a small amount of RAM (Random Access Memory), program memory or
both of them. The program memory might be from the type of field-alterable flash, erasable
read-only memory or electrically erasable read-only memory. At clock speeds of as little as 32
kHz, microcontrollers often operate at very low speed compared to microprocessor, but this is
adequate for typical applications.
Microcontrollers consume relatively little power in the range of milliwatts (mW) or even
microwatts (μW) and generally have the ability to retain functionality while waiting for an
event such as a button press or interrupt. Power consumption while sleeping (CPU clock and
peripherals disabled) may be in the range of nanowatts (nW), making them ideal for low power
or battery powered applications [11]. Microcontroller programs must fit in the available on-
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chip program memory. Compilers and assembly language are used to turn high level language
programs into a compact machine code for storage in the microcontroller’s memory. Some
common characteristics of microcontrollers include:
 Volatile Memory (RAM) for data storage

 ROM, EPROM, EEPROM or Flash memory for program and operating parameters
storage
 Peripherals such as Timers, Event-counters, PWM-generators and Watchdog- timers
 Central processing unit that ranges from small and simple 4-bit processor to complex
32 or 64 bit processors
 Discrete input and output bits, allowing control or detection of the logic state of an
individual package pin
 Serial input/output such as serial ports (USART)
 Clock generator – often an oscillator for a quartz timing crystal, resonator or RC circuit.
 Many include built in analogue-to-digital converters (ADCs)
 In circuit programming and debugging support
2.2.8 Programmable Logic Controller (PLC)
A programmable logic controller (PLC) is a solid state digital industrial computer that employs
integrated circuits instead of electromechanical relays and coils to implement control functions.
PLCs may also be defined as solid state user programmable control systems with functions to
do counting, control logic, arithmetic data manipulation, sequencing, and timing. A generalised
PLC system is shown in figure 2.7.
A PLC generally comprise of the following:
 Central Processing Unit (CPU)

 Memory (RAM)
 I/O cards or modules or cards
 Communication modules or cards
 Power supply
 Programmable panel (HMI)
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2.2.8.1 CPU
This is the brain of the programmable controller. Intelligence of the PLC is derived from the
microprocessor being used which has the tremendous computing and controlling capability.
The Central Processing Unit performs the following tasks:
 Scanning
 Execution of program
 Peripheral and external device communication
 Self-diagnostics
Figure 2.7 Generalised PLC system [13]
2.2.8.2 Input modules
Input modules are interface circuits that provide optical isolation or coupling between the actual
transducers and sensors in a PLC system and the PLC’s CPU. Optical coupling is vital between
the field instruments and the processor so as to prevent electromagnetic interference and radio
frequency interference. The input modules can either be digital (discrete) or analogue
(continuous) and they handle discrete and continuous data respectively. Each input is assigned
a unique address by the processor. Input modules usually have between 6 and 32 outputs on
each card although Siemens have cards with 64 outputs [12] [13].
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2.2.8.3 Output modules
These are used for activating, deactivating or regulating the actuators depending on the result
of program execution by the CPU. Output modules usually have between 6 and 32 outputs on
each card although Siemens have cards with 64 outputs. The outputs, just like the inputs are
optically coupled to the CPU to prevent interference. They control actuators like relays,
solenoid valves, motors, pumps and globe valves [12] [13].
2.2.8.4 Communication in a PLC
Recently designed PLCs are built with the ability to communicate with other PLCs as well as
networking. They can communicate using Ethernet (RJ45), RS232 or RS485 [14]. PLC vendors
like Siemens also have developed specific communication protocols for networking their
equipment. Siemens PLC systems can be networked using technologies like Profinet IO and
Profibus DP (Distributed Peripherals) [13] [14].
2.2.8.5 PLC operation
A PLC executes a fetch – execute cycle just like an ordinary computer. This fetch execute cycle
in programmable logic controllers is referred to as a scan cycle. The number of scan cycles
performed per second depends on the central processing unit’s speed.
In every scan cycle the programmable logic controller checks the status of all inputs on the
input modules connected to the PLC. These inputs will indicate the status of transducers and
sensors in the field.
After checking the status of the inputs, the PLC takes a snapshot of the input status and save it
in process input image file (PII). The programmable logic controller then executes the program
accordingly depending on the condition of the inputs. The results of logic and mathematical
operations performed during the cycle are then saved or sent to the process output image file
(PQI). After updating the PQI the outputs are then updated and the next scan cycle begins
again.
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Figure 2.8 PLC Scan cycle [14]
Figure 2.8 shows a single PLC scan cycle. The PLC continuous performs scan cycles as long
as the CPU is in the run mode. The PLC will constantly, continuously monitor the input signals
from the various sensors and transducers.
2.2.9 Motor protection
The primary objective of overload protection is to protect the motor, the motor controller and
the motor branch circuit conductors against excessive heating due to motor overloads, supply
voltage flactuations resulting in over current being drawn by the motor and failure to start [15].
Mechanical problems like collapsed bearings can also result in motor damage. If such
conditions are allowed to persist for a sufficient length of time, dangerous overheating and
damage may occur. The most common and widely used method for motor protection is thermal
overload protection. However transducers like current loops and torroids can also be used to
monitor the current and voltage supply thus these can also be manipulated to protect the motor
from damage.
2.2.9.1 Thermal overload protection
This device or circuit, called a thermal overload relay is used to protect three phase motors
from overcurrent and single phasing. In any of these cases, the electromechanical relay used in
the device trips and switches off the motor to protect it. An ordinary thermal overload relay
works using the basic operating principle of a bimetallic strip based thermostat.
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Figure 2.8 Thermal overload relay [15]
Thermal overload relays are operated by heat derived from the motor line current and
proportional to the square of that current. The heat generated is used to trip open contacts of a
manual contactor or to open an integral normally closed contact in series with a magnetic
contactor coil. This de-energizes the motor in case of over current or overload. Figure 2.8
illustrates this concept.
In many cases, the cause of an overload relay tripping is a temporary, easily correctable
problem. An under voltage condition or phase loss could cause the overload relay to trip.
Overload protection is intended to deal with current ranging from motor full load current to
locked motor current (10 * full load current) [15].
2.3 CONCLUSION
This design will create a cheap range weight monitoring conveyor system. The system will
employ a load cell for sensing the weight of the different units and it will display the mass of
each unit as it passes the weighing point. It will also allow centralised as well as remote access
and control of the system via the SCADA system. The system will also have motor protection
as well as a degree of self-diagnosis capabilities in case of a breakdown or faulty.
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CHAPTER 3: DESIGN
3.0 INTRODUCTION
This chapter details out the design process that was undergone to come up with a functional
weight monitoring conveyor belt system. The PIC based intelligent controller design was done
first. This included signal processing circuit design, load cell calibration and the PIC assembly
program design. The design of the PLC program, SCADA HMI and prototype then followed
afterwards. The overall functional block diagram of the whole system is shown in figure 3.0.
As shown in the system block diagram in figure 3.0, the load cell and the keypad are connected
to the PIC as input devices while the 16*2 character LCD and 7seg LED display are the outputs
from the PIC.
The PIC and the PLC were interfaced via an opto-coupler. The PIC based portion of the system
is an analog input module for the PLC since it receives analog input signals and process them
to give a digital signal to the PLC. The other inputs to the PLC were retro-reflective photo
sensors and overload relays for motor protection.
An HMI in the form of a TD200 panel was connected to the PLC to implement a SCADA
system for the conveyor belt system.
The system flow chart is shown in figure 3.1.
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SYSTEM BLOCK DIAGRAM
Main conveyor
Power Supply
drive motor
Rejects
Instrumentation
conveyor drive
amplifier
motor
Rejecter arm
Keypad
S7-200
PLC TD200
PIC
Overload relays CPU 212
16F877
Buzzer
Photocell /
Proximity Status
sensor Indicators
Photocell /
16*2 LCD
Proximity
sensor 7 SEG LED
Figure 3.0 System block diagram
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START
Initialization
Is system N
on?
PLC scan cycle

Read input from
load cell
Reject
present?
ADC N
Actuate rejecter
arm
Unit ok?
N
Increment
Y counter 2
Consecutive
rejects?
Increment Send signal to Y N
counter 1 PLC
Alarm and No Operation
Status indicator
Figure 3.1 System flow chart
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3.1 INTELIGENT WEIGHT INPUT CARD DESIGN
This section gives detailed description of the steps and procedures followed, tasks performed,
calculations made and considerations made to come up with a properly working intelligent
weight input card for the Siemens S7 200 / CPU 212 PLC.
Block diagram of the weight input card
16*2 CHAR
LOAD LCD
CELL
ADC MEMORY
PIC TO PLC
COMPARATOR
4*4
TED 7 SEG LED
KEYPAD
Figure 3.2 Block diagram of the intelligent PIC based weighing module / input card
The intelligent module shown in the block diagram in figure 3.2 comprises of two main input
devices namely: capacitive load cell and 4*4 keypad.
The load cell is the force transducer in the system while the keypad is used to input
authentication password into the system.
The 16*2 Liquid Crystal Display mainly serves to relay information to the operator while the
7 segment light emitting diode display mainly serves to display the mass of each unit as it
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passes the weighing point. The transducer electronic datasheet (TED) contains default
calibration data for the load cell and is embedded in the circuit responsible for driving the 7
segment LED display.
Figure3.3 shows a flow chart for the operation of the intelligent weight input card. After a
successful initialisation process, the system reads the input from the load cell. However this
input will comes from the signal conditioning circuitry not directly from the load cell. The
analog signal then undergoes analog to digital conversion as shown on the same flow chat in
figure 3.3.
The intelligent input card’s controller then makes the decision whether the detected mass is
acceptable or not. Depending on whether the mass is okay or not, the controller will display an
appropriate message on the LCD. The actual mass of the unit will be displayed on another
screen. In case of a reject having been detected, a signal is also then sent to the PLC for it to
actuate the rejection.
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START
Initialization
Is system N
on?
Read input from

load cell
ADC
Y Mass = ref N
Mass < ref

Output accept Y
Send signal to
message to LCD PLC
N
Mass > ref Y

Output accept Output reject
message to LCD message to LCD
Display mass on Display mass on

