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DEBRE MARKOS UNIVERSITY

COLLEGE OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING

Design and Simua!i"n "# Au!"ma!i$ S"%!ing and S!a$&ing S's!em in manu#a$!u%ing

indus!%'

Semes!e% (%")e$! %e("%! su*mi!!ed in (a%!ia #u#imen! "# !+e %e,ui%emen! #"% !+e

a-a%d "# !+e deg%ee "# Ba$+e"% "# S$ien$e in ee$!%i$a enginee%ing

PO.ER STREAM

B'

  GROUP MUMBER//////////////////// 0////////////////////////// ID

12 ADANE TA3IE/////////////////////////////////////////////TER45677487

52 GEBREMEDIN MASRESHA////////////////////////TER4998:487

92 FENTAHUN ;ENBERIE////////////////////////////////TER45775487

72 ASMAMA. MASCHALU/////////////////////////////TER459

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Ce%!i#i$a!e4De$a%a!i"n

This is to certiy that the !ro"ect re!ort entit#ed $%esi&n and Simu#ation o Automatic

Sortin& and Stac'in& System in the Manuacturin& (ndustry? bein& submitted by

 

GROUP MUMBER////////////////////////////////////////////////////ID

12 ADANE TA3IE/////////////////////////////////////////////TER45677487

52 GEBREMEDIN MASRESHA////////////////////////TER4998:487

92 FENTAHUN ;ENBERIE////////////////////////////////TER45775487

72 ASMAMA. MASCHALU/////////////////////////////TER459

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ACKNO.LEDGEMENT

*irst#y+ we wou#d #i'e to than' G,%. -ecause has he#!ed our to com!#ete this semester 

ro"ect re!ort ./e wou#d #ac' words+ how to e!ress my res!ect or our ather who used

to ins!ire our rom our hi#dhood by &ivin& his !recious advice to &et our #earned. (t is my

 !#easure to

Ac'now#ed&e the rest o our ami#y a#so. /e wou#d #i'e to than' our advisor+ Gebrehiwot

Miruts + or his &uidance throu&hout the course o this !ro"ect. e he#!ed us immense#y

with both the technica# and administrative as!ects o our wor'. /e wou#d #i'e to a!o#o&i3e

our teacher+ D%/ Ru@e Cuasi!" to he#! &enera# introduced about the sotware 4automation

studio sotware and how to or&ani3in& the com!onent o each sotware com!onent such as

in!ut out!ut com!onent contro# circuit and !ower circuit .

/e wou#d #i'e to a!o#o&i3e to any !erson or !eo!#e that have been invo#ved i there are any

mista'es that ( have done in the duration o this semester !ro"ect.

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ABSTRACT

%esi&n the automated sortin& and stac'in& system to need the manuacturin& industry in

many ie#ds is a very com!#e !rocess. The system needs to deve#o! in order to meet the

industry Satisactions. urrent#y+ this system is used or sine !ur!ose.

The main contribution o this !ro"ect is to im!rove the current !arts sortin& and stac'in&

system in manuacturin& industry. The investi&ation was made in sco!e o the #ac'in& in

current !arts sortin& and stac'in& system in manuacturin& industries. The ste! o 

deve#o!ment o the !ro"ect starts with survey the manuacturin& current scenario+ ana#ysis

the current sortin& system+ deve#o!ment o conce!t desi&n and deve#o!ment o the detai#

desi&n usin& the en&ineerin& sotware ca##ed Automation Studio sotware. %esi&ned and

ana#y3ed the conce!t desi&n usin& simu#ation in order to &et the detai# resu#ts. The detai#

resu#ts shows that the desi&ned system can encounter the !rob#em that current automated

sortin& and stac' aced. The outcomes o this the semester !ro"ect can be used as reerence

to su!!ort in deve#o!in& the automated sortin& and stac'in& systems in uture.

  C"n!en!s

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AT67 1 (T7,%9T(,.......................................................................................1

1.1-ac'&round and rationa#e..............................................................................................1

1.2 Sstatement o !rob#em))))))))))))))))))))))))...2

1. ,b"ective o the study...................................................................................................

1.; Sco!es and #imitation)))))))))))))))))))))))))

  1.5 Si&niicance o the study  00000000000000000000000/7

  1.< *ramewor' o the study)).))))))))))))))))))))).;

AT67 2.=(T67AT976 76>(6/)))))))))))))))))))..5

2.1 (ntroduction))))))))))))))))))))))))))))...5

2.2 Sortin& and stac'in& system com!onents.....................................................................5

2.2.1 (nduction motor..........................................................................................................5

2.2.2 neumatics system................................................................................................5

2.2.2.1. 6#ectro?!neumatic system..................................................................................<

2.2.. neumatic va#ves..................................................................................................<

2.2.;. Sine actin& y#inders 4s!rin& return.....................................................................<

2.2.5. %oub#e actin& cy#inder............................................................................................<

2.2.< onveyor system........................................................................................................@

2.2.

