HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY SCHOOL OF MECHANICAL ENGINEERING PROJECT II MECHATRONICS SYSTEM DESIGN PRODUCT SORTING SYSTEM Do Hoa An an.vn Faculity of Mechatronics Instructor: Assoc.Prof Pham Hong Phuc Instructor’s singature Department: Mechatronics School: Mechanical Enginenering HA NOI 01-2024 TABLE OF CONTENT Page PREFACE…. 6 LIST OF FIGURES. 8 LIST OF TABLE. 12 CHAPTER 1- DESCRIPTION OF THE MECHANICAL SYSTEM.1- Definition and Application.2- Types of classification and selection.3- Principle of Product Sorting System.4- Basic Elements in A Typical Product Sorting System…………… 1.2- System in Detailed.1- System Transmission schematic.5- Shaft and Bearing.8- Programmable Logic Controller.5- 3D Model of the Product Sorting System.4- System Control Charts.
43 CHAPTER 2- CONTROL SYSTEM CONFIGURATION.1- Operation Block Diagrams.2- AUTO Mode’s Principle.2- Electric Components Selection.1- LED Indicator Lights.3- Emergency Stop Buttons.4- Rotary Switch for MANUAL/AUTO Running Mode.6- General Purpose Relays. 54 CHAPTER 3- CONTROL PROGRAM AND DIAGRAMS.1- Control Program Specifications.1- Inputs and Outputs.2- PLC Program Blocks.3- The simulation Program Interface in TIA PORTAL.2 Control System Diagrams.1 The component Connection Diagram. 73 3 ĐẠI HỌC BÁCH KHOA HÀ NỘI SME.a Trường Cơ khí Học kỳ: 2023-1 Khoa Cơ điện tử Năm học: 2023-2024 ĐỒ ÁN MÔN HỌC: THIẾT KẾ HỆ THỐNG CƠ ĐIỆN TỬ Mã HP: ME4186 Thời gian thực hiện: 15 tuần; Mã đề: VCK01-05 Ngày. ĐƠN VỊ CHUYÊN MÔN NGƯỜI RA ĐỀ CB Hướng dẫn (ký, ghi rõ họ tên) (ký, ghi rõ họ tên) (ký, ghi rõ họ tên) PGS.TS Mạc Thị Thoa Ngày giao nhiệm vụ: ./2023; Ngày hoàn thành: …/…/2024 Họ và tên sv: Nguyễn Đức Minh Hiếu MSSV: 20195777 Mã lớp:.
Nhiệm vụ thiết kế: Thiết kế hệ thống phân loại sản phẩm II. Số liệu cho trước: 1. Hệ thống cấp phôi tự động 2. Nguồn lực cấp phôi và đẩy phôi: Khí nén 3.
Nguồn lực quay băng tải: Động cơ điện 4. Bộ truyền ngoài: Xích 5. Thông số hình học phôi: Hình trụ : h1= 5 cm, h2= 7 cm, h3=9 cm d1=5cm, d2=5cm, d3= 5 cm Hình lập phương : h1=…cm, h2=…cm, h3=…cm 6. Trọng lượng phôi: Qmin = 0.2 kg; Qmax = 5 Kg 7.
Năng suất làm việc : N = 20 sp/ph 1. Nội dung thực hiện: Phân tích nguyên lý và thông số kỹ thuật 4 - Tổng quan về hệ thống; - Nguyên lý hoạt động; - Phân tích tính chất, đặc điểm của phôi/sản phẩm để lựa chọn phương pháp cấp phôi phù hợp; Phân tích tính chất, đặc điểm của phôi/sản phẩm để lựa chọn phương pháp cấp phôi phù hợp - Xác định các thành phần cơ bản của hệ thống điều khiển và thông số/yêu cầu kỹ thuật của hệ thống. Tính toán thiết kế hệ thống điều khiển - Ý tưởng điều khiển, tính năng điều khiển và giao tiếp - Lựa chọn phương án điều khiển - Thành lập sơ đồ điều khiển - Diễn giải sơ đồ điều khiển - Tính toán chi tiết, lựa chọn thành phần, linh kiện - Giao tiếp hệ thống với người sử dụng - Mô phỏng hệ thống điều khiển 5. Xây dựng bản vẽ thiết kế mạch điện điều khiển - Xây dựng bản vẽ thiết kế mạch điện điều khiển (1 Bản A1 hoặc A2) 6.