LED screen LED screen
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3.1.1 Weight detection circuit design
A capacitance based load cell was used to detect weight or mass of the different objects or
packages. The output of the load cell was very small, in the range of millivolts. Such
magnitudes of voltages are neither useful in that nature nor are they directly applicable to most
industrial controllers like PLCs and PICs. The nature of the signal obtained from the load cell
made it necessary to employ signal conditioning circuitry to produce a useful signal, useful to
give a reasonably accurate reading of the weight. Figure 3.3 shows a capacitive load cell based
weighing system. The concept in figure 3.3 was used to design the weight detection circuit for
this project.
Figure 3.3 capacitive load cell based weighing system [7]
Reasons for using a capacitance based load cell instead of a resistance based load cell include:
 Capacitive load cell are usually more sensitive, hence more responsive than resistive
load cells
 The resolution of many capacitive load cells is better than resistive load cell
 Due to their higher resolution and better responsiveness, capacitive load cells are more
suitable for measuring smaller masses or forces with better accuracy
 They require very little excitation voltages (many are compatible with as low as 3V)
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There was need to amplify the output signal obtained from the load cell. An instrumentation
amplifier was used to amplify the differential output voltage obtained from the load cell. Three
instrument amplifier designs were done and tested.
3.1.1.1 INA125P based amplifier circuit design
The first instrumentation amplifier used for the designing the amplifier circuit was the
INA125P. Some of the reasons for this choice of amplifier include;
 Easy availability
 INA 125P is laser trimmed for low offset voltage and offset voltage drift
 It has an on-board precision voltage source for bridge (and other transducer)
connections
 Low power consumption (it also has a SLEEP function which temporarily suspends the
amplifier when not in operation)
 High accuracy
 High common mode rejection ratio (100 dB min)
Determining gain resistance of the instrumentation amplifier circuit
60𝑘Ω
𝐺 = 4+ , where G is the gain and Rg is the gain setting resistor,
𝑅𝑔
60𝑘Ω
𝑅𝑔 = , setting gain at 150
150−4
Therefore 𝑅𝑔 = 411 Ω
Therefore, 𝑉𝑜 = (VN +– VN –) G
Setting the gain at 1500,
60𝑘Ω
𝑅𝑔 = ,
1500−1
Therefore Rg = 40.03Ω
The gain was set at 150, then at 1500 to observe the output trend since the magnitude of the
raw output signal from the load cell was ranging from about 1mV as shown in table 3.0 such
that the corresponding output voltage of the instrumentation amplifier will be of a reasonably
measurable magnitude. The sensitivity of the load cell is specified to be 2mV/V.
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The Proteus simulation of the schematic circuit is shown in figure 3.4. The results of the
simulation are shown in table 3.0.
Figure 3.4 Proteus simulation of a load cell output amplifying circuit based on INA125P
The following results were obtained from simulations that were performed using Proteus.
Table 3.0 Results of INA125P based amplifier circuit simulation
Input Voltage/ mV Voltage Gain / mV (150) Voltage Gain / mV (1500)

0 70.0 280
0.5 75.0 745
1.0 150 1458
1.5 225 2250
2.0 301 3000
As shown in table 3.0, when amplified by a smaller gain, G = 150, the output response of the
amplifier circuit was almost linear. When the gain was increased to 1500, the response of the
instrumentation amplifier was observed to maintain the linearity nature. This made the
INA125P a possible choice. However alternative amplifier designs were made to try and design
the best performing circuit.
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3.1.1.2 AD623 based amplifier circuit design
An analog signal processing (amplifying) circuit based on an amplifier AD623 was also
designed to contrast the output of the circuit to that of the circuit based on the instrumentation
amplifier INA125P. The following factors were considered for choosing the AD623
instrumentation amplifier.
 It has rail-to-rail output swing

 Easy gain setting, the gain is set with only one external resistor
 High accuracy dc performance
 Low power consumption (1.5mW at 3V)
 Low voltage offsets
 Absolute gain accuracy
Setting the gain of the amplifier

100𝑘Ω
𝐺 = 1+ , where G is the gain and Rg is the gain setting resistor
𝑅𝑔
100𝑘Ω
150−1
100𝑘Ω
Therefore 𝑉𝑜 = (1 + ) 𝑉𝑖𝑛, where Vo is output voltage and Vin is input voltage
𝑅𝑔
100𝑘Ω
𝑅𝑔 = ,
1500−1
The gain was set at 150, then 1500 because the magnitude of the output signal from the load
cell was very small, ranging from about 1mV which is very small and easily vulnerable to
corruption by noise. The corresponding output voltage of this stage of instrumentation
amplifier was intended to be at least approximately of the magnitude of 100mV. The sensitivity
of the load cell is specified to be 2mV/V.
A Proteus simulation of the designed circuit was done as shown in figure 3.5 to determine the
feasibility of the proposed design. The results of the simulation are shown in table 3.1.
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Figure 3.5 AD623 instrumentation amplifier based sinal conditioning circuit
Table 3.1 Results of AD623 based amplifier circuit simulation

0 77.0 770
0.5 74.3 760
1.0 150 1020
1.5 226 597
2.0 302 462
The output voltages of the amplifier did not show a very linear response as testified by the
results tabulated in table 3.1 thus the amplifier was not chosen for the final design. Another
amplifier circuit based on the AD620 amplifier was then designed and simulated as shown
below to compare the performances.
3.1.1.3 AD620 based amplifier circuit design
A third circuit was designed using an AD620 monolithic instrumentation amplifier. The AD620
has the following strengths and advantages.
 Easy to use
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 Gain is set using one gain setting resistor

 Low noise
 Low power consumption (1.3mA maximum supply current)
 Suitable for weighing scale applications
 Suitable for data acquisition systems
 Applicable in industrial process controls
Setting the gain of the amplifier

49.4𝑘Ω
𝐺 = 1+ , where G is the gain and Rg is the gain setting resistor
𝑅𝑔
49.4𝑘Ω
150−1
49.4𝑘Ω
Therefore 𝑉𝑜 = (1 + ) 𝑉𝑖𝑛, where Vo is output voltage and Vin is input voltage
𝑅𝑔
49.4𝑘Ω
𝑅𝑔 = ,
1500−1
The gain was set at 150, then at 1500 because the magnitude of the output signal from the load
cell was too small, ranging from about 1mV so the corresponding output voltage of the
instrumentation amplifier will be approximately of the magnitude 150mV after amplification
by the gain factor. The sensitivity of the load cell is specified to be 2mV/V.
A Proteus simulation of the designed circuit was done as shown in figure 3.6 to determine the
feasibility of the proposed design. The results of the simulation are shown in table 3.2.
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Figure 3.6 AD620 based signal conditioning circuit
Table 3.2 Results of AD620 based amplifier circuit simulation

0 966 970
0.5 968 1000
1.0 971 1520
1.5 973 2270
2.0 976 3020
From the results tabulated in table 3.2, it was observed that the amplification trend of the
instrumentation amplifier AD620 was not linear in this particular range of voltages. The
manufacturer of the instrumentation amplifier also recommends it for use in “higher resistance
pressure sensors powered at lower voltages”. This disqualified the application of the AD620 in
this final design.
*From the observations made from the three experiments above, the INA125P was proven to
be the most suitable available instrumentation amplifier for the final weight sensing circuit
design.
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3.1.2 Calibration of the load cell
Calibration of the load cell refers to the process of establishing as accurate as possible the
corresponding change of the output signal of the load cell to any change in the weight or force
applied to it. The load cell used in this project was calibrated by following the following steps:
i. The datasheet for the load cell, shown in appendix A was obtained from the internet
and studied
ii. An appropriate power supply (4.5V) was designed using a potential divider circuit and
a 5V supply obtained from the USB port of a computer.
VO R1
Vin
R2
R1
4.5V = R1+R2 * 5V
4.5(R1+R2) = 5R1
0.5R1 = 4.5R2
Therefore, R1 = 9R2
iii. The load cell was properly connected to the power supply and its output terminals, S+
and S- were connected to a digital voltmeter.
iv. Various known weights and standard masses were then put on the load cell and the
corresponding output voltages noted. The results of the calibration process are tabulated
in table 3.3
v. The output signal terminals were then connected to the input terminals of the
instrumentation amplifier circuit and the magnitudes of the corresponding amplified
signals recorded. The results are shown in table 3.4.
The correct procedure for calibrating the load cell was carefully, correctly followed. The load
cell had to be calibrated on-site (NUST) because weight is a force which is directly proportional
to acceleration due to gravity (g), and g varies by geographical location.
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F = m*a, thus when taking a to be acceleration due to gravity and force to be the weight,
W =m*g, however as stated earlier on, in this document, the terms weight and mass are
interchangeable.
Table 3.3 readings obtained during load cell calibration
Standard Weight/g Voltage/mV

0 1
25 1.3
50 1.4
75 1.5
100 1.6
125 1.8
Table 3.3 shows the values that were obtained during the load cell calibration process. The
values were read directly from a multimeter while different standard weights were placed on
the load cell weighing platform. The voltage read across the load cell’s S+ and S- terminals is
differential voltage and is very small, thus need for amplification.
Voltage/mV
2
1.8
1.6
1.4
Voltage/mV
1.2
1
0.8 Voltage/mV
0.6
0.4
0.2
0
0 25 50 75 100 125
Standard Weight/g
Figure 3.7 Load cell calibration curve
Figure 3.7 shows the load cell calibration curve obtained after plotting the voltages the readings
that were recorded in table 3.3.
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The calibration process was repeated but now with the load cell connected to the amplifier
circuit. The readings that were obtained are tabulated in table 3.4.
Table 3.4 readings obtained during load cell calibration
Standard Weight Gain Voltage/mV

0 174
25 195
50 210
75 225
100 240
125 270
Figure 3.8 shows the load cell calibration curve obtained after plotting the amplified output
voltage from the amplifier circuit. The instrumentation amplifier that was used was the
INA125P with a gain of 150. However, when using the INA125P with a single voltage supply
typically +5V, Vin+ and Vin- must both be at least 1V above ground level in order for a stable
differential voltage to be detectable and measurable across the pins. This means that the true
output voltage will be at most 4V.
It is also by manufacturer’s design that when using a single supply voltage, the output voltage
will be at least 1V above the reference voltage.
Gain Voltage/mV
300
250
Gain Voltage/mV
200
150
100 Gain Voltage/mV
50
0
0 25 50 75 100 125
Standard Weight/g
Figure 3.8 load cell calibration with amplifier gain
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Table 3.5 shows both the actual load cell output voltages and the load cell output voltages with
gain (150) against the shown corresponding standard weights.
Table 3.5 load cell output voltages
Standard Weight/g Voltage/mV Gain Voltage/mV

0 1 174
25 1.3 195
50 1.4 210
75 1.5 225
100 1.6 240
125 1.8 270
3.1.3 Analog to digital conversion of the weight signal
The output signal from the signal conditioning (amplifier) circuit is an amplified analog voltage
signal. However, for effective digital control applications the analog signal should be converted
to a digital signal. There are usually two approaches to achieving analog to digital conversion
namely
 Hardwired logic based analog to digital conversion (sigma-delta ADCs)