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.1.;. Sensors....................................................................................................................1

.1.;.1. roimity sensors..............................................................................................1;

.1.;.2. Advanta&es o !roimity sensors are:?..............................................................1;

.1.;.. %isadvanta&es o !roimity sensors are:?............................................................1;

.1.5. ush button switches...............................................................................................1;

.1.< So#enoids.............................................................................................................15

.2 M6T,%S.................................................................................................................15

.2.1 The desi&n................................................................................................................15

  .2.2 The deve#o!ment and inte&ration))))))))))))))))))...1

.2. The simu#ation..........................................................................................................20

AT67 ;. 76S9=TS A% %(S9SS(,S)))))))))))))))..2

;.1. 7esu#ts and %iscussions.............................................................................................2

AT67 *(>6 5. ,=9S(,S+ 76,MM6%AT(, A% *9T976

/,7C)))))))))))))))))))))))))))))))...28

5.1 onc#usion...................................................................................................................28

5.2 7ecommendations.......................................................................................................28

5.. *uture /or's..............................................................................................................2

76*6766S..................................................................................................................2

=ist o tab#es

Ta*e 1/1: *ramewor' o the study)))))))))))))))))))))..;

Ta*e 9/1 the (D, devices uti#i3ed in the system)))))))))))))))).18

Tab#e .2: The initia# motion seEuence dia&ram))))))))))))))))..20

Ta*e 9/9: The continuation motion seEuence))))))))...................................20

Tab#e ;.1: The motion seEuence dia&ram)))))))))))))))))).....2

  =ist o i&ure

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Figu%e 1/1 contro# system rame wor' 000000000000000000007

Figu%e 5/1: >isua# c#assiication setu! in an industria# settin& )))))))))).8

 Figu%e 9/1 in!ut out!ut mode#))))))))))))))))))))))..12

Figu%e 9/5The motor?driven conveyor)))))))))))))))))))..1<

Figu%e 9/9: The #inear eeder actuators))))))))))))))))))).1<

Figu%e 9/7: The materia#s detection re!resentation)))))))))))))))..1@

Figu%e 9/=The stora&eDstac'in& area)))))))))))))))))))))1@

Figu%e 9/6 The in!ut?out!ut devices F = interace)))))))))))))..18

Figu%e 9/ !ower circuit #adder dia&ram)))))))))))))))))))22

Figu%e 7/1The sortin& and stac'in& system ramewor'D the in!ut?out!ut devices F =

interaceD the materia#s detection re!resentation o out!ut resu#ts)))))))))2;

Figu%e 7/5 The contro# circuit = #adder !ro&ram out!ut resu#t))))))))))25

Figu%e 7/9 The !ower circuit = #adder dia&ram !ro&ram out!ut resu#t))))))...2<

 

A**%e@ia!i"n

ASRS Automatic stora&e and retrieva# system

IEC (nternationa# 6#ectro technica# ommission

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I4O (n!ut out!ut

NC  orma# c#osed

NO  orma# o!en

PLC ro&ramin& #o&ic contro#

RST reset 

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CHAPTER 1

INTRODUCTION

1/1Ba$&g%"und and %a!i"nae

  Sortin& and stac'in& systems are reEuired in many industria# ie#ds such as in

manuacturin& industry 4sot drin'in& com!anies to ma'e sure the manuacturin&

 !rocess more eicient#y. A## sortin& and stac'in& !rocesses+ a#thou&h dierent+

&enera##y consist o #oo'in& at the ob"ects distributed on movin& conveyor+ #oca#i3in&

any sine !art+ reco&ni3in& the re#evant eatures that ma'e it acce!tab#e or not and

se!arated the !arts de!end on their cate&ories. The automated sortin& and sta'in&

systems are simi#ar with the manua# sortin& and stac'in& systems. The dierence

 between those two is that the automated sortin& and stac'in& system is more eicient

and used more techno#o&y eatures intar&eted into their system than the manua#

sortin& and stac'in&. Another name o automatic sortin& and stac'in& system is

 !o!u#ar#y 'nown in advanced manuacturin& industry as the automatic stora&e and

retrieva# systems. An automated stora&e 4stac' and retrieva# 4sort system 4AS7S or 

ASD7S consists o a variety o com!uter contro##ed systems or automatica##y

 !#acin& and retrievin& #oads rom deined stora&e.

The techno#o&y o interest has si&niicant im!act on various economic sectors.

Automatic sortin& and stac'in& systems are deve#o!ed or automatic stora&e and

retrieva# o !arts in manuacturin&+ distribution+ retai#+ who#esa#e and institutions

throu&h en&ineerin& the use o micro?contro##er?based contro# system. Automatic

sortin& and stac'in& system ty!ica##y used in a!!#ication where there is a very hi&h

vo#ume o #oads bein& move in and out o stora&e. The system is needed to be

deve#o!ed in order to meet the industry customer satisaction. owever+ the

si&niicant im!act o the techno#o&y a#so !osed some cha##en&es and !rob#ems. (n

most industria# situations where a sortin& and stac'in& !rocess is needed+ a hi&h#y

structured environment can be ound+ s!eciica##y desi&ned or the o!tima#

e!#oitation o system ca!abi#ities. (n order to accom!#ish u##y automated !arts

sortin& and stac'in& systems+ some !rob#ems are identiied in the o##owin& areas as

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e!erienced by various industries #i'e the automatic stora&e in the stac'in& without

over#a!!in& materia#s+ c#assiication o a various materia#s and its automatic

identiication+ and o!timi3ation o the se!aration strate&y in order to u!&rade the

 !erormance the system.

The above mentioned !rob#ems identiied in the base#ine research on the uti#ity o 

sortin& and stac'in& techno#o&y a#so have identiied a#ternatives and so#utions as

initiated by other industry !ractitioners. The !rob#em occurs because o the sortin&

and stac'in& systems that has been used are rea##y not suitab#e in manuacturin&

industry current scenario. -esides that+ it ha!!ened when the system is not meetin&

the manuacturin& industry desired needs and !ur!ose. This sortin& and stac'in&

system is not on#y ocusend on the system but a#so ocusend on the !art or eEui!ment

that has been used. Some system was deve#o!ed based on the manua# sortin&

conveyor uti#i3ed by some traditiona# manuacturin& industry. ,n this ty!e o 

conventiona# conveyin& system+ !oor Eua#ity materia#s are manua##y removed rom

the !ac'in& #ine+ #eavin& on#y the &ood Eua#ity manuacturin& industry !roduct to

continue the !ac'in& !rocess..