Mô phỏng nguyên lý hoạt động (điều khiển) 5 BẢNG SỐ LIỆU CÁC PHƯƠNG ÁN THIẾT KẾ Năng suất Kích thước hình học phôi Đề số làm việc Trọng lượng phôi (cm) [N,sp] [Qmin, kg] [Qmax, kg] [h1;d1] [h2;d2] [h3;d3] [h1] [h2] [h3] VCK01- 1 20 0,2 5 5;5 7;5 3;5 5 5 5 VCK01- 2 18 0,3 5,5 10;6 5;6 3;6 5 5 10 VCK01- 3 16 0,4 6 8;6 7;6 4;6 5 5 15 VCK01- 4 14 0,5 6,5 15;5 10;5 5;5 3 3 5 VCK01- 5 12 5,5 7 5;6 4;6 12;6 3 3 10 VCK01- 6 10 0,2 5 10;4 5;4 4;4 3 3 15 VCK01- 7 8 0,3 5,5 8;5 7;5 5;5 3 4 5 VCK01- 8 6 0,4 6 15;5 10;5 3;5 3 4 10 VCK01- 9 25 0,5 6,5 5;4 6;4 3;4 3 4 15 VCK01- 10 20 5,5 7 10;4 5;4 4;4 4 6 5 VCK01- 11 15 0,2 5 8;5 7;5 6;5 4 6 10 VCK01- 12 10 0,3 5,5 15;5 10;5 4;5 4 6 15 VCK01- 13 5 0,4 6 5;4 6;4 3;4 5 5 5 VCK01- 14 30 0,5 6,5 10;6 5;6 6;6 5 5 10 VCK01- 15 25 5,5 7 8;8 7;8 15;8 5 5 15 VCK01- 16 20 0,2 5 15;4 10;4 3;4 3 3 5 VCK01- 17 15 0,3 5,5 5;5 7;5 3;5 3 3 10 VCK01- 18 10 0,4 6 10;6 5;6 3;6 3 3 15 VCK01- 19 20 0,5 6,5 8;6 7;6 4;6 3 4 5 VCK01- 20 15 5,5 7 15;5 10;5 5;5 3 4 10 VCK01- 21 10 0,2 5 5;6 4;6 12;6 3 4 15 6 PREFACE As society continues to develop, the material and spiritual needs of people are increasing, so the issue of supply and demand is being addressed by manufacturers. Automation in the production line is an optimal solution, requiring speed, accuracy, and reduced labor. The more the production process is automated, the higher the production efficiency and the lower the cost, increasing competitiveness for businesses. In Vietnam, the process of industrialization and modernization is increasingly utilizing modern equipment to automate production, processing, and manufacturing processes.
This has led to the formation of flexible production systems that allow for high-level automation of small and medium-sized batch production using CNC machines and industrial robots. One important aspect that affects the quality of products sold is the product sorting system. As a result, there has been an increasing emphasis on implementing advanced technologies such as machine vision and artificial intelligence to improve the accuracy and efficiency of product sorting systems. This trend towards automation and advanced technologies in production is expected to continue as Vietnam strives to increase its competitiveness in the global market.
The project "Design of an automatic product sorting system" aims to reinforce the knowledge of students while helping them see the relationship between what they learn in school and its practical applications. The topic has many important applications in various fields such as product transportation, product counting, and product sorting. With this automated system, we can reduce labor costs associated with production. Additionally, this system can improve the accuracy and efficiency of product sorting, which is important for ensuring the quality of the final product.
