CHAPTER 4

PART DETAILS

4.1) Belt Conveyor -: A Rubber Belt Conveyor is used with a dimension of 100cm in
length . which is placed on the rollers for transportation of the product as Shown in
Fig 4.1 . The purpose of using this type of belt is keep grip on on the product
transport. Rubber conveyor belts are commonly used to convey items with irregular
bottom surfaces, small items that would fall in between rollers (e.g. a sushi conveyor
bar), or bags of product that would sag between rollers. Belt conveyors are generally
fairly similar in construction consisting of a metal frame with rollers at either end of a
flat metal bed. The belt is looped around each of the rollers and when one of the
rollers is powered (by an electrical motor) the belting slides across the solid metal
frame bed, moving the product. In heavy use applications the beds which the belting
is pulled over are replaced with rollers. The rollers allow weight to be conveyed as
they reduce the amount of friction generated from the heavier loading on the belting.
Belt conveyors can now be manufactured with curved sections which use tapered
rollers and curved belting to convey products around a corner. These conveyor
systems are commonly used in postal sorting offices and airport baggage handling
systems. A sandwich belt conveyor uses two conveyor belts, face-to-face, to firmly
contain the item being carried, making steep incline and even vertical-lift runs
achievable
.

Fig 4.1 – Belt Conveyor

4.2) Rollers -: In fig 4.2 Two Plastic Rollers Driver And Driven with attached to
servo motor with a diameter of 10 cm is Fixed for motion of belt. It has Minor Cut At
centre of the rotor for gripping purpose.
 Fig .4.2- Roller

4.3) Stepdown Trasnformer -: As Shown in fig 4.3,A stepdown Trasnformer is

used to supply current to the circuit , Which has 220 v to 12 v converting power
supply Abiliity. For the project 12 V current in DC for working of model. Stepdown
Transformer is used for application of converting power output from AC to
DC.Transformers are static electrical devices with no moving parts, transforming
electrical power from one voltage and current setting to another. The frequency of the
electrical current remains constant
Transformers are classified by their function, which is either step up or step down.
Step-up transformers increase the voltage of the incoming current, while step-down
transformers decrease the incoming current’s voltage. The incoming voltage is
referred to as the primary voltage, while the outgoing stream is referred to as
secondary.
Generally, step-up transformers are located at power generation plants, stepping up
the voltage flowing from the power plant to long-distance distribution networks. Step-
down transformers, on the other hand, decrease the voltage of power streams received
at the local distribution level. The long-distance stream is first stepped down to a level
acceptable for local distribution, and then stepped down again at each consumer node
(residential homes and offices).

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 Fig 4.3- Stepdown Transformer

4.4) SCADA -: A supervisory Control and DATA Advisory is used in PLC circuit for
smooth working of All sensors and used to collect the sensor data in output with
accuracy.
4.5) PLC circuit -: A Programmable Logic Circuit is (PLC) is Placed for Giving
The input Signal to Temperature , & IR sensors with inbuild Coding is provide in it. It
is attached with Display With Shows the Object Counting , Temperature and Other
Parameters form output From sensors. IT using By Embedded system which widely
used in PLC .It is 16 bit microcontroller which is Commonly used. This whole system
is operated by proximity sensor, motor and PLC in our project we use capacitive type
of proximities sensor to sense the material at which position and it gives the signal
towards the PLC .The PLC of our project depends on the number of input output
module and analog signal .We select PLC in our project, because Programmable
Logic Controller, popularly known as PLC is a tool. It is the imagination that limits
it's scope .Currently it is abundantly used in process control and machine control.
With increased applications prices shall come down and that will further boost it's
application .PLC basically a low current device so usually electronic faculty people
can handle it or design the PLC, but coming to application, i.e. sales and marketing
,mostly it is uses in high electric network system, so a electrical knowledge is
essential .The PLC is user friendly digitally, operating electronic device that uses
programmable memory for internal storage of instruction that implement specific