The aorementioned ar&uments are worthwhi#e base#ine research that !rovides

si&niicant in#uence to the conduct o this !resent study. As such !rovides motivation

to initiate an innovative sortin& and stac'in& conce!t throu&h mode##in& and

simu#ation. ence+ the conduct o this study may be he#!u# to some re#evant

industries in the manuacturin& ie#d.

1/5 s!a!emen! "# (%"*em

  The desi&n and simu#ation o automatic sortin& and stac'in& system !rovides better 

 benchmar' mode# or urther im!#ementation in the #oca# industry in 6thio!ia+ Arica

in an eort to miti&ate !rob#ems in the manuacturin& industry. Automatic sortin& and

stac'in& system enab#es the useu# arran&ement o !roducts in suitab#e order and

storin& suitab#e #oca#i3ation by usin& inte##i&ent system. The desi&n and deve#o!ment

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o this automatic sortin& and stac'in& system wi## !reserve Eua#ity !roducts throu&h

autonomous contro#. The study thereore see's to address the o##owin& Euestions:

1. /hat desi&n !arameter that has to be considered re#ative to the conveyor+

#inear actuators+ sensors+ and contro# ramewor' o the automated sortin& and

stac'in& system

2. /hat deve#o!ment strate&y to be ado!ted in the inte&ration o the sub?system

desi&ns

. /hat simu#ation techniEues and !ro&rammin& a!!roach that has to be uti#i3ed

to eective#y mode# the system

;. /hat eva#uation !arameters to consider in measurin& the !erormance and

acce!tabi#ity o the !ro"ect

1/9 O*)e$!i@e "# !+e s!ud'

The &enera# ob"ective o this study is to desi&n and simu#ate an automatic sortin& and

stac'in& system or the manuacturin& industry in 6thio!ia. The s!eciic ob"ectives

are:

 a. To desi&n the automated sortin& and stac'in& system usin& a combination o 

conveyor+ #inear !neumatic actuators+ !roimity sensors+ and !ro&rammab#e #o&ic

contro#.

 b. To deve#o! and inte&rate the sortin& and stac'in& system usin& the desi&n

 !arameters estab#ished.

c. To simu#ate the sortin& and stac'in& system usin& the Automation Studio

sotware.

d. To eva#uate the !erormance and acce!tabi#ity o the sortin& and stac'in&

machine usin& descri!tive statistics.

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System ProcessorInput Devices Output Devices

Software Programming an Interfacing

1/7 S$"(es and imi!a!i"n

The !remise o this study invo#ves the mode##in& and simu#ation o a basic automated

sortin& and stac'in& system uti#i3in& conveyor+ #inear !neumatic cy#inders+ sensors+

and !ro&rammab#e #o&ic contro#. The sco!e o this !resent study is ec#usive#y done

throu&h simu#ation and that im!#ementation o !hysica# com!onents and system is

inhibited.

1/= Signi#i$an$e "# !+e s!ud'

The study wi## have si&niicant contributions to the manuacturin& industry to have

we## estab#ished sortin& and sta'in& system that aci#itates it to !rovide better services

to its customer. *urthermoreH the study can be used with sma## ada!tation in simi#ar6thio!ian manuacturin& industries. The study is a#so va#uab#e or urther and better

research.

1/6 F%ame-"%& "# !+e s!ud'

The ramewor' o the study uti#i3es the in!utF!rocessFout!ut !aradi&m as shown in

Ta*e 1/1 where the base#ine researches+ benchmar' inormation+ and in!ut devices

are c#assiied into the in!ut variab#e. -ase#ine research synthesis+ circuit

deve#o!ment+ = !ro&rammin& are !rocessed+ and the out!ut o the study is

e!ected to !roduce the mode# sortin& and stac'in& system. *i&ure 1 a#so shows the

contro# ramewor' o the automated system.

Ta*e 1/1: *ramewor' o the study

in!ut !rocess ,ut !ut

  Automation Studio

simu#ation+ !neumatic

va#ve sensorDswitch

  Automation Studio

simu#ation+ =

 !ro&ramin&

Automatic sortin& and

stac'in& system

mode#+ s'i## set in

simu#ation +=

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Figu%e 1/1: ontro# system ramewor' 

CHAPTER 5

LITERATURE REVIE.

5/1 In!%"du$!i"n 

There severa# issues re&ardin& to the usa&e o automated sortin& systems in

manuacturin& industries. These !rob#em occurs because o the sortin& systems that been

used are rea##y not suitab#e in manuacturin& industry current scenario. -eside that+ it

ha!!ened when the system is not meetin& the manuacturin& industry desired and needed.

*or this !ur!ose+ many !arties try to deve#o! the automated sortin& and stac'in& system

that on#y ca!ab#e to u#i## the tas' o manuacturin& but a#so easier to o!erate and to

hand#e. This sortin& and stac'in& system is not on#y ocus on the system but a#so ocus on

the !art or eEui!ment that been used.

5/5 S"%!ing and s!a$&ing s's!em $"m("nen!s

 The o##owin& is detai#ed discussion o the ma"or !iece or section o the sortin& and

stac'in& system com!onents.

5/5/1 Indu$!i"n m"!"%

(nduction motors are the most wide#y used motors or a!!#iances+ industria# contro#+ and

automationH hence+ they are oten ca##ed the wor'horse o the motion industry. They are

re#iab#e+ and durab#e. /hen !ower is su!!#ied to an induction motor at the recommended

s!eciications+ it runs at its rated s!eed. Motor cab#e si3e wi## be de!endin& on the current

va#ue o the motor.