 Software based analog digital conversion – using software to sample, quantize and
digitize a given analog signal
For this design project, a software based digital converter was designed. The PIC16F877 which
was used for this design project has a built in Analogue to Digital Converter (ADC)
functionality. The built in Analogue to Digital Converter has a resolution of 10 bits. This means
that it samples up to 2^n -1 = 2^10 – 1 = 1023 during conversion of an analog signal. This in
other words imply that for every conversion cycle, the analog, continuous signal is quantized
into 1024 discrete steps or pulses which then give a digital signal.
The higher the resolution of an Analog to Digital Converter, the more accurate the digital
signal becomes. The closer the digital signal is to resembling the continuous signal that gave
rise to it (from which it was formed), the more accurate it is deemed to be.
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The program for performing the analogue to digital conversion of the amplified signal was
developed using the MPLAB IDE v8.56. The snippet of the section of the program performing
the analogue to digital conversion is shown in the window in figure 3.9.
Figure 3.9 Code snippet of assembly language performing ADC of the signal
Pin 3 of the PIC was configured to function as an analog input channel to the PIC. The analogue
signal then is received into special registers, ADCON1 and ADCON2 in the accumulator of
the PIC controller to enable computation of the binary or hexadecimal equivalence of the
analog signal entering pin 3.
After conversion of the weight or mass signal to a digital or binary approximation, the value is
then compared to set reference voltage values programmed into the controller. The reference
voltages were arrived at during the calibration process of the load cell. To calibrate the load
cell, the procedure outlined earlier was followed.
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Two reference voltages, corresponding to the upper and the lower threshold for the mass within
acceptable mass range or tolerance were set. The desired set point was set at 100g for
demonstration purposes. The reference voltages were converted into hexadecimal form and
then used in the program as shown in the code snippet in figure 3.10 below.
Figure 3.10 Code snippet comparing input signal against reference
The result of the analog to digital conversion is stored in a special register in the accumulator
called ADRESL. Care should always be taken to avoid overflowing ADRESL since
overflowing will result in errors in subsequent instructions.
The subroutine “GET_MASS”, compares the value returned by the analogue to digital
converter subroutine “ADC1_CONVERT” with the minimum or lower reference. If it is greater
than the lower reference point, the program then goes on to test if the value is greater than or
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lower than the set upper reference voltage value by executing the subroutine called
“TEST_HIGH”.
If the weight signal is in between the upper and the lower reference voltage, the weighed unit
or object is deemed acceptable. If the weight signal is not between the upper and the lower
reference voltage, the weighed unit or object is categorised as a reject.
When a reject has been detected, pin 23 (PORT C: 4) is set high for 5 seconds. A corresponding,
appropriate message depending on whether or not a reject has been detected is displayed on
the 16*2 LCD.
A signal is then sent to the programmable logic controller’s central processing unit from the
intelligent controller depending on the outcome of the analog to digital conversion process and
the subsequent comparison. However, the output of the PIC is ideally 5V, while practically it
can be as low as 4.3V when set high yet the PLC inputs require 24V signals.
To enable this signal to be translated to the PLC from the PIC, an intermediate opto-coupled
circuit was desired. A solid state relay, Celduc D91A5100 was used as part of the switching
circuit since it employs opto-coupling for switching.
Reasons for using opto-coupling include:
 To kill or attenuate voltage and signal spikes

 To provide a standard voltage signal to the PLC’s central processing unit
 To protect the programmable logic controller’s central processing unit from damage
The schematic circuit of the “intelligent PLC analog controller” is shown in figure 3.11. Figure
3.12 shows a picture of the fabricated motherboard circuit of the analogue weight input card.
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Figure 3.11 Schematic Circuit diagram of the designed controller
Opto-coupled relay
PIC INA125P
Bus to
4*4
Keypad
Bus to 16*2
Char LCD
From load cell
Figure 3.12 Circuit of the analog input module
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The system could allow different set points to be used depending on the password entered. Two
different passwords corresponding to two different mass set points programmed such that one
password will execute the subroutine “GET_MASS” with a different pair of set points from
the other.
This means that the system can be used for checking consistency of the weight of more than
one package size depending on the selection made by the operator.
The correct execution of the program is controlled by the “MAIN” program. The complete
program that was developed for the PIC 16F877 is in Appendix B.
3.1.4 PLC system and HMI design
This section gives a detailed description of the steps and procedures that were followed and
tasks that were performed to come up with a fully, correctly functioning PLC controlled and
monitored conveyor belt system.
3.1.4.1 S7 200 PLC system
The programmable logic controller used for the design project was a Siemens S7 200-CPU
212. The PLC has 7 on-board digital inputs and 5 on-board outputs. The S7 200 combines a
microprocessor, an integrated power supply, input circuits, and output circuits in a compact
housing to create a powerful Micro PLC. A typical S7 200 PLC is shown in figure 3.13.
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Figure 3.13 typical S7200 PLC block diagram [11]
The PLC was programmed using a software called Simatic Step7 Micro/Win. The same
software is also used for monitoring the PLC while it is in the run mode and for simulation,
testing and debugging.
3.1.4.2 Why a PLC?
 It has very fast processing speed

 It allows real-time response
 High data transmission rates of up to187.5kbit/s
 Allows industrial networking with other systems and equipment
 Allows HMI functions
 Can withstand harsh operating conditions like vibrations, dust or moisture typical of
heavy industry
Tasks performed by the PLC in the designed system
The programmable logic controller in this system was programmed to perform several tasks
including the following:
 Switching on and off the main conveyor drive motor

 Switching on and off the rejects conveyor motor
 Electric motor protection from thermal as well mechanical overloads
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 Actuating and controlling the rejecter arm

 Giving appropriate visual indication according to real time conditions prevailing in
the system
 System as well as self-diagnosis in case of a fault
 Ensuring that the system is fail safe (in case of a fault or failure, the system by
default assumes a status which eliminates risk or harm, both to people and
equipment) by isolating power
 Counting the number of rejected units as well as the number of unit accepted into
the “warehouse”
 Generate alert messages when system maintenance(preventive maintenance) is due
 Controlling the Human Machine Interface (Simatic TD 200 HMI)
3.1.4.3 Remote I/O
In this design and project, the system was implemented following the DP (distributed
peripheral) protocol which is commonly implemented or realised as a technique or system
called remote I/O. Common Siemens remote I/O implementations are based on the Profibus
DP protocol.
Remote I/O refers to a PLC system in which some of the field devices (sensors, transducers
and actuators) are connected to intelligent input modules or dedicated controllers, which are in
the plant or field not directly to the PLC.
These dedicated controllers contain dedicated microprocessors or microcontrollers which

specialize in performing some specific, complex or specialized function(s) without the aid of
the main controller or computer. Intelligent input cards for PLCs usually take the form of high
speed counters, RTD input cards and in this design and project, a load cell compatible weighing
module. The use of intelligent controllers in control systems is usually categorized as
distributed control system – hence distributed peripheral.
Advantages of implementing remote I/O include:
 It saves or reduces installation costs since less cable is used

 It reduces or eliminates phasing errors
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 It reduces the load on the PLC since the dedicated controller comprises of a
powerful microcontroller which performs most of the computations and
calculations
 It makes troubleshooting and fault diagnosis easier in case of equipment or and
machinery failure
 For transducers like load cells, the signal can be distorted or be totally corrupted by
noise and signal interference with signals in other cables if it is transmitted over
long distances since the load cell output is very small
 Remote I/O improves the system’s ability to work (with limited functionality) even
in the event of a faulty having occurred in the main controller
 It improves fault tolerance
3.1.5 PLC setup
In order to write the PLC program as well as to network the PLC with the HMI device and the
programing device, PLC set up was performed. The setting up involved the following steps:
 Connecting the PLC to the programming device

 Setting PC/PG interface
 Selecting the appropriate COM Port
 Configuring the appropriate baud rate
3.1.5.1 Connecting the PLC
The programming device that was used for this design and project was a laptop computer
loaded with Windows Xp SP3 running in a virtual environment. The Simatic Step 7 MicroWin
programming software was installed and run in Windows Xp. A USB-PPI (USB to RS485)
adapter for Siemens s7-200 was used to connect the PLC to the programming device.
After establishing the physical connection, logical connections were made. Figure 3.14 shows
how the communication port, COM1 was selected and configured.
In Simatic Step 7 MicroWin, COM1 is a USB 2.0 port. PG/PC (programmer / personal
computer) interface was set to PC/PPI (personal computer / point to point) since a USB-PPI
(USB to RS485) adapter for Siemens s7-200 was used.
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Figure 3.14 Configuring COM1 Port
After configuring PG/PC interface and selecting COM1, communications parameters for the
system were configured as shown in figure 3.15.
 The PLC was assigned network address 2

 The Highest Address was set to 31, which is the system default (Highest
Address specifies the number of devices that can be networked in the system)
 Baud Rate was set at 9.6Kbps
 Gap factor was set at 10
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Figure 3.15 Assigning PLC network address
After the network configuring and PG/PC parameter setting had been done, connection was
established between the PLC’s CPU and the programming device as shown in figure 3.16
below.
Figure 3.16 Connection established between PLC CPU and programming device
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3.1.5.2 Programming the PLC
The program for the PLC was written using LL (ladder logic) and STL (statement list
language). Ladder logic had to be used since the STL instruction set for S7 200-CPU 212
excludes some instructions which are included in the ladder logic instruction set.
How the conveyor system works
 There are two conveyor belts, the main conveyor belt and the rejects conveyor belt. The
main conveyor belt is driven by the main drive motor (DM_1) while the rejects
conveyor is driven by another motor (RM_1).
 The main drive motor runs continuously as long as the system is running
 The rejects conveyor belt motor runs for a set period of time then is switched off in
order to save power
 The rejecter arm is controlled by a solenoid and is actuated when a reject has been
detected on the conveyor belt
 A motor is automatically switched off by the PLC when an overload fault has been
detected in order to protect it from damage
 The system should count the number of rejected units as well as accepted units
 The system switches on differently colour coded lights to give a visual indication of the
system status (Green = Ok, Red = Fault, Amber = Maintenance)
 The system alerts the operator that system preventive maintenance is due by switching
on an Amber status indicator as well as generating an alarm on the HMI display.
 All system alarms require authenticated acknowledgement for them to clear
3.1.5.3 Motor wiring
For this design and project, 12 V DC motors obtained from a motor vehicle wipers were used
to drive the conveyor belts on the model, however in real life industrial applications three phase
induction motors coupled to gearboxes are used.
Each of the motors is protected by an overload relay. An overload relay is used to protect three
phase motors from overcurrent and single phasing. In any of these cases, the electromechanical
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relay used in the device trips and switches off the motor to protect it. In this design project,
toggle switches were used in place of overload relays to simulate the occurrence of an overload.
When any of the toggle switches representing an overload relay is activated, it implies that the
overload relay has tripped and one of the corresponding motor has stopped. A 24V signal is
sent to the programmable logic controller when a toggle switch is activated. In turn the
programmable logic controller then identifies the input port of the toggle switch. This implies
that a motor protected by that toggle switch (overload relay) has drawn too much current and
is now down. Overload protection is intended to handle current ranging from motor full load
current up to locked motor current (10 * full load current).
Usually thermal overload relays are used for motor protection. Thermal overload relays are
activated by the heat derived from the motor line current. The generated heat during overload
is used to trip open the contacts of a contactor thereby de-energizing the control circuit.
In the case of this design project, this system was designed in such a way that in case of an
overload, a memory bit is set in the PLC and it latches even if the thermal overload eventually
clears itself. The set bit will generate both a visual indication and an alarm on the HMI panel
which will only clear after the operator acknowledges the thermal overload fault.
Reasons for overload protection include:
 To protect the motor from damage

