UTHM

Universiti Tun Hussein Onn Malaysia

FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF ELECTRICAL ENGINEERING TECHNOLOGY

MTPI

(MAKMAL TEKNOLOGIPERANTIINDUSTRI)

TECHNICAL REPORT

Course Code & Name /

Kod & Nama Kursus BND 25603 ELECTRO-PNEUMATIC TECHNOLOGY LABORATORY

Code & Title of Activity/ Kod & W11-W14_DESIGN PROJECT

Tajuk Aktiviti
Date of Experiment/ 7 December 2021
Tarikh Ujikaji
Programme/'Program BND
Group/ Kumpulan 9
Matrix No./
Name/Nama No. Matrik
Group Members/
1. MUHAMMAD AKMAL BIN MUSA CN200089
Ahli Kumpulan
2. MUHAMMAD IRHAM BIN KHALID CN200044
3. IZZUL HAKIM BIN SAMSAIFUL CN200222
4. ABDUL RASYDAN BIN ABD AZIZ AN190126
Instructor Name / 1. PUAN SUMAIYA BINTI MASHORI
Nama Instruktor 2.

COGNITIVE /10m

Assessment / Penilaian

PSYCHOMOTOR /10m

AFFECTIVE /10m

Link youtube video https://youtu.be/4-sYAblldPc

 1. INTRODUCTION

An automatic colour sorter and packed using optical sensor is proposed in this research. The
design model and characterization of an automated classification system product using a conveyor belt
with optical and capacitive proximity sensor to control three single acting cylinder. The application of
automatic colour sorter is for the pneumatic design that used fluidsim festo and cx-progammer software
for the design and implementation of this project.

The Objectives of this project is first to create a system that can separate a red item from any
colour of item and packed into box with quantity of 5 item per box and one operator will push reset
button and put empty bos to replace the box that full of item. Colour sorters are can be used for the food
processing industry, such as coffee, nuts, and oil crops. The goal is the separation of items that are
discoloured, toxic (such as ergot), not as ripe as required, or still with hull after dehulling such as
sunflower seeds.

This project based on colour can be used for Industrial purposes, for sorting skittles, coloured
balls and M&Ms. Can be used in Automobile Industries.Food Processing industries, pharmaceutical
industries, automotive industries, agriculture industries, pharma industry, logistic industry, separation
of rotten vegetables, In food industries to identify the rotten or damaged fruits, separation of ripe or
unripe fruits, packing of tablets having different colours where this system reduces the human effort,
labour cost and also time of operation. In bio medical field, colour and shape analyzing algorithm can
be used for recognition of cancer cells

This project is needed to fulfill course learning outline that is to analyze the electro-pneumatic
control circuit for various application and to analyze the PLC programming using different process
description to control an automation system for various application.
 2. CASE STUDY STATEMENT

The case study statement is to Creating a system that can separate a red item from many colour
of item and packed into box with quantity of 5 item in the box. How this will work is all mix item will
be put at moving conveyer when detent switch is pressed as shown as Figure 2.1. Optical sensor is used
to detect red color item to activated actuator 1 while make a way and fill in the box. While counting the
red color item five-time, actuator 2 will push the full box after few second red items fall in the box.
Then, Reset button1 need to push to retract the actuator 2 and reset the counter. For item other than red
color, capacitive sensor is used to count the item five-time and few second after it, actuator 3 will push
the box for different color. Then the reset button will be pushed to retract actuator 3 and reset the
counter. The program will be looping until detent switch is pressed and counter will reset when each
push button is pressed.

Figure 1: One operator put the mix item on conveyer

 3. FLUIDSIM SOFTWARE

a) LIST OF EQUIPMENT

Number Item Picture

1 Compressor

2 Air service unit

3 Manifold

4 3/2-way directional
control valve,
normally close

5 Single acting cylinder

6 Push button module

7 Relay module
8 Timer module

9 Counter module

10 24 Vdc Power Supply

11 Banana Cable

12 Optical Sensor

13 Capacitive Sensor

14 Fluidsim Software
b) ELECTRICAL AND PNEUMATIC CONTROL CIRCUIT
 Base on figure 2 below, this is a picture of circuit to control the system in pneumatic, using 24v
source power supply and connected to detent switch (-SF1) connected to relay (-KF1). Relay (-KF1)
will active low optical sensor (-OPT_S) and capacitive sensor (-CAP_S). Signal of optical sensor will
connected to timer relay (-T1) and capacitive sensor signal will connected to counter 2 (-C2). –T1 will
connected to solenoid valve (-MB1) and counter relay (-C1). Reset button (-R1) will reset –C1 counter.
–C1 counter will activate timer relay (-T2) and –T2 will connected to solenoid valve (-MB2). Reset
button (-R2) will reset the counter relay –C2 and –C2 will activate timer relay (-T3). –T3 will
connected to solenoid valve (-MB3).