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2.2.2 neumatics system /

neumatic reers to any system or machine that is moved usin& &as !ressure .!neumatic

systems store ener&y in com!ressed &as and use the ener&y to !erorm tas's as the &as is

a##owed to e!and. A !neumatic system can be contro##ed either manua##y or automatica##y.(n manua# contro# systems+ o!eration is seEuenced by o!erator who decides which action to

ta'e. (n automatic contro# systems+ o!eration is seEuenced by contro##er that automatica##y

decides each action to be ta'en. Automatic contro# can be accom!#ished by means o 

e#ectrica# and !neumatic si&na#s.

5/5/5/1/ Ee$!%"(neuma!i$ s's!em

The most used !neumatic actuation systems are e#ectrica##y contro##ed system.

 These system are ca##ed e#ectro?!neumatic contro# system is a combination o e#ectrica#

unit and !neumatic contro# unit both in one unit. (n e#ectro !neumatics+ so#enoid o!erated

directiona# contro# va#ves+ #imit switches and !ressure switches are used on an automation

system one can ind three ami#ies o com!onents+ which are sensors+ va#ves and actuators.

A so#enoid is used in !neumatic va#ves to acts the actuatin& e#ement. 6#ectro !neumatics is

now common#y used in many areas o (ndustria# #ow cost automation.

They are a#so used etensive#y in !roduction+ assemb#y+ !harmaceutica#+ chemica# and

 !ac'a&in& systems. There is a si&niicant chan&e in contro#s systems. The !ro&rammab#e

#o&ic contro##ers have increasiny re!#aced re#ays in order to meet the &rowin& demand or 

more #eib#e automation.

5/5/9/ Pneuma!i$ @a@es

neumatic va#ve is a device consistin& o a#uminum or brass body and an interna# movin&

 !art+ which contro#s the movement o air within the va#ve body. (n other words !neumatics

va#ves are devices to contro# direction o #ow or rate o #ow or !ressured o the

com!ressed air 

5/5/7/ Singe a$!ing C'inde%s s(%ing %e!u%n

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Sine actin& cy#inders 4s!rin& return is a ty!e o cy#inder in which air !ressure a!!#ied to

the !iston to drive it in one direction.

5/5/=/ D"u*e a$!ing $'inde%

%oub#e actin& cy#inder is a cy#inder in which air !ressure maybe a#ternate#y a!!#ied to the

 !iston to drive it in either direction.

5/5/6 C"n@e'"% s's!em

  A conveyor system is a common !iece o mechanica# hand#in& eEui!ment that

moves materia#s rom one #ocation to another. onveyors are es!ecia##y useu# in

a!!#ications invo#vin& the trans!ortation o heavy or bu#'y materia#s. onveyor systems

a##ow Euic' and eicient trans!ortation or a wide variety o materia#s+ which ma'e them

very !o!u#ar in the materia# hand#in& and !ac'a&in& industries

Many 'inds o conveyin& systems are avai#ab#e+ and are used accordin& to the various

needs o %ierent industries. There are chain conveyors 4#oor and overhead$2I as we##.

hain conveyor consists o enc#osed trac's+ (?-eam+ tow#ine+ !ower ree+ and hand

 !ushed tro##eys.

onveyor systems are used wides!read across a ran&e o industries due to the numerous

 beneits they !rovide.

onveyors are ab#e to sae#y trans!ort materia#s rom one #eve# to another+ which when

done by uman #abor wou#d be strenuous and e!ensive.

They can be insta##ed a#most anywhere+ and are much saer than usin& a or'#it or other 

machine to move materia#s. (n a system that uses !recise#y contro##ed be#ts+ such as a sorter 

system+ re&u#ar ins!ections shou#d be made that a## be#ts are trave#in& at the !ro!er s!eeds

at a## times.

Ty!es o conveyor systems

;.1 neumatic conveyor systems

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;.2 >ibratin& conveyor systems

;. *#eib#e conveyor systems

;.; >ertica# conveyor systems and s!ira# conveyors

;.5 eavy duty ro##er conveyors

(n our !ro"ects we use !neumatic conveyor system

5/5/6/1 Pneuma!i$ $"n@e'"% s's!ems

6very !neumatic system+ wou#d ma'es use o !i!es or ducts ca##ed trans!ortation #ines that

carry miture o materia#s and a stream o air. These materia#s are such as dry !u#veri3ed or 

ree #owin& or #i&ht !owdery materia#s #i'e cement+ #y ash etc. These materia#s can be

trans!orted convenient#y to various destinations by means o a stream o hi&h ve#ocity air 

throu&h !i!e #ines. roducts are moved throu&h various tubes via air !ressure+ a##owin& or 

etra vertica# versati#ity. neumatic conveyors are either carrier systems or di#ute?!hase

systemsH carrier systems sim!#y !ush items rom one entry !oint to one eit !oint+ such as

the money?echan&in& !neumatic tubes used at a ban' drive?throu&h window. %i#ute?!hase

systems use !ush?!u## !ressure to &uide materia#s throu&h various entry andDor eit !oints

5/9 A((i$a!i"n "# Au!"ma!ed S"%!ing and s!a$&ing S's!ems

Accordin& to -ache#or -G+ -ra&&ins %/ 412 in their artic#e+ industria#

A!!#ications reEuire some sort and stac' o automated visua# !rocessin& and the

c#assiication o items !#aced on a movin& conveyor. A ty!ica# !rocess com!rises o: at

i. #oo'in&. on the conveyor via some ty!e o sensor such as at the items !rimet sensors

ii. =oca#i3in& any sine item n.

iii. #assiyin& the item based on a set o eatures such as sha!e

iv. erormin& the necessary action de!endin& on the c#assiications made.

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Accordin& to the . (?si# -o3rna+ .u#ya Ba#?cin 42002 in their "ourna# e!#ains about a

>isua# c#assiication setu! i n an industria# settin& ty!ica# setu!. The *i&ure 2.1 shows the

ty!ica# setu!about visua# c#assiication.

