Module in

EE - 10

MACHINE AUTOMATION AND

PROCESS CONTROL
PACKET 2

Prepared By:
Engr. Efren A. Nayra, ECE, ECT, RME, MET
 TABLE OF CONTENTS

Automated Machinery

Lesson 1 : Machine Systems

Lesson 2 : Process Systems
Lesson 1:

Machine Systems

Introduction:
The elementary actuators and techniques described are used in concert with one
another to accomplish different tasks. For instance, motors, gearboxes, bearings, and
belts are combined within a frame to form a conveyor, or pneumatic actuators;
vibratory thrusters and sensors are built into a vibratory part feeder. Manufacturers
often concentrate their expertise into combining these techniques into standard
products, whereas custom machine builders use these systems to create unique
combinations for each application.

Conveyors

Conveyors are used to move objects or substances from one point to another.
They can take many forms and are usually driven by a motor, air, or gravity. Large
conveyor systems often have a centralized control system controlled by a PLC.
Because of the long distances associated with conveyor systems, sensors and
actuators were historically often operated at 120VAC; however, with advances in
technology using distributed I/O and modern safety regulations, 24VDC systems are
now common. Figure 4.1 shows a conveyor system in a cotton-testing facility.
Motors on these large systems are usually of the three-phase 480VAC variety.
This requires I/O and motor power to be run separately if 24VDC I/O is used because of
the potential of electrical interference. Distributed I/O using communication methods
such as Profibus, Ethernet, or Device Net requires additional cabling that is also usually
attached to the frame of the conveyors. A local disconnect is often provided near each
motor and may be monitored by the control system. Safety devices such as E-Stop
push buttons and cable pull actuated E-Stops are also generally mounted to the frames.
HMIs often depict the layout of the system, showing the status of the system
components along with production or packaging machines integrated with the system.
Conveyor control systems can be very elaborate and have hundreds or thousands of
I/O points. They also often use multiple variations of the types of conveyors described in
this lesson.
 Figure 4-1 Conveyor System

Belt Conveyors

A belt conveyor consists of two or more pulleys or rollers with a continuous loop
of material with the conveyor belt rotating around them. One or both of the pulleys may
be powered, moving the belt and the material on the belt forward. Powered pulleys or
rollers are called drive or driven elements, while the undriven rollers or pulleys are
called idlers. Idlers may also be located on the underside of the conveyor for support of
the return strand of belt. Motors for belt conveyors are typically located at the head, or
pulling end, of the conveyor. For reversing conveyors, the motor may be located in the
middle.
Belts may be made of many different materials ranging from rubber or plastic
compounds to metal mesh. Many belts are made of composites with an under layer for
strength and a cover material to protect the product. Belt conveyors are usually used in
applications requiring a solid surface, where materials cannot be easily passed across
rollers. Belt materials are often chosen based on strength requirements or load, the
amount of friction required, and the environment that they are exposed to. Cleats and
sidewalls may be attached to the belt surface to help confine materials or reduce the
need for high-friction surfaces that may damage products. Cleat spacing and durability
are key factors in the choice of material and bonding methods for a cleated belt.
 Figure 4-2. Cleated belt inclined conveyor
If belt conveyors are used on an incline or decline, the friction coefficient of the
belt is typically high. A nose-over section is often placed on the top, bottom, or both
sections of incline belt conveyors to allow for easy transitions of material from other
conveyors or into hoppers. Figure 4-2 shows a small cleated conveyor on wheels used
for packaging.
Belt conveyors are one of the least expensive types of conveyor. They typically
have a metal framework with rollers at each end. The belt may be pulled across a flat
surface or bed. For heavier loads, it may also move across additional rollers. These are
known as slider bed and roller bed conveyors, respectively. To ensure the belt is at the
proper tightness and tracks well across the rollers, the end roller is often adjustable.
Rollers may also be crowned to ensure belt centering.

Roller Conveyors
Roller conveyors can take several forms: they may be powered or unpowered,
belt or chain driven, or even series of individually powered rollers. Rollers are usually a
metal shell with a shaft on each end. Depending on the weight and material being
conveyed, rollers may be thin-wall aluminum or heavier-gauge steel, rubber coated or
individual gravity “skate wheels.” Thin-wall rollers are easily bent, dented, or cut and are
not suitable for all applications, but they are often used for package handling. Axles on
these rollers are often spring-loaded for easy removal.
Roller conveyors are usually used for moving packages with flat bottoms, like
boxes. Rollers should be spaced so that at least three rollers are underneath the
package at any time. Rollers may be driven using various methods. A line shaft may be
placed along the length of the conveyor with individual urethane belts attached to each
roller from spools on the shaft. Another method of driving rollers is to place either a flat
or V belt on the underside of the rollers.
Metal chain can also be used to drive the rollers. A single chain can be used to
drive all of the rollers or rollers can be linked together with roller-to-roller links. A greater
number of sprocket teeth in contact with the chain allows for heavier loading.
Roller conveyors present special challenges when used on a curved section.
Rollers must be spaced farther apart at the outside edge of the curve. Using a double
section of rollers with more rollers on the outside section can mitigate this. Some rollers
are even made that are larger on one end than the other. One note on curved
conveyors—product should never be accumulated on a curve.
Figure 4-3 illustrates part of a roller conveyor system for cardboard containers.
This section is known as a “merge.”
An interesting product sometimes used for roller conveyors is the individually
powered roller. These are essentially cylindrical motors with fixed shafts. These are
usually DC powered and can be used to drive products section by section.
Gravity roller conveyors may be of the roller, or “skate wheel,” type. These
unpowered conveyors are usually used in short horizontal runs where operators push
products from one end to the other or when products drop from one level to another.
Skate wheel conveyors are often placed on a wheeled frame so that it can be moved
from one location to another. Another closely related non-powered conveying device is
the ball table, which allows products to be moved in any direction by pushing them
across a table embedded with large ball bearings. These are often used when moving
totes of parts in machine loading and unloading areas.