 To protect the motor controller and motor branch circuit conductors from excessive
heating
 Persistent overcurrent cause overheating which may eventually lead to fire outbreaks
 Prolonged motor lifespan
3.1.5.4 Rejecter arm
The rejecter arm is actuated by a solenoid or electromagnet. The rejecter arm was used instead
of a pneumatic piston rejecter due to reasons of unavailability. The rejecter arm diverts the
rejects onto the rejects conveyer rather than the traditional knocking off or punching. This
ensures that corrective action may be performed on the rejects if that is deemed permissible
and necessary.
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Figure 3.17 Overload protection function programmed in the PLC
Figure 3.17 shows part of the PLC program written in statement list language (STL) which
performs the overload protection function.
LDN OL_DM1
A REG1
= REG2
The result of this program will only be true if there is no overload detected in DM1 circuit. In
other words, REG2 (REG2 and REG1 are memory bits or auxiliary relays) is only at logic 1 if
there is no overload in the circuit of the main drive motor (DM1) AND REG1 is at logic 1.
Logic 1 in REG2 will in turn switch on the conveyor motor DM1. Similar logic was
programmed to control the rejects conveyor belt motor. The complete PLC program is shown
in Appendix C.
3.1.5.4 Counting the units
A retro reflective sensor, with its corresponding reflector was mounted on each conveyor belt.
The retro reflective sensor emits a ray of electromagnetic waves (light) which is reflected back
by the reflector. Whenever this continuous ray is interrupted, a counter in the PLC,
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corresponding to each diffuse sensor was programmed to increment by a step of one. Figure
3.18 shows the rung in the ladder logic program which was programmed to do the counting of
the units with correct or consistent mass. The arbitrary pre-set value (PV) was set at 500units.
The counter is pre-set and reset only if the reset button is pressed.
Figure 3.18 Counter for units with consistent weight
3.1.6 SCADA HMI TD 200 design
Maximum transparency is essential for the operator who works in an environment where
processes are becoming more complex, and requirements for machine and plant functionality
are increasing. The Human Machine Interface (HMI) provides this transparency. A Siemens
TD 200 text display which is compatible with the S7 200 programmable logic controller was
used to display alarms and messages and to display and / or monitor the conveyor belt system.
The TD 200 device comes as a 2 or 4-line text display device that can be connected to the S7-
200 CPU. The TD device allows the operator to view, monitor and / or change the process
variables depending on the application. An HMI assumes the following functions:
 Process visualization
The process is visualized on the HMI device. The screen on the HMI device is dynamically
updated. This is based on process transitions.
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 Operator control of the process
The operator can control the process by means of the GUI. For example, the operator
can preset reference values for the controls or start a motor.
 Displaying alarms
Critical process states automatically trigger a system alarm.
 Archiving process values and alarms
The HMI system can log alarms and process values.
 Process values and alarms logging

 Process and machine parameter management
The TD device, shown in figure 3.19 allows the operator to configure a set of hierarchical user
menus to provide additional structure for the interaction with the application. It can also be
configured to display alarms or messages that are enabled by specific bits in the S7-200 CPU.
The TD device in this design project was programmed and used to perform the following tasks:
 viewing a hierarchy of user menus and screens that allow an operator to interact with
the application or process
 displaying alarms (bit-enabled messages) that are generated by the S7-200 CPU
 Modifying designated program variables - The TD device allows the operator to define
a variable as either a text string (All characters in a variable are editable) or a numeric
string.
 Forcing or unforcing I/O points: The operator can force individual I/O points in the S7-
200 CPU to be on or off, overriding the current status of the field devices
 viewing the CPU status (including version information, adjusting screen contrast etc.)
 enables the operator to change the operating mode (RUN or STOP) of the S7-200 CPU
 giving the operator access and means with which to edit the data stored in the memory
of the S7-200 CPU
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Figure 3.19 Simatic TD 200 [11]
Figure 3.19 shows the Simatic TD 200 text display. The arrows on the side of the panel are
used to scroll and navigate through the menus and the pages. The ENTER button is used to
confirm selection of an option or to acknowledge some alarms.
3.1.6.1 Process tags
External tags enable the communication (data exchange) between the components of an
automation process for example between the HMI device and the PLC.
The tags in this design project are the states of the overload relays, diffusion sensors, status
indicators (lights), rejecter arm and the conveyor drive motors. These are digital signals (bits).
In the configuration of Simatic STEP 7 MicroWin, the operator may directly access all tags
when creating the external tags which were created with STEP during the programming of the
Programmable Logic Controller.
The tag table in figure 3.20 shows the process tags for the system’s HMI. Each process tag is
used to map a physical device onto the TD 200 HMI to enable it to monitor as well as control
both the inputs and the outputs of the conveyor system.
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Figure 3.20 Process tags (Symbols table) for the system
3.1.6.2 Configuring alarms
Alarms are anomalies in the functioning of the system or any condition or status of the system
which may require intervention of the operator.
For this design project alarms were programed in order of priority, the one with highest priority
takes precedence. Alarms in the HMI are triggered by setting a bit or a corresponding flag in
the PLC memory. Some alarms depending on their priority, were configured in such that they
are only cleared after the operator acknowledges them, else they remain latched on.
Figure 3.21 shows how the alarm for “SYSTEM FAULTY” was configured. The alarm is
triggered by setting of the message enable bit V 14.7. The bit is set as shown in the window in
figure 3.22. If the logic of the rung evaluates to true, the output V 14.7 goes high thus triggering
the alarm. The alarm only clears from the screen or display of the HMI panel after the operator
acknowledges the alarm. Acknowledging an alarm serves to reset the flag bit.
Other messages which are not alarms were also programmed into the TD 200 HMI device.
These messages are accessed by using the HMI panel navigation keys to scroll through.
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Figure 3.21 Configuring highest priority alarm in the TD 200 HMI
Figure 3.22 Programming alarms in ladder logic

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In order to display data and system status or to perform dynamic updating of the system, the
TD 200 text display a memory space in the PLC called the POU Data block. The non-alarm
messages were directly programmed in the data block as shown in the window in figure 3.23.
Figure 3.23 TD 200 data block
3.2 METHODOLOGY
The weight detection transducer for the system is the load cell. The load cell was connected to
the PIC 16F877 via a signal processing and conditioning circuit. The weight measuring module
was interfaced with the PLC via an opto-coupling relay. Retro-reflective photo sensors were
used to detect the presence of objects or units on the conveyor belt. These sensors were
connected to the PLC’s on-board digital inputs. A TD200 HMI panel was connected to the PLC
via an RS485 link. The TD200 HMI was used for implementing SCADA.
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A field programmer (laptop computer) was also connected to the system via a USB to Serial
link adaptor. A digital multimeter was used for measuring the various electrical parameters in
the system
3.2.1 Instruments
Load cell – the load cell that was used was a capacitance based load cell. It was used to detect
weight or mass of the different objects or packages. The sensitivity of the load cell was 2mV/
V. The load cell had the capacity to measure from 0 – 125 g. For this design project this was
deduced from the recommendations of the manufacturer of the load cell and confirmed by the
calibration results shown in table 3.4 and table 3.5. It was observed that the load cell could be
reliably be used to measure masses way above 0g but below 125g.
Multimeter – a HellermannTyton multimeter (model TBM126) was used to measure the D.C
output voltage directly from the load cell as well as from the amplifier stage. The multimeter
had “auto-range” facility thus it was capable of giving results of acceptable accuracy. It was
also used for measuring the electrical parameters like voltage and current in the system
Retro reflective photo sensors – these sensors were used to detect the units as they move
along either the main conveyor belt or the rejects conveyor belt. Every time that the continuous
path followed by light from the diffusion sensor to the reflector is disturbed, a signal is sent to
the PLC. The PLC then counts these positive or rising edge transitions.
Instrumentation amplifier – the instrumentation amplifier in this design and project is used
to amplify the differential output voltage obtained from the load cell. The instrumentation
amplifier also acts as an input filter circuit to suppress noise from the surrounding environment.
3.2.2 Data
During the weight detection and sensing process, the load cell system is supposed to give
varying output corresponding to the weight of a unit placed on the weighing platform. If the
output voltage from the weight detection circuit increases with an increase in the load and
decreases with a decrease in the load, an approximately linear relationship should be obtained
between the load and the output voltage.
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During normal operation, the count of rejects or warehoused units should increment in steps of
one for every unit that passes a retro reflective sensor.
3.2.3 Analysis
The analysis of the results and data obtained during the practical and simulations testing is
provided in chapter 4.
3.2.4 Limitations
The instrumentation amplifiers used in the proposed designs that have been explained before
could not filter out all the noise. A higher gain resulted in much more pronounced noise
disturbances.
The PIC16F877 that was used in the design of the remote intelligent weighing module has a
10 bit ADC. This resolution is relatively low as compared to some 16 bit and 24 bit
microcontrollers and this reduces the sensitivity as well as the accuracy of the intelligent
weighing module.
3.3 CONCLUSION
The experiments outlined in earlier sections of the design process were performed both on
simulation and practically. The obtained main results and or observations are given in the next
chapter. The appropriate configurations for the various modules used in the project was done
to come up with a model to illustrate the concept of the system. The programs for the PIC and
PLC were developed, tested and debugged then downloaded into the respective controllers.
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CHAPTER 4: RESULTS AND DISCUSSION
4.0 INTRODUCTION
This chapter mainly serves to give the actual results obtained from the practical work that was
done and the observations made on the prototype that was designed. An analysis or contrast
between theoretically expected results and the actual results obtained is also drawn in this
chapter.
4.1 RESULTS OF PRACTICAL TESTING OF WEIGHING SYSTEM
After the load cell calibration process, the weight detection system was mounted on the
conveyor belt. Different masses were put on the weighing station while the output voltage was
measured using a multimeter. The weights that were used for the practical demonstration were
a sealed 100g petroleum jelly container and an opened, partly used container of the same brand
of petroleum jelly (to represent an inconsistent unit).
Table 4.0 output voltages corresponding to masses placed on weighing detection system
Weight /g Output Voltage/mV

00 1890
25 2450
50 2700
75 2850
95 2980
98 2990
100 3010
102 3029
105 3040
125 3070
The results shown in figure 4.0 above were obtained from the amplifier stage of the weight
detection circuit. The INA125P amplifier was configured using a single +5V supply thus the
output was expected to lie in-between 1V and 4V. The results in the table and the practical
running of the conveyor system demonstrated that the system could reject units which had mass
not within the 100g ± 5% threshold. Desirable accurate rejection however would be ± 2%.
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3500
3000
Output Voltage /mV
2500
2000
1500
1000
500
Mass /g
0
0 25 50 75 95 98 100 102 105 125
Figure 4.0 Mass against output voltage

