Implementation of Programmable Logic Controller in multi machine operations with product sorting and packaging based on colour detection

Abstract

Automation is widely used in various industries to increase the speed, accuracy and effectiveness of production and reduce the risk of hazards. In general, the manufacturing industry has a product packaging and sorting process based on size, weight, shape, height and color. Currently, the sorting process in the industry is still mostly done manually which causes human error problems, so the development of industrial automation that is low cost, easy to maintain, efficient, user friendly and more accurate needs to be done. Programmable Logic Controller (PLC) is one of the most widely used for automation equipment in the industry and can be programmed to control machine operations. In this paper, the Mitsubishi Melsec PLC with ladder diagram programming using GX work2 has been developed to control multi-machine operation by product sorting and packaging based on product color. Multi-machine operation consists of three DC motors used for conveyors, two single solenoids, proximity sensors, inductive sensors and limit switches. The proximity sensors are used to detect the products based on color. The system is equipped with an emergency button and alarm system to facilitate the implementation of troubleshooting. To facilitate communication with operators and user-friendly systems, the human machine interface (HMI) is used as an interface for system monitoring and controlling. HMI uses Pro-face from Schneider which is programmed using GP-Pro EX4.0. The ladder diagram has been implemented in the PLC and tested on hardware to simulate the system. Based on test results, MELSEC PLC can communicate with HMI and control multi-operation machines with product sorting and packaging. The machine can separate and package metal products by colour and the packaging system can be monitored and controlled remotely automatically with HMI.