Figure 4-3. Roller Conveyor

Chain and Mat Conveyors

Chain conveyors use a continuous chain that runs from one sprocket
to another at each end of a frame. Pendants or containers may be
attached to the chain for product containment and transport. The
most common type of chain conveyor is the tabletop chain conveyor,
which has flat plates connected to the chain. Cleats are sometimes
added to these plates for product separation and indexing.
Chain conveyors often use parallel strands of chain mounted to
dual sprockets or gears on each end of an axle or shaft. This allows for
devices such as lifts, stops, or transfers to be mounted between the
chains. Tabletop chains with slats or plates can then be used to move
pallets or products between these devices.
Tabletop chains may be composed of a thermoplastic material
or metal. The chain is usually contained in a channel between the
sprockets that guide it. The plates can also be made in such a way
that they overlap and can turn, allowing for curved conveyor runs.
Another term for this type of conveyor is multiflexing since the
chain is flexible both sideways and on an incline. An example of a
tabletop chain conveyor is shown in Fig. 4.4. Because the plates
have space between them, they are also effective for drainage or
airflow—an important consideration if working with metal machine
parts.
Tabletop chain conveyors are not placed under tension like a belt
conveyor since a sprocket is used to drive it. A catenary is typically
used at the ends on the chain; this is a hanging loop that allows for an
easy return of the chain on the underside of the conveyor frame. The
catenary runs from the sprocket over a “shoe” and into containment
by Teflon guides underneath.
Chain conveyors may also be used for suspending parts or
pendants. A common application for this type of conveyor is for paint
booths or ovens. In this case, the chain is almost always metal with
hooks located at intervals along the chain.
The mat top conveyer is closely related to the single column of
links used in a chain conveyor. This type of conveyor uses multiple
columns of links chained together in a mat. Although not as flexible
as tabletop chains on curves, mat top conveyors can generally support
more weight. Chain and mat conveyors are usually driven by AC motors, often
with variable speed drives for speed control. Chain and mat conveyors
with cleats may also be driven with a servo for indexing purposes.
Typically this is done using a sensor at the cleat for stopping the
indexing motion and verifying position.

Figure 4-4. Tabletop chain conveyor

Vibrating Conveyors

Vibrating conveyors are used for moving bulk materials. Sometimes

called shakers or shaker tables, they have a solid conveying surface
with sides to contain the material being conveyed.
Vibrating conveyors operate on the natural frequency principle.
With only a small energy input, an object can be made to vibrate at
some frequency by alternately storing and releasing energy using
supporting springs. The drive mechanism is usually an electric motor
with a fixed eccentric shaft or rotating weight. A flat pan vibrating
conveyor will convey most materials at a 5° incline from horizontal.
Food grade applications use vibrating conveyors extensively.
Because vibrating conveyors are often made of stainless steel and can
be easily coated with materials such as Teflon, they are suitable for
wash-down and corrosive environments. They are low maintenance
and excellent for sanitary applications. They are also used in
applications for sorting, screening, classifying, and orienting parts.
Accessories for vibrating conveyors include counterbalance
members for reducing reactions by generating an out-of-phase
response to conveyor motion and weighted bases with isolation
springs to reduce transmitted vibrations.
Air knife separators are an air-driven method of separating
different weight materials. They are sometimes used with vibrating
conveyors as a sanitary noncontact method of diverting material.

Pneumatic Conveyors

Pneumatic conveyors use pipes or ducts to transport materials using

a stream of air. The most commonly transported materials using this
method are dry pulverized or free-flowing powdery materials.
Carriers can also be transported using air. Items can simply be
pushed from one location to another using a push or pull pressure
system.
Following are three basic systems that are used to generate highvelocity
airstreams for conveying:
1. Suction or vacuum systems use a vacuum created in the
pipeline to draw the material with the surrounding air. The
system is operated at a low pressure, usually 0.4 to 0.5 atm of
pressure. This method is used mainly in conveying light freeflowing
materials.
2. Pressure type systems use a positive pressure to push material
from one point to the next. The system is ideal for conveying
material from one loading point to a number of unloading
points. It operates at a pressure of 6 atm and upward.
3. Combination systems use a suction system to convey material
from a number of loading points and a pressure system to
deliver it to a number of unloading points. Air pressure may be generated using an
industrial blower or fan.
Alternatively, compressed air is sometimes used for small-volume
applications.
 GOOD TO KNOW

A conveyor system is a fast and Reference :

efficient mechanical handling
apparatus for automatically 1. Mechanical Conveyors
transporting loads and materials By: Thomas Skocir
within an area.

Learning Check :
1. Discuss the Following in your own understanding:
a. Belt Conveyors
b. Roller Conveyors
c. Chain and Mat Conveyors
d. Vibrating Conveyors
e. Pneumatic Conveyors