From the results tabulated in table 4.0, it was observed and concluded that the weight detection
system could detect mass inconsistences from approximately 2g and upwards. Considering the
graph in figure 4.0, it was observed that there was a very slight variation in output voltage
between 98g and 102g. This then would be the strict sense tolerance leeway of the mass,
however for many non-food products, ±5% mass variation is set as the threshold limit.
Weights close to 100g gave readings which were fluctuating around 3000mV. The range of
weights that gave output voltage fluctuating around 3V was then the acceptable range for this
project.
4.2 CIRCUIT SIMULATION
The complete circuit for the intelligent weighing module was simulated and tested using
Proteus. The scenario of a reject being detected and that of a unit with acceptable weight being
detected were both simulated using proteus. Figure 4.2 shows the simulation results when a
reject was being detected while figure 4.3 shows a unit within acceptable mass range being
detected. Figure 4.4 shows a photograph of practical testing of rejection of an underweight unit.
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Figure 4.2 a unit with inconsistent mass being detected
Figure 4.3 a unit with consistent mass being detected
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Figure 4.4 Practical testing showing the rejection of a 28.3g underweight unit
4.3 PROTOTYPE
A functional prototype of the system was designed and constructed. Initially 220Vac motors
were used to drive the two conveyor belts in the prototype model, however the 220Vac motors
were later replaced with 12Vdc motors. This adjustment was done mainly to allow better speed
control of the motors. Figure 4.5 shows a photograph of the working prototype of the design.
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Power supply Switchgear
S7 200 PLC
HMI Programming Unit
Figure 4.5 Prototype of the conveyor belt
Reasons for using D.C motors
 unavailability of variable speed drive

 easier speed control when using D.C as compared to A.C
Table 4.6 Electrical parameters of the conveyor system
Actuator Voltage Current

Main conveyor drive 12V 1.95A
Rejects conveyor drive 12V 2.10A
Rejecter coil 24V 2.00A
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Table 4.6 shows a summary of the electrical requirements of the main power-consuming
components of the prototype. The design saves power since the rejects conveyor drive motor
does not run continuously but rather, it only runs for a limited time, only sufficient to clear the
rejects off the conveyor belt.
4.4 SCADA
The prototype’s Supervisory Control and Data Acquisition system was tested partly by
inducing conditions that would trigger some system alarms and then observations were made
for those particular functionalities.
The photograph in figure 4.6 shows the SCADA system displaying a system fault or alarm.
The alarm was indicating that an overload had been detected in the circuit of the rejects
conveyor belt drive motor. A red status indicator corresponding to the motor will be switched
on in conjunction with the text alarm displayed on the HMI screen. The alarm will only clear
after an authenticated person enters the correct password and acknowledges the faulty after it
has been resolved.
System alarm
RM1 faulty
indicator
Figure 4.6 SCADA displaying Overload Alarm in RM1 (Rejects conveyor belt motor)
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Figure 4.7 SCADA system reporting that the system is running correctly with no fault
Figure 4.8 viewing the number of rejected units from the SCADA system
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4.5 ANALYSIS OF RESULTS
The results obtained during the process of testing the system showed that the system correctly
performed weight measurement and rejecting or accepting the units according to set conditions.
However due to hardware limitations of the ADC of the PIC16F877 that was used in the design,
the resolution of the ADC did not always maintain the desired accuracy for all the weights,
thus as a result some flactuations were experienced during testing.
The small voltage signals obtained from the load cell have vulnerability to corruption by noise.
This can be established from the test results of the amplifier circuits shown in tables 3.1, 3.2
and 3.3 the results show that when no voltage is applied to the input of the amplifier circuit,
the detected noise will give an output whose magnitude will be proportional to the gain of the
amplifier. However, the designer tried to prevent this by using de-coupling capacitors on the
input of the amplifier.
The simulations performed using the various software packages for the PIC, PLC and SCADA
/ HMI and the practical or physical tests performed during system testing showed that the
system works. The system displayed the mass of the units as they passed the weigh-checker,
however, due to the highly sensitive nature of the capacitive load cell, some vibrations of the
conveyor belt introduced noise spikes in the system’s mass measurements. Units with
inconsistent weight were rejected onto the side conveyor belt. Triggering the overload relays
(toggle switches) resulted in the concerned motor stopping as expected and the appropriate
alarm was displayed on the HMI. The system correctly counted the number of inconsistent
(rejected) units as well as consistent (acceptable) units as well as giving the total number of
units (both rejected and warehoused units) that had passed through the system.
4.6 CONCLUSION
The results discussed in the preceding sections were used to come up with a functional weight
measuring conveyor system. The discrepancies between software simulation based results and
practical work based results had an impact in the functionality of the design since simulation
packages like Proteus have components behaving ideally and at often times, the “ideal”
component values used for simulations may not be available in practical situations. However
despite the challenges, the obtained results were acceptable since they compared reasonably
well to anticipated results.
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CHAPTER 5: CONCLUSION
5.0 INTRODUCTION
This chapter contains a summary of the findings, observations and results that were made and
obtained respectively during the course of the project. Challenges and problems that were
encountered as well as suggestions for further improvements that can be made on the system
are outlined herein.
5.1 SUMMARY OF FINDINGS
In this design and project, it was observed that load cell based weighing system detected and
measured the mass of units below 125g with accuracy of +/- 2g. The conveyor belt system
managed to determine whether a unit was a reject or within acceptable weight constraint.
The SCADA system for the weight consistency monitoring conveyor system could perform
functions such as starting and stopping the system, displaying system alarms and faults,
performing self-diagnostics of the system for easier trouble shooting to minimise plant
downtime and providing statistics of consistent versus inconsistent units produced.
Table 5.0 below shows a success / fail criterion summary for the designed PIC based weight
sensing module.
Table 5.0 Success / fail criterion for intelligent weight sensing circuit
Parameter Outcome
Display mass of each unit as it passes the weighing platform 
Display on a 16*2 LCD whether unit is a reject or not 
Reject detected underweight and overweight units 
Accurately detect within ± 5g 
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Table 5.1 shows a success / fail criterion summary for the designed SCADA system.
Table 5.1 Success / fail criterion for the SCADA / HMI system
Parameter Outcome
Authentication 
Start / Stop the conveyor belt 
Display system alarms and faults in order of priority 
System diagnostics 
Production figures (rejected vs warehoused units) 
5.2 POSSIBLE IMPROVEMENTS ON THE DESIGN
i. Use of a more powerful, recent model Programmable Logic Controller
Using an advanced PLC will enable the use of some specific programming instructions
which cannot be handled by the PLC used in the project
ii. Logging all the masses of produced units in a centralized database
This would allow easier analysis and trending of the performance of the packaging line,
however this practice requires a lot memory in the PLC and usually is not a critical area
of concern
iii. Use variable speed drives and A.C motors properly coupled to gearboxes.
Using variable speed drives to control the speed of induction motors conserves energy
since the motors are made to run at speeds corresponding to the real-time demand on
the packaging line. The life span of the induction motors will also be increased.
iv. Use star-delta connection for the conveyor belt induction motors instead of direct-on-
line
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Figure 5.1 Characteristics of Delta and Star motor connection [15]
Figure 5.1 shows typical parameters for a motor when connected in delta and when it is
connected in star. Delta connection evidently draws higher starting current than star
connection. On the other hand, star connection draws more full-load current than delta
configuration. Further analysis will therefore suggest that a hybrid of the two configurations
be used to maximise efficiency.
5.3 CHALLENGES ENCOUNTERED
The project was a very interesting insight into the possibilities of marrying a PIC, PLC and
SCADA monitoring into a packaging line weight consistence inspector conveyor belt. This was
possible but not without its hurdles. Some of the challenges faced while working on the project
include:
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 Finance. The project required some costly components like the PLC, retro-reflective
photo sensors, connectors, a full PLC kit and a power supply. A compromise approach
had to be adopted (a USB-RS485 adaptor had to be used for programming the PLC)
 The author failed to purchase geared induction motors and variable speed drives to
demonstrate the real set up of conveyor belt motors due to financial constraints. As a
result dc wiper motors were used
 Instrumentation amplifier was damaged during system testing phase and progress was
retarded as procuring a replacement was a challenging process
5.4 SUMMARY OF CONTRIBUTIONS
Successfully implementing a PIC based weight measuring circuit and interfacing it with a
Programmable Logic Controller for industrial quality control was a revolutionary achievement.
Many of the previous attempts by some hobbyists and students mainly revolved around
modifying pre-existing electronic scales and connecting them to simple-to-use controllers like
Arduino, Arduino Uno and Raspberry pi.
The concept of automated quality control stands to improve the profitability and efficiency of
those local companies which will migrate from traditional, manual means of weight
consistency monitoring and adopt automated systems such as this one.
5.5 CONCLUSIONS
The designed system managed to successfully monitor the consistency of the weight of
different units that were put on the conveyor belt during testing. The system allowed units
within the required mass leeway to proceed to the warehouse while those with weight outside
the acceptable limits were diverted onto the side conveyor belt. The SCADA system managed
to provide the Supervisory, Control and Data acquisition functionalities to the conveyor belt
system.
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REFERENCES
1. Mark Fritz and Emil Hazarian (1999) “Mass and Weight Measurement” , Denver
Instrument Company
2. Jorge (2012),
http://casainho-projects.googlecode.com/svn/trunk/sdcard_bathroom_scale (12
February 2012) [October 16 2014]
3. http://www.foodonline.com/doc/x-ray-inspection-and-checkweighing-system-x-
weigh-0001 [09 January 2015]
4. X-ray checkweighers http:// www.NovusXray.com [09 January 2015]
5. https://www.transducertechniques.com/wheatstone-bridge.aspx [21 December 2014]
6. http://www.ishida.com/technologies/loadcell/ [17 January 2015]
7. http://www.loadstarsensors.com/digital-load-cells.html [17 January 2015]
8. https://www.sparkfun.com/products/10245 [16 January 2015]
9. http://www.analog.com/static/imported-
files/design_handbooks/5823456682185109215Chapter_III.pdf
10. http://www.techonline.com/electrical-engineers/education-training/tech-
papers/4129288/A-Designer-s-Guide-Monolithic-Instrumentation-Amplifiers
11. SIMATIC S7-200 Programmable Controller System Manual (Edition 08/2008)
12. SITRAIN Training for Automation and Industrial Solutions (Siemens AG 2006)
13. http://www.automationtraining.ca/siemens-S7-200.asp (October 2012) [15 January
2015]
14. https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx (July 2013)
[15 January 2015]
15. Motor protection overload relays ISO 9001:2000 www.dsquareinstruments.com [09
September 2014]
16. http://www.ebah.com.br/content/ABAAAfVJQAI/instrumentacao-eletronica-
complete-in-amp?part=4 [29 April 2015]
17. Standards Association of Zimbabwe
18. Consumer Protection Act
19. TRADE MEASURES ACT 51/1973, 1/1987, 22/2001.
20. FOOD AND FOOD STANDARDS ACT 25/1971, 39/1973 (s. 52), 61/1973 (s. 8),
42/1976 (s. 35), 32/1979 (s.12), 29/1981, 8/1988, 22/1994, 22/2001.
21. https://ez.analog.com/message/80366
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22. http://airtripper.com/1626/arduino-load-cell-circuit-sketch-for-calibration-test/
23. https://electronics.stackexchange.com/questions/131613/arduino-leonardo-3-wire-
load-cells-ina125p-analog-signal-bounce-noise
24. http://cdn.instructables.com/FNY/02KS/HFSH4TQO/FNY02KSHFSH4TQO.MEDIU
M.jpg
25. http://www.interfaceforce.com/sys/pic.php?cache&q=100&w=750&img=.../UserFiles
/specifications/FDB31C07-EE91-4835-4968-7C8D368FC7B9.jpg
26. http://www. TU-UJ - 引張・圧.html
27. Thayer Scale Process Measurement and Control Equipment
28. Yuson Pang (2010), Intelligent Belt Conveyor Monitoring and Control
29. www.rsonline.co.za
30. www.microchip.com/downloads/en/devicedoc/39582b.pdf, PIC 16F877A datasheet
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APPENDIX A: DATASHEETS
Figure A.0 Load cell specifications [7]
Figure A.1 Load cell connections legend [7]
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Figure A.2 Load cell calibration curve [7]
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D91A . 1 . 0
RELAIS REED DUAL IN LINE / un contact travail
DUAL IN LINE REED RELAY / 1 normally open contact
SCHEMA DE BORNAGE - ENCOMBREMENT / PIN CONFIGURATION - DIMENSIONS
vue de dessus / up view
REFERENCES D91A . 1 . 0
Tension Options
nominale
Options
Nominal input
3 --> 5 V = 0 --> sans / without option
5 --> 12 V = 1 --> diode ( D )
6 --> 15 V = 2 - -> écran électrostatique ( E ) / electrostatic shield
7 --> 24 V = 4 - -> ( D + E )
Références disponibles / Available references
D91A3 120
D91A5100 - D91A5140 D91A6110 - D91A6140
D9 1 A7 100
N***** Page 75
N***** Page 76
APPENDIX B: PIC 16F877 ASSEMBLY PROGRAM
LIST p=16F877; tell assembler what chip we are using