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function, such as logic sequence, timing, counting to control machine and process
.The PLC signal can be use for start and stop motor . As Shown in Fig 4.4 The PLC
we use here dc motor that operated at 12(v)/24(v) DC supply .The voltage depend
upon speed require for the process .This conventional method of conveyor control is
his conventional method of conveyor control is further mobilized by use of dimmers.
They were better option in the case of on off control they can be operated in full load
condition also. But the main problem with them is stoppage of conveyors . the
pneumatic stoppers were used which did not stop the belts completely but use to stop
materials on it. This leads to wear and tear of the belts as well as the product also the
rejection ratio is increased .Computerized conveyor belt system isused. In this the
control of these belts is achieved by the use of the pc interface and plc based. These
lead to better option of conveyor control in today’s industrial environment. It is very
difficult for those to maintain them at constant or through variable speeds .Recently
single shop conveyor belt systems are modified to become multiple type i.e instead of
single conveyor multiple conveyors are used in series, parallel and speed is controlled
using remote monitoring. Also the recent trend is Airports, mines, cement plants,
distribution facilities, assembly, and food processing plants all utilize conveyors.
Conveyors are typically constant torque loads, meaning the required torque to drive a
conveyor is independent of speed. A fixed amount of torque is also required to
overcome the frictional, or machine drag, portion of the total load. Conveyors can
have nominal amounts of friction and machine inertia for which to compensate.
Material flowing over the belt may be weighed in transit using a belt weigher . Belts
with regularly spaced partitions, known as elevator belts, are used for transporting
loose materials up steep inclines. Belt Conveyors are used in self-unloading bulk
freighters and in live bottom trucks..

Fig 4.4– PLC circuit With LCD Display

4.6) Temperature Sensor -: A precision Temperature Sensor is placed before the

Cooling Fan Which Provide the accurate temperature to PLC circuit & if temperature
goes up beyond given limit it Starts the cooling Fan for cooling.

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4.7) Object Counting Sensor -: A object Counting Snesor in Fig.4.5 fitted at the last
part of the conveyor belt . If all Parameters like Length , height & temperature is
Satisfied Then only the Object is count As per given Input . otherwise it Won’t Sacn
the object. In this sensor theTrasmitter & receiver Both Are present for Counting of
an object. This sensor Notation is Given as “Z” in PLC LCD Display. Means it is
denoted as “Z”. A white LED is receiver & Black LED as Tansmitter which receives
signal.

Fig 4.5– IR Sensor (object Counting)

4.8) Cooling Fan-: A Cooling is placed beside the Tempersture Sensors, which is
cool down the temperature of product Passing through Conveyor Belt. A 120mm

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Diameter cooling having 12V DC power supply which is Connected to PLC circuit.

Fig 4.6– Cooling Fan

4.9) Servo DC Motor-: A servo Dc Motor is Attcheed to The driver Roller which is
used to run the conveyor Belt . A DC Sevo motor Requires 12 v DC input current.
Which is run at very low 50rpm . It is just made up of simple motor which run
through servo mechanism. If motor is used is DC powered then it is called DC servo
motor, you want to rotate and object at some specific angles or distance, then you use
servo motor. It is just made up of simple motor which run through servo mechanism.
If motor is used is DC powered then it is called DC servo motor, and if it is AC
powered motor then it is called AC servo motor. We can get a very high torque servo
motor in a small and light weight packages. Doe to these features they are being used
in many applications like toy car, RC helicopters and planes, Robotics, Machine etc.
Servo motors are rated in kg/cm (kilogram per centimeter) most hobby servo motors
are rated at 3kg/cm or 6kg/cm or 12kg/cm. This kg/cm tells you how much weight
your servo motor can lift at a particular distance. For example: A 6kg/cm Servo motor
should be able to lift 6kg if the load is suspended 1cm away from the motors shaft, the
greater the distance the lesser the weight carrying capacity.
The position of a servo motor is decided by electrical pulse and its circuitry is placed
beside the motor.
Servo Mechanism
It consists of three parts:
1) Controlled device
2) Output sensor
3) Feedback system
It is a closed loop system where it uses positive feedback system to control motion
and final position of the shaft. Here the device is controlled by a feedback signal
generated by comparing output signal and reference input signal.