*i&ure 2.1: >isua# c#assiication setu! in an industria# settin&

*rom i&ure 2.1+ the authors e!#ain how to detect the items at random!ositioned and

oriented on a conveyor. A camera #ocated above the conveyor views the item

ortho&ra!hica##y.

5/7 Ad@an!ages and Disad@an!ages

There severa# stren&th that have been identiied with these !art sortin& system. The

Advanta&es are as o##ows:

a. The !roduction rate o the manuacturin& industry has been increased since

These sortin& systems re!#aced the human resources.

 b. The accidents in manuacturin& industry can be !revented because the uses o

,!erator in manuacturin& #oor had been reduced.

c. urrent sortin& system is avai#ab#e in various coni&urations and has the

/idest ran&e o custom eatures and o!tions to best suit the a!!#ication.

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CHAPTER 9

METHODOLOGY

  The methodo#o&y o this !resent study is anchored on the desi&n+ deve#o!ment+

simu#ation and eva#uation o the research?based !ro"ect which is in con"unction with the

ob"ectives o the study. -ase#ine research ana#ysis is subsumed in the bac'&round andrationa#e o the study.

9/1 MATERALIS

Materia#s have been used in this wor' are artic#es+ and reerence and tet boo's+ reco&ni3ed

and re&u#ated documents+ sotwareKs4=+ internet+ and !ersona# com!uter 

9/1/1/ Use "# Ee$!%"(neuma!i$ s's!em

The most used !neumatic actuation systems are e#ectrica##y contro##ed system. These

system are ca##ed e#ectro?!neumatic contro# system is a combination o e#ectrica# unit and

 !neumatic contro# unit both in one unit. (n e#ectro !neumatics+ so#enoid o!erated

directiona# contro# va#ves+ #imit switches and !ressure switches are used on an automation

system one can ind three ami#ies o com!onents+ which are sensors+ va#ves and actuators.

A so#enoid is used in !neumatic va#ves to acts the actuatin& e#ement.

Si&na# in!ut devices?Si&na# &eneration such as switches and contactor+ various ty!es o 

contact and !roimity sensors. Si&na# rocessin&F 9se o combination o ontactors o 

7e#ay or usin& ro&rammab#e =o&ic ontro##ers. Si&na# ,ut !utsF ,ut !uts obtained ater 

 !rocessin& are used or activation o so#enoids+ and indicators.

9/1/1/1/ Ad@an!age"us "# Ee$!%" Pneuma!i$ S's!em

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The system a##ows easy automation o com!#e !rocess. The hi&h s!eed si&na# transmittin&

and !rocessin& #eads to a si&niicance enhancement o the !roductivity o the automation

system. Si&niicance #oads are contro# with reduced contro# si&na#. The #oadin& &au&e o 

contro# eEui!ment is reduced. 6#ectronic !ro&rammers and !rocess com!uter are used or 

contro# o the system.

9/1/1/5 Disad@an!age"us "# Ee$!%"(neuma!i$ s's!em

The system has two su!!#y units 4!neumatic and e#ectric.

The unction not a##owed in#ammab#e environments+ in environments sub"ected to ha3ard

o e!#osion or in hi&h humidity conditions.

9/1/5/ Su((' eemen!s

/e have to contro##ed !neumatic systems via !neumatic si&na#s usin& !neumatica##y

actuated va#ves. (t is !ossib#e to contro##ed !neumatic systems via !neumatic si&na#s usin&

 !neumatica##y actuated va#ves. neumatica##y contro##ed systems+ si&na#s are transmitted as

com!ressed air. /here as in e#ectrica##y actuated systems+ si&na#s transmitted as e#ectrica#

current but sti## the cy#inders are driven by com!ressed air to !erorm their duties .

So we e!ect to ind sources o !ower in e#ectro?!neumatic systems: com!ressors ande#ectrica# !ower su!!#ies. The e#ectrica# !ower su!!#ies can be either dc or ac su!!#ies but

we use ac !ower su!!#ies o 2;v in this system. (n !neumatica##y contro##ed systems+

si&na#s are transmitted as com!ressed air. /hereas in e#ectrica##y actuated systems+ si&na#s

are transmitted as e#ectrica# current+ sti## the cy#inders are driven by com!ressed air to

 !erorm their duties.

Thereore+ we e!ect to ind two sources o !ower in e#ectro?!neumatic systems. 6#ectro?

 !neumatic system is sti## !neumatic system in essence+ which means that it has the mainour com!onents o a !neumatic system

(n!ut e#ements

rocessin& e#ements

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*ina# contro# e#ements

ower e#ements 4actuators

An im!ortant conce!t in e#ectro?!neumatic systems is the #adder dia&ram. This dia&ram is a

&ra!hica# re!resentation o the e#ectrica# !art o the e#ectro?!neumatic system. (t re#ects

our way o thin'in&. So in order to bui#d an e#ectro?!neumatic system+ we have to start with

 !uttin& the #adder dia&ram. =adder dia&ram is an im!ortant conce!t not on#y at e#ectro?