+24V 1 2 3 4 5 6 7 8 9 10 11 12 13

3 3 3 3 ACTU
3 2 4 2 4 3 3
3
-T1 -R1 -C1 -T2 -KF1
-SF1 -KF1 -C2 -T3
-R2
4 4 4 4
4 1 1 4 4
4

-MB1
1 3

-OPT_S -M
A1 -MB1 -CAP_S
-KF1
A1
A2 A1 R1
-C1 5 -T2 4 -MB2 A1 R1 A1
A1
A2 R2 -C2 5 -MB3
A2 -T3 4
-T1 3 A2 R2
A2
0V A2

2 2 4 7 8 12 13
9 9

Figure 2: Electrical circuit

In figure 3, the pneumatic circuit is shown the compressor is connected to air service unit. The output
will go to manifold and connected to three 3/2 way valve solenoid. Every each solenoid will activate
9 one single
10 11 acting
12 cylinder.
13

3 ACTUATOR1
2 4 3 3
3
-KF1 -C2 -T3
-R2
4
1 4 4
4

2
ACTUATOR2
-MB1
1 3

2 ACTUATOR3

-MB2
-CAP_S 1 3

2
A1 R1 A1
-C2 5 -MB3 -MB3
-T3 4
A2 R2
1 3
A2

12 13

s
Figure 3: Pneumatic circuit

c) SIMULATION AND ANALYZE THE CONTROL CIRCUIT

-Base on figure 4, when the detent switch pressed the optical and capacitive sensor will active low.

Figure 4: After detent switch pressed

- Base on figure 5, when optical sensor active high, single acting cylinder will extend.

Figure 5: When optical sensro active high

- Base on figure 6, when counter C1 finish countdown when timer T2 finish, single acting
cylinder 2 will extend. R1 will make the single acting cylinder retract.
 Figure 6: When counter 1 finish and timer 2 finish

- Base on figure 7, when capacitive sensor –CAP_S active high for 5 times, counter relay -C2
activate and make timer relay -T3 active for 4 second then after finish, -T3 activate solenoid
valve –MB3 make single acting cylinder ACTUATOR3 extend.

Figure 7: When capacitive sensor active high 5 times.

- Base on figure 8, reset button -R2 will make the single acting cylinder ACTUATOR3 retract.
 Figure 8: When -R2 is pressed

- Base on figure 9, all the component will turn off when detent switch is pressed. All three acting
cylinder are normally closed.

Figure 9: When detent switch is pressed

 d) WIRING CONNECTION

This is a connection we have made on pneumatic lab and we have drawing back. Blue colour
will go to ground and red is a 24V and signal. While dark blue are tube to connect air between
component. This can be shown in figure below.

Figure 10: Connection of all pneumatic component

e) PHOTO OF EXPERIMENTAL SETUP

i. Initial Condition When Detent Switch is pushed:

Figure 11
 ii. When Optical Sensor Detect red color, actuator 1 will extend for few second because timer 1
hold it, and counter 1 will start counting:

Figure 12

iii. When counter 1 count to five, actuator 2 extend after few second when timer 2 activated:

Figure 13
iv. When reset button 1 is pressed for counter 1, back to initial condition:

Figure 14

v. When counter 2 is counted for five time by capacitive sensor, actuator 3 extend after timer 3
activated:

Figure 15
vi. When reset button 2 is pressed for counter 2, back to initial condition, and will looping the
program until detent switch is pressed again :

Figure 16
4. CX-PROGRAMMER SOFTWARE

a) LIST OF EQUIPMENT

Compressor (1)

Air service unit (1)

Manifold (1)

3/2-way directional control valve, normally

close (3)
Single acting cylinder (3)

Optic sensor (1)

Capacitive sensor (1)

PLC CP1E training kit (1)

Laptop with CX-Programmer Software (1)

 USB cable (1)

Ste

b) ASSIGN INPUT AND OUTPUT DEVICE:

Input: Start (I:0.00), RS1 (I:0.03), RS2 (I:0.04), Sensor opt (I:0.01), Sensor cap (I:0.02)
Output: Conveyor (Q:100.00), SAC1 (Q:100.01), SAC2 (Q:100.02), SAC3 (Q:100.03)

c) Process Sequence Description (PSD) – Simple Narrative

Step Input Output

1 Detent switch pressed Conveyer motor start
2 Optical sensor detect red TIM 000 #40,Single Acting
Cylinder 1 extend
3 T000 CNT 000 #5
4 C000 TIM 001 #30
5 T001 Single Acting Cylinder 2
extend
6 Sensor Capacitive detect other CNT 001 #5
colour
7 C001 TIM002 #30
8 T002 Single Acting Cylinder 3
extend
d) LADDER DIAGRAM

Figure 17
e) SIMULATION LD USING WORK ONLINE SIMULATOR– DISCUSS THE
OBSERVATION
 When Start Switch is pressed:
Rung 0: The conveyor will on.
Rung 1: Sensor opt will on when detect red box and SAC1 extend for 4 seconds.
Rung 2 : Every time when contact T000 NC, CNT000 will energize for 5 times.