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 Here reference input signal is compared to reference output signal and the third signal
is produces by feedback system. And this third signal acts as input signal to control
device. This signal is present as long as feedback signal is generated or there is
difference between reference input signal and reference output signal. So the main
task of servomechanism is to maintain output of a system at desired value at presence
of noises.
Working principle of Servo Motors
A servo consists of a Motor (DC or AC), a potentiometer, gear assembly and a
controlling circuit. First of all we use gear assembly to reduce RPM and to increase
torque of motor. Say at initial position of servo motor shaft, the position of the
potentiometer knob is such that there is no electrical signal generated at the output
port of the potentiometer. Now an
electrical signal is given to another input terminal of the error detector amplifier. Now
difference between these two signals, one comes from potentiometer and another
comes from other source, will be processed in feedback mechanism and output will be
provided in term of error signal. This error signal acts as the input for motor and
motor starts rotating. Now motor shaft is connected with potentiometer and as motor
rotates so the potentiometer and it will generate a signal. So as the potentiometer’s
angular position changes, its output feedback signal changes. After sometime the
position of potentiometer reaches at a position that the output of potentiometer is
same as external signal provided. At this condition, there will be no output signal
from the amplifier to the motor input as there is no difference between external
applied signal and the signal generated at potentiometer, and in this situation motor
stops rotating.
4.10) 8051with display :- As in Fig 4.7 LCD display is an inevitable part in almost
all embedded projects and this article is about interfacing 16×2 LCD with 8051
microcontroller. It is connected to PLC circuit which Shows the data Output of the
sensors in numeric format. 8051 microcontroller is an 8-bit family of microcontroller
is developed by the Intel in the year 1981. This is one of the popular families of
microcontroller are being used all across the world. This microcontroller was
moreover referred as “system on a chip” since it has 128 bytes of RAM, 4Kbytes of a
ROM, 2 Timers, 1 Serial port, and 4 ports on a single chip. The CPU can also work
for 8bits of data at a time since 8051 is an 8-bit processor. In case the data is bigger
than 8 bits, then it has to be broken into parts so that the CPU can process easily. Most
manufacturers contain put 4Kbytes of ROM even though the number of ROM can be
exceeded up to 64 K bytes.
8051 Microcontroller :-
The 8051 has been in utilized in a wide number of devices, mostly because it is easy
to integrate into a project or make a device approximately. The following are the
major areas of focus:
1) Energy Management: Efficient metering systems facilitate in controlling energy
usage in homes and manufacturing applications. These metering systems are prepared
capable by incorporating microcontrollers.

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2) Touch screens: A high number of microcontroller providers incorporate touch-
sensing capabilities in their designs. Portable electronics such as cell phones, media
players and gaming devices are examples of microcontroller-based touch screens.
3) Automobiles: The 8051 finds wide taking in providing automobile solutions. They
are broadly used in hybrid vehicles to handle engine variants. Furthermore, functions
such as cruise control and anti-brake system have been prepared more capable with
the use of microcontrollers.
4) Medical Devices: Moveable medical devices such as blood pressure and glucose
monitors use microcontrollers will to show data, thus provided that higher reliability
in providing medical results.

Fig 4.7 – LCD display 8051

4.11) IR Sensor :- IR sensor basically consist an IR LED and a Photodiode, this pair
is generally called IR pair or Photo coupler. IR sensor work on the principal in which
IR LED emits IR radiation and Photodiode sense th beat IR radiation. Photodiode
resistance changes according to the amount of IR radiation falling on it, hence the
voltage drop across it also changes and by using the voltage comparator (like LM358)
we can sense the voltage change and generate the output accordingly.
The placing of IR LED and Photodiode can be done in two ways: Direct and Indirect.
In Direct incidence, IR LED and photodiode are kept in front of one another, so that
IR radiation can directly falls on photodiode. If we place any object between them,
then it stops the falling of IR light on photodiode.
And in Indirect Incidence, both the IR LED and Photo diode are placed in parallel
(side by side), facing both in same direction. In that fashion, when a object is kept in
front of IR pair, the IR light gets reflected by the object and gets absorbed by
photodiode. Note that object shouldn’t be black as it will absorb all the IR light,
instead of reflect. Generally IR pair is placed in this fashion in IR sensor Module.
To build an IR module, we mainly need IR pair (IR LED and Photodiode) and LM358
with some resistors and a LED.
4.12) Ultrasonic Sensor:- Ultrasonic ranging module HC - SR04 provides 2cm -
400cm non-contact measurement function, the ranging accuracy can reach to 3mm.
The modules includes ultrasonic transmitters, receiver and control circuit. The basic
principle of work:
(1) Using IO trigger for at least 10us high level signal,

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(2) The Module automatically sends eight 40 kHz and detect whether there is a pulse
signal back.
(3) IF the signal back, through high level , time of high output IO duration is the time
from sending ultrasonic to returning.
Test distance = (high level time×velocity of sound (340M/S) / 2,

5V Supply
Trigger Pulse Input
Echo Pulse Output
0V Ground
Electric Parameter :-
Working Voltage DC 5 V
Working Current 15mA
Working Frequency 40Hz
Max Range 4m
Min Range 2cm
MeasuringAngle 15 degree
Trigger Input Signal 10uS TTL pulse
Echo Output Signal Input TTL lever signal and the range in proportion
Dimension 45*20*15mm

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