 !neumatic systems+ but a#so at =. 6ach #adder dia&ram is constructed rom in!ut

switches and out re#ays that #ies between the !ositive and ne&ative !ower #ines

*i&ure

.1 in!ut

out!ut

mode#

/hi#e the e#ectrica# !arts are:

ushbutton to contro# the start o the system

ushbutton to contro# the sto! o the system

 orma##y o!en contacts

 orma##y c#ose contacts

oi#s

The connectin& o !neumatic circuit the connectin& o !neumatic circuit

onnect each out!ut !art o each directiona# va#ve to the thrott#e va#ve. onnect each

thrott#e va#ve to each cy#inder so that the !ort o the directiona# va#ve that is connected

to the !ressure source is connected to a !art that is res!onsib#e or retractin& the !iston

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throu&h the thrott#e va#ve whi#e the other !ort directiona# va#ve connected to the

ehausted or movin& the !ressure out is connected to the cy#inder throu&h another 

thrott#e va#ve. The in!ut !ort o each directiona# va#ve which is res!onsib#e o retractin&

the !iston connected to the com!ressor. The !ort o directiona# va#ve+ which is

res!onsib#e o movin& out the !ressure rom the other side o !iston+ connected to the

ehaust. The com!ressor is connected to the !ressure source

9/1/9/ Rea'

An associated conce!t with re#ays is the norma##y o!en and norma##y c#osed contacts .

 A

re#ay is an e#ectro ma&netica##y actuated switch. (t is a sim!#e e#ectrica# device used or 

si&na# !rocessin&. 7e#ays a#so !ossess inter#oc'in& ca!abi#ity that is an im!ortant saety

eature in contro# circuits. (nter#oc'in& avoids simu#taneous switchin& o certain coi#s .

9/1/9/1/ T'(es "# $"n!a$!s

The name o the contact comes o its natura# 4norma# !hysica# state when the re#ayLs

oi# is not actuated. As #on& as the coi# o the re#ay is not activated 4no current is #owin&

throu&h it+ then the s!rin& orce wi## 'ee! the contacts in their !ositions. ,nce the coi# is

activated 4ener&i3ed the contacts wi## chan&e their !hysica# stat. Thus the norma##y o!en

contact wi## become c#osed and the norma##y c#osed contact wi## become ,!en. As we said

above+ the in!uts can be e#ectrica# !ush buttons or !roimity switches. roimity switches

can be: inductive+ and ca!acitive.

9/1/9/5/ O@e%"ad %ea's

,ver#oad re#ays are !rovided to !rotect motors+ motor contro# a!!aratus and Motor?branch

circuit conductors a&ainst ecessive heatin& due to motor over#oads and ai#ure to start.

9/1/7/ Sens"%s

(nductive sensor use currents induced by ma&netic ie#d to detect the nearby meta# ob"ects.

The inductive sensor uses a coi# or inductor to &enerate a hi&h reEuency ma&netic ie#d. ( 

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there is a meta# ob"ect near the chan&in& ma&netic ie#d+ current wi## #ow in the ob"ect.

This resu#tin& current #ow sets u! a new ma&netic ie#d that o!!oses the ori&ina# ma&netic

ie#d. The net eect is that it chan&es the inductance o the coi# in the inductive sensor. -y

measurin& the inductance the sensor can determine when a meta# have been brou&ht

nearby. These sensors wi## detect any meta#s+ when detectin& mu#ti!#e ty!es o meta#

mu#ti!#e sensors are used. The sensors can detect ob"ects a ew centimeters away rom the

end. The switchin& distance o inductive sensors de!ends on the conductivity and

 !ermeabi#ity o the meta# !art whose !resence or absence to be detected. a!acitive

 !roimity sensors are simi#ar to inductive !roimity sensors.

9/1/7/1/ P%"imi!' sens"%s

The !roimity sensor reacts to the !resence o ob"ects disturbin& the ma&netic ie#d emitted

 by the sensor. #aced a&ainst an a#uminum cy#inder+ it reacts to the !assa&e o the stee# rod.

The switch is then c#osed and an e#ectrica# si&na# activates the com!onent rom the

e#ectrica# dia&ram associated with this sensor.

The !roimity sensors can be used or various a!!#ications+ these inc#ude:

Sensin& o end !osition o #inear actuators #i'e cy#inders and semi rotary

actuators .(nductive roimity Sensors detect meta# ob"ects without touchin& them.

9/1/7/5/ Ad@an!ages "# (%"imi!' sens"%s a%e

They are se#?contained+ ru&&ed and etreme#y re#iab#e

They have #on& service #ie

They have shorter switchin& time

They are suitab#e or detectin& nonmeta##ic ob"ects

9/1/7/9/ Disad@an!ages "# (%"imi!' sens"%s a%e

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T+e' $ann"! *e used in en@i%"nmen!s sub"ected to ma&netic ie#ds 4 #i'e resistance

we#din& machine

They are sensitive es!ecia##y in humid environment

/ithout the com!ensator rin&+ the sensor wou#d be very sensitive to dirt+ oi#

and other contaminants that mi&ht stic' to the sensor 

9/1/=/ Pus+ *u!!"n s-i!$+es

A !ush button is a switch used to c#ose or o!en an e#ectric contro# circuit. They are

 !rimari#y used or startin& and sto!!in& o o!eration o machinery. They a#so !rovide

manua# override when the emer&ency arises. ush button switches are actuated by !ushin&

the actuator into the housin&. This causes set o contacts to o!en or c#ose.

The contact o the !ush buttons+ distin&uished accordin& to their unctions+

i orma##y o!en 4, ty!e

ii orma##y c#osed 4 ty!e

9/1/6 S"en"ids

6#ectrica##y actuated directiona# contro# va#ves orm the interace between the two !arts o 

an e#ectro?!neumatic contro#. The most im!ortant tas's o e#ectrica##y actuated %>s

inc#ude.

i Switchin& su!!#y air on or o

ii 6tension and retraction o cy#inder drives

6#ectrica##y actuated directiona# contro# va#ves are switched with the aid o so#enoids. They

can be divided into two &rou!s:

i S!rin& return va#ves on#y remain in the actuated !osition as #on& as current

#ows throu&h the so#enoid

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ii ii %oub#e so#enoid va#ves retain the #ast switched !osition even when no

current #ows throu&h the so#enoid.