Include "P16F877.inc”; include the defaults for the chip
ERRORLEVEL 0, -302; suppress bank selection messages
__CONFIG _BODEN_ON & _XT_OSC & _WDT_OFF & _PWRTE_ON & _CP_OFF & _LVP_OFF
PORTA EQU 0X05
PORTB EQU 0X06
TRISA EQU 0X85
TRISB EQU 0X86
OPTION_REG EQU 0X81
Z EQU 2
TMRO EQU 0X01
NUM1 EQU 0X34
NUM2 EQU 0X35
NUM3 EQU 0X36
NUM4 EQU 0X37
NUM5 EQU 0X38
NUM6 EQU 0X39
COUNTER2 EQU 0X40
COUNTT1 EQU 0X41
COUNTT2 EQU 0X42
COUNNT EQU 0X43
C1 EQU 0X44
C2 EQU 0X45
C3 EQU 0X46
Counter3 EQU 0X47
LCD_BUFFER EQU 0X60
COUNTD1 EQU 22h ;User-defined variable
COUNT10 EQU 25h ;User-defined variable
COUNT100 EQU 26h ; User-defined variable
count5 equ 29H ; User-defined variable
MDARA EQU 2AH
count6 equ 30h ; User-defined variable
COUNT EQU 31h
N***** Page 77
LCD_TEMP EQU 0X32
LCD_CTRL EQU PORTC ; LCD control lines interface
LCD_DATA EQU PORTD ; LCD data lines interface
CONTROL EQU PORTA
LCD_E EQU 2 ; LCD E on portb, 3
LCD_RW EQU 1 ; LCD RW on portb, 2
LCD_RS EQU 0 ; LCD RS on portb, 1
THE PROGRAM
Org 0X0000
GOTO MAIN
ORG 0X0004
RETFIE
MAIN
CALL FIRST
CALL LCDINIT
CALL WELCOME_TAFA
CALL RELAY_DEL ; 1SEOND DELAY
CALL RELAY_DEL
CALL RELAY_DEL
CALL ENTER
CALL PASSWORD_PROMPT
CALL RELAY_DEL
CALL RELAY_DEL
GOTO GET_MASS
; LCD initialisation & other subroutines
LCDPUTCHAR1
MOVWF LCD_TEMP ; Character to send is in W
CALL LCDBUSY ; Wait for LCD to be ready
MOVLW 0x01
CALL DEBOUNCE
BCF LCD_CTRL, LCD_E ; Lower E clock
BCF LCD_CTRL, LCD_RW ; Set LCD in Write mode
BSF LCD_CTRL, LCD_RS ; Set LCD in data mode
MOVF LCD_TEMP, W
MOVWF LCD_DATA ; Send data to LCD
BSF LCD_CTRL, LCD_E ; LCD E-line High
NOP
NOP
BCF LCD_CTRL, LCD_E ; LCD E-line Low
N***** Page 78
RETURN
LCDPUTCHAR
MOVWF LCD_TEMP ; Character to send is in W
MOVLW 0x01
CALL DELAY
BSF LCD_CTRL, LCD_RS ; Set LCD in data mode
MOVF LCD_TEMP, W
MOVWF PORTD ; Send data to LCD
NOP
NOP
RETURN
LCDPUTCMD1
MOVWF LCD_TEMP ; Command to send is in W
MOVLW 0x01
CALL DEBOUNCE
BCF LCD_CTRL, LCD_RS ; Set LCD in command mode
MOVF LCD_TEMP, W
NOP
NOP
RETURN
LCDPUTCMD
MOVWF LCD_TEMP ; Command to send is in W
MOVLW 0x01
CALL DELAY
BCF LCD_CTRL, LCD_RS ; Set LCD in command mode
MOVF LCD_TEMP, W
N***** Page 79
NOP
NOP
RETURN
LCDSTART
BCF LCD_CTRL, LCD_RS
BCF LCD_CTRL, LCD_RW
BCF LCD_CTRL, LCD_E
MOVLW 0x01
CALL DEBOUNCE
MOVLW 0x38 ; 8-bit-interface, 2-lines
MOVWF LCD_DATA
NOP
BSF LCD_CTRL, LCD_E
NOP
NOP
BCF LCD_CTRL, LCD_E
RETURN
LCDINIT
BCF LCD_CTRL, LCD_RS
BCF LCD_CTRL, LCD_E
CALL LCDSTART
CALL LCDSTART
MOVLW 0x38 ; 8-bit-interface, 2-lines
CALL LCDPUTCMD1
MOVLW 0x0E ; disp.off, curs.off, no-blink
CALL LCDPUTCMD1
MOVLW 0x06 ; auto-inc (shift-cursor)
CALL LCDPUTCMD1
BSF PORTD, 3
CALL LCDCLEAR
RETURN
LCDBUSY
BSF STATUS, RP0
MOVLW 0xFF
MOVWF TRISD ; PortC is an input Port
BCF STATUS, RP0
BCF LCD_CTRL, LCD_RS ; Set LCD for command mode
N***** Page 80
BSF LCD_CTRL, LCD_RW ; Setup to read busy flag
AGAIN
NOP
NOP ; extra
MOVF LCD_DATA, W ; Read busy flag + Dram address
NOP
ANDLW 0x80 ; Check Busy flag, High = Busy
BTFSS STATUS, Z ; only skip if Z = '1', not busy
GOTO AGAIN ; still BUSY = '1' => Z = 0 keep waiting
LCDNOTBUSY
NOP
NOP
BSF STATUS, RP0
MOVLW 0x00
MOVWF TRISD ; PortA is an output Port
BCF STATUS, RP0
RETURN
LCDCLEAR
MOVLW 0x01
CALL LCDPUTCMD1
RETURN
LCDHOME
MOVLW 0x02
CALL LCDPUTCMD
RETURN
LCDEMODE
ANDLW 0x03 ; Strip upper bits
IORLW 0x04 ; Function set
CALL LCDPUTCMD
RETURN
LCDDMODE
ANDLW 0x07 ; Strip upper bits
CALL LCDPUTCMD
RETURN
LCDSCGA
ANDLW 0x3F ; Strip upper bits
N***** Page 81
CALL LCDPUTCMD
RETURN
LCDSDDA
CALL LCDPUTCMD
RETURN
LCDGADDR
BCF LCD_CTRL, LCD_RS ; Set LCD for command mode
BSF LCD_CTRL, LCD_RW ; Setup to read busy flag
MOVF LCD_DATA, W ; Read busy flag + RAM address
ANDLW 0x7F ; Strip upper bit (BUSY BIT)
RETURN
; DELAY SUBROUTINES;
DELAY_5mS
MOVLW 0x0B ; = 10
MOVLW 0X02 ; XXXXXX DEBUGGING - REMOVE FOR RUN
LOOP_30us
MOVLW 0x65 ; = 100
MOVLW 0X0A ; XXXXXX DEBUGGING - REMOVE FOR RUN
MOVWF COUNT100 ; = 100 x 30us = 3000us
LOOP_3us
NOP ; Adjust number of NOPs for fine tuning of delay
NOP ; 2 NOPs = 2us
NOP
NOP
NOP
DECFSZ COUNT100, 1 ; + 1us = 3us
GOTO LOOP_3us ; repeated 100 times = 300us
DECFSZ COUNT10, 1
GOTO LOOP_30us ; repeated 10 times = 3000us (3ms)
RETURN
WELCOME_TAFA
MOVLW 0x01
CALL LCDPUTCMD
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x57
N***** Page 82
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x4C
CALL LCDPUTCHAR
MOVLW 0x43
CALL LCDPUTCHAR
MOVLW 0x4F
CALL LCDPUTCHAR
MOVLW 0x4D
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x3A
CALL LCDPUTCHAR
MOVLW 0x4E
CALL LCDPUTCHAR
MOVLW 0x30
CALL LCDPUTCHAR
MOVLW 0x31
CALL LCDPUTCHAR
MOVLW 0x30
CALL LCDPUTCHAR
MOVLW 0x36
CALL LCDPUTCHAR
MOVLW 0x37
CALL LCDPUTCHAR
MOVLW 0x30
CALL LCDPUTCHAR
MOVLW 0x31
CALL LCDPUTCHAR
MOVLW 0x42
CALL LCDPUTCHAR
RETURN
FIRST ; this is the main initialisation of the whole program
BCF STATUS, IRP
BCF STATUS, RP1 ; Select BANK 0
BCF STATUS, RP0
MOVLW 0X80
MOVWF RCSTA
BSF STATUS, RP0
N***** Page 83
MOVLW 0X24 ; ASYCHRON, HIGH RATE
MOVWF TXSTA
MOVLW 0X19 ; BDR OF 9600
MOVWF SPBRG
BCF STATUS, RP0
CLRF PORTA ; clear port A to start port initialisation
CLRF PORTC ; clear port C to start port init
CLRF PORTD ; clear port B to start port init
BSF STATUS, RP0 ; BANK 1 for setting data directi registers
MOVLW 0X07
MOVWF OPTION_REG
MOVLW 0x06 ; ADCON1 = 0xxx 011x
MOVWF ADCON1 ; set all portA pins as digital
MOVLW 0x3F
MOVWF TRISA
MOVLW 0XF0
MOVWF TRISB ; set port A all inputs
CLRF TRISD ; set all port B AND C as output
CLRF TRISC
MOVWF 0XC2
MOVWF ADCON1
MOVLW 0X01
MOVWF TRISE
BCF STATUS, RP0 ; select BANK 0 normal
RETURN
; PASSWORD;
ENTER
MOVLW 0x01
CALL LCDPUTCMD
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x50
CALL LCDPUTCHAR
MOVLW 0x41
CALL LCDPUTCHAR
MOVLW 0x53
CALL LCDPUTCHAR
MOVLW 0x53
CALL LCDPUTCHAR
MOVLW 0x57
CALL LCDPUTCHAR
N***** Page 84
MOVLW 0x4F
CALL LCDPUTCHAR
MOVLW 0x52
CALL LCDPUTCHAR
MOVLW 0x44
CALL LCDPUTCHAR
MOVLW 0x3A
CALL LCDPUTCHAR
RETURN
; P/W PROMPT
PASSWORD_PROMPT
MOVLW 0X01 ; FIRST NUMBER
MOVWF NUM1
MOVLW 0X03 ; SECOND NUMBER
MOVWF NUM2
MOVLW 0X07 ; THIRD NUMBER
MOVWF NUM3
BEGIN
CALL SCAN
SUBWF NUM1, W ; INPUT ONE
BTFSS STATUS, Z
GOTO SEKURU ; TRY AGAIN
CALL SCAN
SUBWF NUM2, W ; INPUT TWO
BTFSS STATUS, Z
GOTO SEKURU ; TRY AGAIN
CALL SCAN
SUBWF NUM3, W ; INPUT THREE
BTFSC STATUS, Z
GOTO GOGO
SEKURU
CALL PASSWORD_INCORRECT
GOTO BEGIN
GOGO
CALL PASSWORD_ACCEPTED ;CODE TO INDICATE CORRECT PASSWORD
; SCANNING THE CHARACTERS FROM 4*4 KEYPAD;
SCAN
NOP
COLUMN1
BCF PORTB, 0
BSF PORTB, 1
N***** Page 85
BSF PORTB, 2
BSF PORTB, 3
CHECK1
BTFSC PORTB, 4 ; IF CLEAR IT IS PRESSED
GOTO CHECK4
CALL DELAYP1
CHECK1A
BTFSS PORTB, 4
GOTO CHECK1A
CALL DELAYP1
RETLW 0X01
CHECK4
GOTO CHECK7
CALL DELAYP1
CHECK4A
BTFSS PORTB, 5
GOTO CHECK4A
CALL DELAYP1
RETLW 0X04
CHECK7
GOTO CHECK0
CALL DELAYP1
CHECK7A
BTFSS PORTB, 6
GOTO CHECK7A
CALL DELAYP1
RETLW 0X07
CHECK0
BTFSC PORTB, 7 ; IF CLEA IT IS PRESSED
GOTO COLUMN2
CALL DELAYP1
CHECK0A
BTFSS PORTB, 7
GOTO CHECK0A
CALL DELAYP1
RETLW 0X00
COLUMN2
BSF PORTB, 0
N***** Page 86
BCF PORTB, 1
BSF PORTB, 2
BSF PORTB, 3
CHECK2
GOTO CHECK5
CALL DELAYP1