With a large amount of comprehensive knowledge and many parts that we have not yet mastered, despite referencing many materials, there may be shortcomings and limitations in the calculation process when carrying out the "Mechanical 7 Design" project. We hope to receive guidance and feedback from teachers and classmates to help us overcome these challenges. We would like to express our sincere gratitude to the teachers in the Department of Electromechanic, especially to, Assoc.Prof Pham Hong Phuc who has guided us with enthusiasm, created favorable conditions and provided us with valuable knowledge for the completion of this project. We sincerely thank you! 8 LIST OF FIGURES Figure 1.1 Color Sorter Schematic [1].2 Sorting System Based on Item’s Height [2].3 Sorter by Weight with Tilt Tray Mechanisms [3].5 Pop-up Wheel/Roller/Belt Sorter [5].6 Pivoting Arm Sorter [6].8 Tilt Tray Sorter [8].9 Cross Belt Sorter [9].10 Push Tray Sorter [10].12 Basic Block Diagram of Object Product Sorting System.13 A Typical Single Conveyor [12].14 Typical Single Belt/Chain Drive [13].15 A Typical Pneumatic Cylinder [14].16 Photoelectric Sensor Schematic [15].17 Typical Motor Model.19 Typical Conveyor Belts [16].20 Typical Roller Conveyor [17].21 Typical Roller Conveyor [18].22 Typical Chain Conveyor [19].23 Typical Slat Conveyor [20].24 Double Acting Cylinder Principle [21].26 5/2-way Valve in Double Acting Pneumatic Cylinder Controlling .27 Some Popular Sensor on the Market.30 Programmable Logic Controller (PLC).32 The Conveyor Frame 3D Model.33 The PVC Belt 3D Model.34 The Motor with Built-in Gear-drive 3D Model.35 The Large Sprocket 3D Model.36 The Small Sprocket 3D Model.37 The Final 3D Model of the Product Sorting System.Error! Bookmark not defined.38 The General Control Chart.39 The General Control Chart.40 The Automatic Mode Control Chart.1 General Block Diagram.2 The Simplified System’s Layout.3 The Simplified System’s Layout.4 The AUTO Mode Block Diagram.5 AD16-22DS LED Indicator Lights [26].6 LA38 Spring Return Push Buttons [27].7 LA38-11ZD Spring Back with Self-locking Push Button [28].8 LA38-11 Rotary Switch for MANUAL and AUTO Mode [29] .9 OMRON E3F3 Photoelectric Sensor [30].10 The Specification of OMRON E3F3 Photoelectric Sensor [30]54 Figure 2.11 OMRON MY2N 24VDC General Purpose Relay [31].1 PLC Main Input Tags.2 PLC Main Input Simulation Tags.3 PLC Intermediate (Middle) Tags.4 PLC Ouput Tags.5 PLC Integer Tags.6 PLC Program Block.7 Network of Main Program Block.8 Network of the Output Functional Block.9 Network of the Manual Operation Functional Block.10 Reset Network of the Automatic Operation Functional Block670 Figure 3.11 Operating Networks of the Automatic Functional Block 683 Figure 3.12 Network for Simulating the Sorting Process as the Movement of the Product on the Conveyor.13 Network for Simulating the Sensor Activations.14 Simulation Interface in TIA Portal V16 Using SIMATIC Module .15 Using the TIA Portal V16 Interface to Simulate Manual Operation.16 Using the TIA Portal V16 Interface to Simulate Automatic Operation.17 PLC Connection Diagram.708 11 LIST OF TABLES Table 1.1 Project’s Calculating and Designing Inputs.2 Chain Drive Parameters.31 12 CHAPTER 1- DESCRIPTION OF THE MECHANICAL SYSTEM 1.1- Definition and Application Currently, product classification is a common and important task in many manufacturing industries, including quality classification, size classification, and type classification, etc.
However, product classification is a repetitive and tedious task for workers, and is prone to errors. Therefore, to improve work productivity and the stability of product quality, automated production systems with partial or full automation control have been introduced into industrial manufacturing. Along with the increasing use of automated production systems, humans have significantly improved their working conditions, reduced labor intensity, avoided boredom, and provided opportunities to access the advancements of science and technology and work in increasingly civilized environments. In the era of market economy and deepening integration into the world economy, competition has become a hot and vital topic, especially in terms of product design, quality, and price competitiveness.
It is evident that to achieve these competitive factors, advanced technological processes must be applied to the production process to lay the foundation for improving product quality and reducing production costs. Sorting systems are used to sort items in warehouses or distribution centers based on their destinations. Random flows of items are sorted into orders ready for shipping. The destination depends on the type of company or application within the supply chain.
For example, an outbound sorter for postal or courier companies often sorts by routes or postal code to gather all items for one driver. However, retail companies sort the items per store. When looking at e-commerce orders, items can be sorted on order level. 13 Within the supply chain, the sorter can be used for various applications to bring more efficiency.
Typical stages within the supply chain where a sorter can be used include inbound, return, outbound or shipping.2 Types of classification and selection. There are multiple product sorting systems based on their applications in the industrial sector or the industrial field. By the aspects of the items, product sorting systems can be divided into four main categories: - Sorting by colors: Color sorters (color sorters) separate items by their colors. They detect the color of objects passing in front of them and sort them into desired groups by different mechanisms.1- Color Sorter Schematic [1] 1) Sensor; 2) Light source; 3) Separating mechanism A color sorter includes 3 main parts (Figure 1.
The types of sensors and lightsources based on the applying technologies could be traditional photoelectric sensors; CCD cameras with LED light sources; infrared light sources with microwave detectors; or even X-ray systems. The separating mechanisms can be mechanical or pneumatic devices.