9/5 METHODS

The desi&n+ the deve#o!ment and inte&ration and simu#ation are the methods used. The

o##owin& sections !resent each o these in detai#.

9/5/1 T+e design

The bui#din& b#oc's o the desi&n are com!osed o the motor?driven conveyor+ the #inear 

 !neumatic eeder cy#inders+ materia#s detection sensors+ the stac'in& conirmation sensors+

the = in!ut?out!ut interacin&+ and the systemKs motion seEuence dia&ram. The

conveyor system uti#i3es a three?!hase motor !rime mover as shown in Figu%e 9/1 which

has a unidirectiona# rotation as the conveyor be#t on#y rotates in orward direction to

transer materia#s into the stac'in& and sortin& stora&e area. The motor is contro##ed

throu&h an eterna# re#ay contacts 40 in which its corres!ondin& coi# is interaced into the

= in!utDout!ut modu#es.

Figu%e 9/5: The motor?driven conveyor 

The #inear !neumatic eeder actuators

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The materia#s transerred throu&h the conveyor be#t are a!!ro!riate#y sorted by the #inear 

 !neumatic cy#inders shown in Figu%e 9/5 so !ositioned in such a way that the materia#s are

stac'ed in the desired stora&e area unti# it is u##y #oaded into it. The actuation o each

cy#inder de!ends u!on the incomin& materia# detection usin& !roimity sensors S8 and S.

Figu%e 9/9: The #inear eeder actuators

The materia#s detection

The materia#s detection is simu#ated by usin& two sine?actin& cy#inders and a !air o 

 !roimity sensors to demonstrate the transer materia#s?detection. As shown in Figu%e 9/9+

every actuation o the cy#inders re!resents one sine materia# detection by the !roimity

sensors S8 and S res!ective#y. /hen the rod?end o the cy#inders is detected by the sensor+

a conseEuent activation o the eeder cy#inder ta'es !#ace. The two #inear cy#inder rod?ends

re!resent the materia#s traversin& on to! o the conveyor be#t as it !asses in !roimity to the

eeder actuators 1 and 2.

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Figu%e 9/7: The materia#s detection re!resentation

The stora&eDstac'in& area

The stora&e area is com!osed o two tandem stac'in& #ane attached with two corres!ondin&

 !roimity sensors S< and S@ as conirmation o a u##y?stac'ed status as shown in Figu%e

9/=. These sensors serve as tri&&erin& switch that !rom!ts the eeder actuators to cease

stora&e on the !articu#ar stora&e #ane.

Figu%e 9/=: The

stora&eDstac'in& area

The in!ut?out!ut devices?=

interacin&

A## the in!ut and out!ut devices o the system are a!!ro!riate#y connected into the =

in!utDout!ut 4(D, modu#es as shown in Figu%e 9/ 6.

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Figu%e 9/6: The in!ut?out!ut devices F = interace

Ta*e 9/1 de!icts the com!#ete detai#ed descri!tion o the (D, devices uti#i3ed in the

system.

in!ut device out!ut device

S0 F Start -utton 0 F Motor contactor  

S1 F Sto! -utton 1 F *eedercy#inder1

S2 F roimity Sensor 2 F *eedercy#inder2

S F roimity Sensor 

S; F roimity Sensor 

S5 F roimity Sensor 

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9/5/5 T+e de@e"(men! and in!eg%a!i"n

The bui#din& b#oc's o the desi&n are inte&rated to orm the who#e systemKs ramewor' as

shown in Figu%e 9/6. The aorementioned i&ure de!icts the inte&ration o the sub? systems

o the who#e ramewor' which consists o the conveyor system+ eedin& actuators+ stora&e+

and materia# detects.

Figu%e 9/

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(

8

(

8

(

8

(

8

(2(

0

O

1

O

1

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1

O

1

?

1

O

1

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1

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1

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(

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Ta*e 9/9: The continuation motion seEuence

(2( ( ( (

2O 2? 2O 2? 2O 2

?

2?D0?D7 

ST

(5 (5 (

5

(@

The = #adder !ro&ram uti#i3es a scientiic method o !ro&rammin& a!!roach.

There are scientiic ste!s that are o##owed in the = #adder !ro&rammin& which adheres

to the !revai#in& (nternationa# 6#ectro technica# ommission 4(6 standard (6 111+ to

wit:

1. 6ach contro# ste!s sha## be re!resented by a uniEue re#ay address and shou#d be se#?

#atched.

2. The irst ste! o the seEuence sha## bear the startu! button connected in series with a

norma##y c#osed inter#oc'in& contact. This ste! shou#d be re!resented by a uniEue re#ay

address and se#?#atched.

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. The !roceedin& contro# ste!s sha## bear the tri&&erin& switchesDsensors connected in

series with a ste! mar'er 4the norma##y o!en contact address o the !revious ste! re#ay

re!resentation address. These !roceedin& ste!s shou#d sti## be re!resented by re#ays and

se#?#atched.

;. The #ast ste! o the contro# circuit which is the 7ST sha## a#so be re!resented by a re#ay

 but may not be se#?#atched. The contact o the re#ay re!resentin& the 7ST sha## be the

address used in the inter#oc'in& contact mentioned in the irst ste! o the contro# circuit.

5. The !ower circuit sha## bear the a!!ro!riate contro# ste! re!resentations o out!ut

com!onent activation and deactivation. Say 0O re!resented by a norma##y o!en contact

sha## be connected to a norma##y c#osed contact o the 0? ste!. This series combination o 

norma##y o!en 4, and norma##y c#osed 4 contacts sha## be connected to the out!ut

com!onent 4so#enoid coi#. The same treatment to the other out!ut com!onents activation

and %6?activation.