CHECK2A
BTFSS PORTB, 4
GOTO CHECK2A
CALL DELAYP1
RETLW 0X02
CHECK5
GOTO CHECK8
CALL DELAYP1
CHECK5A
BTFSS PORTB, 5
GOTO CHECK5A
CALL DELAYP1
RETLW 0X05
CHECK8
GOTO CHECK10
CALL DELAYP1
CHECK8A
BTFSS PORTB, 6
GOTO CHECK8A
CALL DELAYP1
RETLW 0X08
CHECK10
GOTO COLUMN3
CALL DELAYP1
CHECK10A
BTFSS PORTB, 7
GOTO CHECK10A
CALL DELAYP1
RETLW 0X0A
N***** Page 87
COLUMN3
BSF PORTB, 0
BSF PORTB, 1
BCF PORTB, 2
BSF PORTB, 3
CHECK3
GOTO CHECK6
CALL DELAYP1
CHECK3A
BTFSS PORTB, 4
GOTO CHECK3A
CALL DELAYP1
RETLW 0X03
CHECK6
GOTO CHECK9
CALL DELAYP1
CHECK6A
BTFSS PORTB, 5
GOTO CHECK6A
CALL DELAYP1
RETLW 0X06
CHECK9
GOTO CHECK11
CALL DELAYP1
CHECK9A
BTFSS PORTB, 6
GOTO CHECK9A
CALL DELAYP1
RETLW 0X09
CHECK11
GOTO COLUMN4
CALL DELAYP1
CHECK11A
N***** Page 88
BTFSS PORTB, 7
GOTO CHECK11A
CALL DELAYP1
RETLW 0X0B
COLUMN4
BSF PORTB, 0
BSF PORTB, 1
BSF PORTB, 2
BCF PORTB, 3
CHECK12
GOTO CHECK13
CALL DELAYP1
CHECK12A
BTFSS PORTB, 4
GOTO CHECK12A
CALL DELAYP1
RETLW 0X0C
CHECK13
GOTO CHECK14
CALL DELAYP1
CHECK13A
BTFSS PORTB, 5
GOTO CHECK13A
CALL DELAYP1
RETLW 0X0D
CHECK14
GOTO CHECK15
CALL DELAYP1
CHECK14A
BTFSS PORTB, 6
GOTO CHECK14A
CALL DELAYP1
RETLW 0X0E
CHECK15
N***** Page 89
GOTO COLUMN1
CALL DELAYP1
CHECK15A
BTFSS PORTB, 7
GOTO CHECK15A
CALL DELAYP1
RETLW 0XFF
RETURN
DELAYP1
CLRF TMRO
LOOPD
MOVF TMR0
SUBLW 0X03
BTFSS STATUS, Z
GOTO LOOPD
RETLW 0X00
; AUTHENTICATION SUCCESSFUL
PASSWORD_ACCEPTED
MOVLW 0x01
CALL LCDPUTCMD
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x41
CALL LCDPUTCHAR
MOVLW 0x55
CALL LCDPUTCHAR
MOVLW 0x54
CALL LCDPUTCHAR
MOVLW 0x48
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x4E
CALL LCDPUTCHAR
MOVLW 0x54
CALL LCDPUTCHAR
MOVLW 0x49
CALL LCDPUTCHAR
MOVLW 0x43
N***** Page 90
CALL LCDPUTCHAR
MOVLW 0x41
CALL LCDPUTCHAR
MOVLW 0x54
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x44
CALL LCDPUTCHAR
RETURN
; AUTHENTICATION FAILED
PASSWORD_INCORRECT
MOVLW 0x01
CALL LCDPUTCMD
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x49
CALL LCDPUTCHAR
MOVLW 0x4E
CALL LCDPUTCHAR
MOVLW 0x43
CALL LCDPUTCHAR
MOVLW 0x4F
CALL LCDPUTCHAR
MOVLW 0x52
CALL LCDPUTCHAR
MOVLW 0x52
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x43
CALL LCDPUTCHAR
MOVLW 0x54
CALL LCDPUTCHAR
RETURN
; SUBROUTINE FOR REJECTION OF UNWANTED UNITS
BVURA
BSF PORTC, 4
CALL DELAY_1S
CALL DELAY_1S
CALL DELAY_1S
N***** Page 91
CALL DELAY_1S
CALL DELAY_1S
CALL DELAY_1S
CALL DELAY1M
CALL DELAY1M
CALL DELAY1M
CALL DELAY1M
BCF PORTC, 4
MOVLW 0x01
CALL LCDPUTCMD
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x2E
CALL LCDPUTCHAR
MOVLW 0x2E
CALL LCDPUTCHAR
MOVLW 0x2E
CALL LCDPUTCHAR
MOVLW 0x52
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x4A
CALL LCDPUTCHAR
MOVLW 0x45
CALL LCDPUTCHAR
MOVLW 0x43
CALL LCDPUTCHAR
MOVLW 0x54
CALL LCDPUTCHAR
MOVLW 0x21
CALL LCDPUTCHAR
CALL RELAY_DEL
CALL RELAY_DEL
BCF PORTC, 4
GOTO GET_MASS
; SUBROUTINE FOR ACCETABLE UNITS
MASS_OK
MOVLW 0x01
CALL LCDPUTCMD
N***** Page 92
MOVLW 0x80
CALL LCDPUTCMD
MOVLW 0x6d
CALL LCDPUTCHAR
MOVLW 0x61
CALL LCDPUTCHAR
MOVLW 0x73
CALL LCDPUTCHAR
MOVLW 0x73
CALL LCDPUTCHAR
MOVLW 0x20
CALL LCDPUTCHAR
MOVLW 0x6F
CALL LCDPUTCHAR
MOVLW 0x6B
CALL LCDPUTCHAR
GOTO GET_MASS
DELAY
MOVLW 0xFF ; load working register
MOVWF count5 ; load count1 variable
loop1
MOVLW 0xFF ; load working register
MOVWF count6 ; load count2 variable
loop2
DECFSZ count6, 1 ; decrement variable count2 and skip next instruction if zero
GOTO loop2 ; loop back
DECFSZ count5, 1 ; decrement variable count2 and skip next instruction if zero
GOTO loop1 ; loop back
RETURN ; return from the subroutine
DEBOUNCE
MOVLW 0x01
MOVWF COUNTD1
LOPA
CLRF COUNTD2
LOPB
CLRF COUNTD3
LOPC
NOP
NOP
NOP
N***** Page 93
NOP
NOP
NOP
NOP
NOP
NOP
NOP
DECFSZ COUNTD3, 1
GOTO LOPC
DECFSZ COUNTD2, 1
GOTO LOPB
DECFSZ COUNTD1, 1
GOTO LOPA
RETURN
GET_MASS
CALL ADC1_CONVERT
NOP
BSF STATUS, RP0
MOVF ADRESL, 0
BCF STATUS, RP0
MOVWF MDARA
SUBLW 0XE1 ; MINIMUM MASS
BTFSS STATUS, C ; IF W IS LESS THAN E1 SKIP
GOTO TEST_HIGH ; TEST FOR HIGH (ELSE IF ACTION)
GOTO BVURA ; IF ACTION
; ADC CONVERSION SUBROUTIME;
ADC1_CONVERT
BSF STATUS, RP0
MOVLW 0xC2
MOVWF ADCON1; PA0, PA1 and PA3
BCF STATUS, RP0
MOVLW 0x88 ; CHANEL AN1
MOVWF ADCON0
BSF ADCON0, ADON
BCF PIR1, ADIF
CALL DELAY0; 20 MICROSECONDS
BSF ADCON0, GO
NOP
WAIT1_ADC
BTFSC ADCON0, GO
GOTO WAIT1_ADC
N***** Page 94
BCF PIR1, ADIF
NOP
RETURN
TEST_HIGH
MOVF MDARA
SUBLW 0XF8 ; MAXIMUM MASS
BTFSS STATUS, C ; IF W IS LESS THAN K SSKI
GOTO BVURA ; TEST FOR HIGH MEANING GREATER
GOTO MASS_OK
;;;;; 1seconds for 4 MHz crystal;;;;;;
DELAY1M
MOVLW 0XFF
MOVWF COUNTT2
DDEL_LO
NOP
NOP
NOP
NOP
NOP
NOP
NOP
DECFSZ COUNTT2, 1
GOTO DDEL_LO
RETURN
; 20 microseconds for 4 MHz crystal;
DELAY0
MOVLW 0x05
MOVWF COUNTT2
DEL_LOOP
NOP
DECFSZ COUNTT2, 1
GOTO DEL_LOOP
RETURN
; DELAY_1S;
DELAY_1S
MOVLW 0XFF
MOVWF COUNNT
TAFA
NOP
DECFSZ COUNNT, 1
GOTO TAFA
N***** Page 95
RETURN
RELAY_DEL
MOVLW 0x06; one second delay for relays
MOVWF C1
O_LOOP
CLRF C2
I_LOOP
CLRF C3
T_LOOP
NOP
DECFSZ C3, 1
GOTO T_LOOP
DECFSZ C2, 1
GOTO I_LOOP
DECFSZ C1, 1
GOTO O_LOOP
RETURN
END
N***** Page 96
APPENDIX C: PLC STL PROGRAM
ORGANIZATION_BLOCK MAIN: OB1
TITLE=PROGRAM COMMENTS
BEGIN
Network 1 // Conveyor system start sequence
// Network Comment: if start is activated and stop off, enable bit
LD I0.0
= M1.0
Network 2 Checking for overload (motor protection)
// if no overload in Main drive motor and conditions for start-up satisfied, enable bit
LDN I0.6
A M1.0
= M1.1
Network 3
// if start up conditions and motor protection conditions are met, start main drive motor
LD M1.1
= Q0.0
Network 4 Input from remote I/O analogue weighing module
// on reject present signal from PIC set bit
LD I0.4
S M1.5, 1
Network 5
// When bit REG6 is set, activate T34
LD M1.5
N***** Page 97
TON T34, +1500
Network 6
// When T34 lapses, reset bit REG6
LD T34
R M1.5, 1
Network 7
// activate rejecter arm as long as REG6 is set
LD M1.5
= Q0.2
Network 8
LD M1.5
TON T33, +100
Network 9
// off-delay timer active, start-up conditions met & no overload in RM1, enable bit
LD T33
A M1.0
AN I0.7
= M1.2
Network 10
// Run rejects drive motor if conditions are met
LD M1.2
= Q0.1
Network 11
// if acceptable package is present, c+
N***** Page 98
LD I0.2
LD I0.1
CTU C1, 500
Network 12
// Moving number of warehoused units from counter to memory address
LD M1.0
MOVW C2, MW6
Network 13
// displaying warehoused
LD M1.0
MOVW MW6, VW361
Network 14
LDN I0.3
= M1.7
Network 15
// If reject has been detected, c+
LD M1.7
LD I0.1
CTU C2, 100
Network 16
// Moving number of rejects from counter to memory address
LD M1.0
MOVW C2, MW8
Network 17
N***** Page 99
// displaying number of rejects
LD M1.0
MOVW MW8, VW401
Network 18
// If overload has been detected in either or both motors, activate REG4
LD I0.6
O I0.7
= M1.3
Network 19
// If overload has been detected activate RED indicator
LD M1.3
= Q0.4
Network 20
// If there is no overload detected in both motors, activate REG5
LDN I0.6
AN I0.7
= M1.4
Network 21
// If REG5 is set, show green indicator
LD M1.4
= Q0.3
Network 22 // TRIAL COUNTDOWN
LD M1.0
LD Q0.0
N***** Page 100

