GROUP TASK TEAM-4

PLC BASED AUTO

DIVERTERS
MAINTENANCE PROBLEM
ENCOUNTERED
Manual intervention required for diverting
rectified cylinders from VLD/OLD rejection loops
to main line.
Negligence by Haulage Workers frequently leads
to accumulation of more than 20 cylinders
leading to undue load on Motor and increase in
wear/tear of chain
Sudden release of >20 cylinders leads to line
jamming upto carousel which reduces utilization
of carousel
 Implemented Solution
Replacing T-Section by Y-Section where the rejection loop is connecting to Main Line.

Sensors are placed both in Main Line and Rejection Loop and auto divertor. Input from sensors
will be processed by a PLC to give output to pneumatic actuators for auto-diverter & stoppers.

They sense the gaps in the main line & loop line, and accordingly actuates the diverter to
control cylinder movement from main & loop lines.

Even if for 2 seconds, check sensor in one line doesn’t sense a cylinder, the auto diverter will
release cylinders (if present) from the other merging line.
 Flow Chart of Solution

Double stopper(1) 2
3
4

1
Check sensor(2)
Diverting arm(3)

Check sensor(4) Diverting arm(3)

Working of new system
 ADVANTAGES OVER PREVIOUS SYSTEM
Preventing Reducing load on
No manual Smart operation for
unnecessary load stoppers, hence less
intervention conversion/diversion of
on loop line DUs breakage & spare
required. cylinders and thereby
consumption
productivity can be
improved.
 Alternative Solution by Group
• Another alternative solution can also be opted for.
• Without modifying the T-Section we can adopt a system which will have two nos of sensors in
the rejection loop line – one for generating a “jamming alarm” (first alarm, with two times
hooter) & the other one generating a “high jamming alarm” (second alarm, with four times
hooter).
• After accumulation of around 4-5 cylinders a jamming alarm will be indicated and 9-10
cylinders “high jamming alarm” will be indicated which will alert the handling labour to
immediately evacuate the cylinders.
• This will be cost-effective since conveyor modification, PLC, sensors will not be required.
• It can solve the issue of jamming by effectively alerting concerned person.
Thank You