Transcript 2.5 High-Speed Discrete Control System

2.5 High-Speed Discrete
Control System
Sponsored by Emerson Process Management
C re ated by : La c ey L ato u r, A n d rew Ro e ssle r a n d S a n N g u ye n
Purpose
• Design a high-speed discrete control solution that could be used to
demonstrate how Emerson could replace a programmable logic
controller (PLC) with their DeltaV system.
• System Requirements:
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Discrete input to output in 5 – 50 ms
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The input is the switch to turn on the conveyor and the output is conveyor
The sensor is read as a analog signal this is also high speed from the time the sensor
reads the color till the actuator extends
Must be movable and fit on a rolling cart.
• Must be controlled by a PLC.
• PLC must be replaceable by Emerson’s DeltaV system.
• Maintain a budget of $3,000 - $5,000.
•
Proposed Solution
• Design a sorting system operated by a programmable logic
controller.
• System Hardware:
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(1) Conveyor Belt
(1) Vibratory Feeder
(1) Linear Actuators
Colored Blocks
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Black and White
(1) Color Sensor
(1) Programmable Logic Controller: Allen Bradley Micrologix 1400
High-Level Design
• Blocks will be manually placed into the vibratory feeder’s tray.
• The color sensor will be placed towards the bottom of the feeder.
• When the blocks are fed, the color sensor will read each block’s
corresponding color and relay this information to the PLC.
• If the block is white, the actuator will then extend and the block will
follow the extension to the correct positioning on the conveyor
• If the block is black, it will stay In the same place on the conveyor
• Once the blocks have reached the end of the conveyor, they will
then fall into their associated bin
Block Diagram
Figure 1: High-Speed Discrete Control System Block Diagram
Bill of Materials
Item
Quantity
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
9
1
1
10
10
Part Number
6C Drive
n12UN/1152A-HW-NSF
HDA2-2
ROB-0953
40-08048-R-D
U4 RS-100N20-31
30-7270
30-7071
40-7031
BLOCKS
Total Overall Price:
Part Name
Price
Vibratory Feeder $360
2"x8" SS Tray
$271
Control
$288
2.00" Stroke
Linear Actuator
Line Sensor
Breakout
Conveyor
Electrical
External Control
Cable
Stand
Bracket
Wooden Blocks
Total Price
$360
$271
$288
$130
$130
$2.95
$2.95
$1,553
$1,553
$26.20
$26.20
$47.86
$12.78
$10.00
$47.86
$12.78
$10.00
$2,701.79
Hardware Specifications (1/5)
• Dorner 1100 Series Mini-Conveyor
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Purpose: means of moving each block from the
vibratory feeder, through the linear actuators, then to
each block’s color-respective bin.
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Purchased as a set including:
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Conveyor
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Extrusion
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Driver
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15 ft. External control cable with option to enable I/O
Features:
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Flat Belt End Drive
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Conveyor height: 1.50”
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Belt Width: 8” (203mm)
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Conveyor Lengths: 48” (1219mm)
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Loads up to 15 lbs. (6.8 kg)
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Voltage: 115 V
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60 Hz
Figure 2. Dorner 1100 Series Mini-Conveyor
Hardware Specifications (2/5)
• Eriez 6C Vibratory Feeder
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Purpose: Means of holding and supplying the blocks
to the conveyor.
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Features:
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Feed Rate: 1250 lb./hr.
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Tray width: 1-1/2”
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Tray Length: 12”
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Overall height: 6-3/8”
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Voltage: 115V AC
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Amps: 1.1
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Noise level: 70 dB
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3600 Vibrations per minute
Figure 3. Eriez 6C Vibratory Feeder
Hardware Specifications (3/5)
• Servocity HDA2-2 Linear Actuator
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Purpose: Means of pushing each block into its
necessary position on the conveyor.
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Potentiometer wires will be responsible for positioning the
blocks correctly on the conveyor belt.
Features:
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Voltage: 6.0-12 Volts DC
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Operating speed (12V): 2.00” second at No load
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Operating Speed (12V): 1.37” second at Max load
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Dynamic thrust (12V): 25 lbs. thrust
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Connector wire length: 24"
Figure 4. Servocity HDA2-2 Linear Actuator
Figure 5. HDA2-2 Linear Actuator Wiring Diagram
Hardware Specifications (4/5)
• Sparkfun Electronics – Line Sensor Breakout (Analog)
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Purpose: Senses the color of the block that is fed
from the vibratory feeder.
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Features:
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Analog output (varies depending on the amount of IR light
reflected back to the sensor)
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Dimensions: 0.30 x 0.55 “ (7.62 x 13.97 mm)
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5VDC operating voltage
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25mA supply current
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Optimal sensing distance: 0.125" (3mm)
Figure 5. Sparkfun Electronics Line Sensor Breakout
Hardware Specifications (5/5)
• Allen Bradley Micrologix 1400 Controller
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Purpose: Responsible for processing the color
sensor’s input data and relaying output commands to
the conveyor and linear actuators.
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Features:
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120 V Power distribution
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12 V Power Supply
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5 V Power Supply
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RS232
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8 point Analog Input Expansion
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20 Discrete Inputs
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12 Relay Outputs
Programmable Logic Controller
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The PLC used was a Allen Bradley Micrologix 1400
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It then used Allen Bradley RSLOGIX 500 Software
I/O Points
• Discrete Input:
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Power Switch
• Discrete Output:
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Linear Actuator
Vibratory Feeder
Conveyor Belt
• Analog Input:
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Line Breakout Sensor
Program
Sensor Scaling
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The sensor reads from 0-5V with white being
lower voltage
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We used PID (proportional-integral-derivative)
scaling
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-10V to 10V is has input minimum to input
maximum at 0 to 16,383
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Since we were just wanting 0 to 5V, we had to
adjust the input min and max - making 0V 8,192
and 5V 12,287
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The scaled Minimum to Maximum is the
percentage of 0V to 5V with 0 being 0V and 100
being 5V
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The efficiency goes up by 20% for every volt
Next Program Step
• Once the switch is turned on, the conveyor will start
automatically
• After the switch has been turned on, the feeder will have a
delay time of 5 seconds before starting
Last Program Step
• Once the feeder and conveyor have started, the sensors output will be read
• If the efficiency is below 50% (under 2.5V) the actuator will then extend for 10
seconds
• If the efficiency is above 50% (over 2.5V) the block will continue down the
conveyor
Maintenance Issues
• Downloading updated firmware to the PLC.
• Replacing fuses and relays in the PLC
• The conveyor belt will need preventive maintenance work, such as: lubricating bearings
and monitoring belt tension.
Stretch Goals and Possible Upgrades
• Wire to Unitronics PLC
• To program the DeltaV system and be able to test the switch from PLC to DeltaV
• To use our HMI on the PLC to also show the visuals of the conveyor and block color
• Possible upgrades:
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Larger conveyor which could allow a wider range of block colors.
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More linear actuators allowing more assortment.
WE WOULD LIKE TO
THANK EMERSON
PROCESS MANAGEMENT
FOR GIVING US THIS
OPPORTUNITY!!!