O Q0.1
ALD
TONR T5, 200
Network 23
LD T31
R T5, 1
Network 24
LD T5
TONR T31, 200
Network 25
LDN T5
R T31, 1
Network 26
LD T31
LD C4
CTU C4, 5
Network 27
LD C4
S M1.6, 1
Network 28
// If countdown to maintenance has lapsed, switch on Amber indicator
LD M1.6
= Q0.5
Network 29
N***** Page 101

// acknowledge maintenance warning
LD I0.1
R M1.6, 1
Network 30
// Maintenance Countdown Counter value
LD M1.0
MOVW C4, MW10
Network 31
LD M1.0
MOVW +5, AC0
-I MW10, AC0
Network 32
LD M1.0
MOVW AC0, MW12
Network 33
// displaying countdown to planned maintenance
LD M1.0
MOVW MW12, VW481
Network 34
// TOTAL PRODUCED
LD M1.0
MOVW C2, AC1
+I C1, AC1
Network 35
N***** Page 102

// Moving Total units value from Accumulator
LD M1.0
MOVW AC1, MW4
Network 36
// Displaying Total units value
LD M1.0
MOVW MW4, VW441
Network 37
// UPDATING SYTEM ALARM: SYSTEM FAULTY;
LD M1.0
AN M1.1
AN M1.2
= V14.7
Network 38
// UPDATING SYTEM ALARM: OVERLOAD DM1
LD M1.0
A I0.6
= V14.6
Network 39
// UPDATING SYTEM ALARM: OVERLOAD RM1
LD M1.0
A I0.7
= V14.5
Network 40
N***** Page 103

// UPDATING SYTEM ALARM: MAINTENANCE DUE
LD M1.6
= V14.4
Network 41
// UPDATING SYTEM ALARM: SYSTEM IN STOP MODE
LDN M1.0
= V14.2
Network 42
// UPDATING SYTEM STATUS: SYSTEM OK
LD M1.0
AN M1.6
A M1.4
= V14.1
Network 43
// DISPLAYING MHAMBURE T N0106701B
LD M1.0
A M1.4
= V14.0
END_ORGANIZATION_BLOCK
SUBROUTINE_BLOCK SBR_0:SBR0
TITLE=SUBROUTINE COMMENTS
BEGIN
Network 1 // Network Title
// Network Comment
N***** Page 104

END_SUBROUTINE_BLOCK
INTERRUPT_BLOCK INT_0:INT0
TITLE=INTERRUPT ROUTINE COMMENTS
BEGIN
Network 1 // Network Title
// Network Comment
END_INTERRUPT_BLOCK
N***** Page 105

APPENDIX D: BUDGET
COMPONENT Price (USD)
Load cell (0 – 125 g) 30.00
PIC 16F877 12.00
Simatic S7-200 PLC N/A
TD 200 HMI N/A
LCD 6.00
INA125P * 2 30.00
Capacitors, resistors, diodes 10.00
5* 220V relays / 24V Relays & bases 50.00
12 V DC motors 40.00
Mechanical fabrication 30.00
9*220V status indicators 9.00
Cables, connectors, lugs 13.00
Total 230.00
N***** Page 106

PLC, SCADA &amp; PIC Based Adaptable Automated Product Weighing Conveyor System - 5th Year Project

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Droits d'auteur :

PLC, SCADA &amp; PIC Based Adaptable Automated Product Weighing Conveyor System - 5th Year Project

Transféré par

Droits d'auteur :

Product weight consistency monitoring conveyor system with SCADA | Tafadzwa Mhambure

FACULTY OF INDUSTRIAL TECHNOLOGY

DEPARTMENT OF ELECTRONICS ENGINEERING

FINAL YEAR PROJECT

PRODUCT WEIGHT CONSITENCY MONITORING

MHAMBURE TAFADZWA – N*******

Submitted in partial fulfilment of the requirements of the Bachelor

PRODUCT WEIGHT CONSISTENCY MONITORING

Department of Electronic Engineering

Faculty of Industrial Technology

National University of Science and Technology

N***** Page iii

2.2.8.1 CPU ............................................................................................................................... 17

N***** Page vii

CHAPTER 4: RESULTS AND DISCUSSION ................................................................... 59

N***** Page viii

To assess the quality of products or goods produced by a certain manufacturing company

Due to economic challenges as well as lagging technological and industrial automation

 The SCADA HMI called TD 200 device.

1.1 PROBLEM STATEMENT

 Design an operational intelligent weight sensing circuit

1.4 IMPORTANCE OF STUDY

1.5 LIMITATIONS OF THE STUDY

i. PLC – Programmable logic controller

The design is relevant to the course of electronic engineering as it incorporates Process

1.9 CHAPTER OVERVIEWS

CHAPTER 2: LITERATURE REVIEW

2.1 MASS AND WEIGHT

W = M * g where M is mass of the object and g is the acceleration due to gravity.

Electro-mechanical and electronic instruments employ transducers for force measurement.

2.2 AUTOMATED WEIGHING TECHNIQUES

2.2.1 Radiation based weighing technology

Advantages of radiation based weight inspection technologies

Disadvantages of radiation based weight inspection technologies

 They face acceptability challenges

2.2.2 Gravimetric based weighing technology

Advantages of gravimetric based weight inspection technologies

 They are more acceptable to the society

Disadvantages of gravimetric based weight inspection technologies

2.2.3 Other designs

2.2.4 Quality Assurance

Reasons for quality assurance

 Satisfy consumer expectations

2.2.5 Weight and mass sensing transducers

2.2.5.1 Strain gauge

Figure 2.0 Strain gauge [5]

Figure 2.1 Strain gauges in Wheatstone bridge configuration [5]

2.2.5.2 Load cell

2.2.5.3 Resistive Load Cell

Figure 2.2 Load cell [6]

2.2.5.4 Capacitive Load Cell

 Highly precise and linear measurements

2.2.5.5 Force sensitive resistors

Force sensitive end

Figure 2.3 Force sensitive resistors [29]

2.2.5.6 Flex sensor

Figure 2.4 Flex Sensor [29]

2.2.6 Weight signal conditioning

2.2.6.1 Instrumentation Amplifier

Figure 2.5 Three Op-Amp Instrumentation Amplifier [AD8698 Datasheet]

 Pressure and strain transducers

2.2.7 PIC Microcontroller

Figure 2.6 Generic Internal Structure of a Microcontroller [10]

 Volatile Memory (RAM) for data storage

2.2.8 Programmable Logic Controller (PLC)

A PLC generally comprise of the following:

 Central Processing Unit (CPU)

PLC, SCADA & PIC Based Adaptable Automated Product Weighing Conveyor System - 5th Year Project

PLC, SCADA & PIC Based Adaptable Automated Product Weighing Conveyor System - 5th Year Project