Figure 18

 After CNT000 counting for 5 times:

Rung 3: Contact C000 will be NC, TIM001 will energize for 3 seconds.
Rung 4: After 3 seconds, contact T001 will be NC and SAC2 will extend.

Figure 19
 When SAC2 is extend:
Rung 2: CNT000 will be reset when the RS1 is pressed, then SAC2 will retract back to its
end position.

Figure 20

 When Start Switch is pressed and conveyor is on:

Rung 5: Sensor cap will on when detect other than red box and CNT001 will energize every
time sensor cap is on for 5 times.

Figure 21

 After CNT001 counting for 5 times:

Rung 6: Contact C001 will be NC, TIM002 will energize for 3 seconds.
Rung 7: After 3 seconds, contact T002 will be NC and SAC3 will extend.

Figure 22
  When SAC3 is extend:
Rung 6: CNT001 will be reset when the RS2 is pressed, then SAC3 will retract back to its
end position.

Figure 23

f) PLC TO HARDWARE CONNECTION

Figure 24
g) PHOTO OF EXPERIMENTAL SETUP
 5. DISCUSSION

In this project, we face a problem for wiring component in plc. For plc, we have trouble shoot
the ladder diagram because there is error in the ladder diagram but we can solve them. There is a short
circuit when we construct the circuit. So the solution that we get is we check every connection and
component in good condition. The problem that we face is not enough component to construct the
circuit.

From this project that we have done, the whole control system based on the observation that we
have done. The system that we have do is colour sorter that will seperate things that have diffrent
colour, in this system by our observation this system can be control using two way which is pneumatic
FESTO module in the station and PLC (Proggrammable Logic Controller).

This system using optical sensor and capacitive sensor as input and three single actuator as
output. The electric system being control by one relay, two counter relay and three timer relay. For
pneumatic the system being control using three 3/2 way valve for input output pressure air.

In pneumatic, how the system work is the optical and capacitive will on after detent switch is
on. When the red sensor detect red, then the sensor will active high and activate single acting cylinder 1
to extend for 3 second. While when the capacitive sensor sense any item for 5 times the single acting
cylinder 3 will extend after four second capacitive sensor active high. Lastly, when the optical sensor
active high five times after detect red, it will make single acting cylinder 2 extend after four second
optical sensor active high.

For our opinion, the control circuit is better is plc because it is more simple, reliable, easy to
understand and more advantage than using relay in ep. In plc it will show the error in rung and easy to
troubleshoot the ladder diagram.in Plc it use a less component than ep because in ep it will use a lot of
relay in it.For plc it need its own component for counter and timer but for plc u can make it in the
ladder diagram.

6. CONCLUSION

From the project that have been done, the project has been done that meet the objective required
in the case study to make a two way for red item color and different item color to put into the box while
also counting the item in the box for five item each box. It will make the works done easier to separate
many items at once. This program will be looping until the detent switch is pressed.

The ability to perform pneumatic functions can outweigh the potential inconveniences of
installing the electrical infrastructure to support a PLC system. While the arguments in favor of
pneumatic hardware are still considerable, changing market conditions may simply force the issue as
those devices are simply unavailable or too expensive. The potential of losing production due to the
inability to find a replacement part for a legacy system could outweigh the cost of upgrading to PLC.

With PLC, features and options preferred in a pneumatic application can be implemented easily
and modified as required with no real physical change to the process. Direct remote access to the
control loop via system provides a level of remote insight into a loop that is simply not possible with
pneumatic equipment. Pneumatic control has had a long and admirable history, but for many it's time to
upgrade to the capabilities of more modern approaches in the applications.
 7. REFERENCE

1. http://www.ijsred.com/volume2/issue3/IJSRED-V2I3P73.pdf
2. https://www.sciencedirect.com/science/article/pii/S2215098616302105
3. https://www.researchgate.net/publication/
317559782_Efficient_Automated_Fruit_and_Vegetable_Sorter_based_on_Colour_detection

8. MINUTES OF MEETING

Meeting objective: Discussion and division of task

Place: google meet website
Date: 26/12/2021
Time: 10.00pm - 11.00pm

Content of meeting:
1. Izzul do the case study project, Irham do circuit, Akmal make the PLC circuit, Rasydan make
the PLC circuit.

2. Report

1. COVER PAGE - Akmal

2. INTRODUCTION - OBJECTIVE - izzul
3. CASE STUDY STATEMENT - irham
4. FLUIDSIM SOFTWARE
a) LIST OF EQUIPMENT - irham
b) ELECTRICAL AND PNEUMATIC CONTROL CIRCUIT - izzul
c) SIMULATION AND ANALYZE THE CONTROL CIRCUIT - izzul
d) WIRING CONNECTION - irham
e) PHOTO OF EXPERIMENTAL SETUP - Irham
5. CX-PROGRAMMER SOFTWARE - akmal
6. DISCUSSION - Rasydan
7. CONCLUSION - Irham
8. REFERENCE- Izzul
9. MINUTES OF MEETING - Rasydan