-ased on the above mentioned scientiic &uide#ines and the sti!u#ated motion seEuence+ the

o##owin& = #adder !ro&ram shown in Figu%e 9/8and Figu%e 9/>

 

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Figu%e 9/: contro# circuit #adder dia&ram #igu%e9/> !ower circuit #adder dia&ram

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CHAPTER FOUR 

7/ RESULTS AND DISCUSSIONS

(n this cha!ter the resu#ts o the desi&n o Automatic sortin& and stac'in& system is

 !resented .the desi&n o Automatic sortin& and stac'in& system+ which used to arran&in&

and storin& the !roduced !roducts with a short !eriod o time and its advanta&eous to the

manuacturin& industry . As mentioned in eeri#y and anthi## at this time the manuacturin&

industry is !rocessed by o!erators .this mated is time #osin& and in eiciency. The resu#ts

o the investi&ation wi## be !resented in the o##owin& !ara&ra!hs.

7/1/ Resu!s and Dis$ussi"ns

The month#y avera&e and the year#y avera&e !roducts o the manuacturin& industry

system by usin& human #abor orce !roduct #oss+ to&ether with other re#ated data such as+

time consum!tionH !roduct #oss due to the absence o modern automatic sortin& and

stac'in& systemH etc. by considerin& the disadvanta&eous o the above mentioned !rob#em.

/e desi&n the best automatic sortin& and stac'in& system that can arran&in& and storin&

within short !eriod o time. The in!ut that was ed into the = sotware is !revious#y

mentioned.

Tab#e ;.1: The motion seEuence dia&ram

(

8

(

8

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8

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8

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24

I2#I!

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(2( ( ( (

2O 2? 2O 2? 2O 2? 2O 2?

0?

7ST(5 (5 (5 (5

The out!ut o the !ro"ect shown be#ow

Figu%e 7/1: The sortin& and stac'in& system ramewor'D the in!ut?out!ut devices F =

interaceD the materia#s detection re!resentation o out!ut resu#ts.

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Figu%e 7/5: The contro# circuit = #adder !ro&ram out!ut resu#t

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Figu%e 7/9 The !ower circuit = #adder dia&ram !ro&ram out!ut resu#t

The &enera# o!eration o the above system can be described as o##ows:

The in!ut com!onents are !ush button 4norma# c#osed and norma##y o!en that are used to

start and sto! the tota# system .That means when we !ress S0 !ush button S1 is norma##y

c#osed then due to the current #ow rom !ower source to motor thereore+ M0 wi## ener&i3e+

c#osin& the norma##y?o!en aui#iary contact in !ara##e# with that switch.

M0 is !ermanent#y ener&i3ed. -ecause o M0 is ener&i3ed then out!ut re#ay M1 is a#soener&i3ed when M0 is ener&i3ed motors 40O rotate continuous#y at the same time the

cover be#ts contro# 40 can start to o!erate.

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,n the other hand due to the M1 ener&i3ed. At the same time M2 a#so ener&i3ed due to the

sensor 4S+ S is now cy#inders 1 41O etended orward. At the same time sensor 4s2

ener&i3ed+ s2 is now cy#inder 1 41? etended bac'ward. Then the system continua##y

wor's unti# our times the cy#inder 141O and 1? etended orwardDbac' ward. Ater that

sensor4S

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CHAPTER FIVE

=/ CONCLUSIONS2 RECOMMENDATION AND FUTURE .ORK 

=/1 C"n$usi"n

This !ro"ect discussed about the way o automatic sortin& and stac'in& system which

inc#udes induction motor+ cover+ stac'er 4stora&e+ other e#ectro !neumatic com!onents and

mechanica# !arts and its !rinci!#e o!erations.

This way o automatic sortin& and stac'in& system is su!!osed to increase the !roductivity

o sot drin'in& !roducts in manuacturin& industry. The merchant a#so it is better to use

this system and they can e!ort &ood Eua#ity sot drin'in& !roducts to #oca# customers and

oba# mar'ets. The sot drin'in& !roduct system is very essentia# or hote#s+ restaurants+

commits and a## over the country area. Main#y this automatic sortin& and stac'in& system

have a &reat or the Eua#ity !roductivity o our country industria# !rocess.

Genera##y this way o automatic sortin& and stac'in& system is very im!ortant to &et Eua#ity

 !roduct in industria# !roductsH thereore it increases the annua# amount o sot drin' 

 !roducts in our country.

=/5 Re$"mmenda!i"ns

The o##owin& recommendations are made rom this !ro"ect:?

6ven i there is shorta&e o e#ectrica# !ower to use this automatic sortin& and stac'in&

system techno#o&y in industria# city !arts o 6thio!ia. (t is !ossib#e to use so#ar ener&y

source and wind ener&y source but most o the manuacturin& industry may not use this

system because o #ac' o e#ectrica# ener&y thereore the &overnment and !rivate sectors

shou#d eert their combined eort to overcome these cha##en&es and e#ectriy

manuacturin& industry areas. This automatic sortin& and stac'in& system or the se#ected

site can be im!#emented i the materia#s are avai#ab#e. *or industria# area communities that

have not enou&h e#ectricity or other industria# !#aces which are ar rom the &rid system it

is better to use so#ar !ane# and wind ener&y source.

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(n order to so#ve the absence o e#ectrica# ener&y in industria# area+ -ecause o the hi&h cost

o day to day diese# !rice. Thereore it is advisab#e to use the so#ar ener&y and wind ener&y.

=/9/ Fu!u%e ."%&s

The uture wor's o the automatic sortin& and stac'in& system are:

This automatic sortin& and stac'in& system wor's on#y 8 sot drin'in& !roducts at the same

time with one #abor as o!erates because o this in uture increasin& the detector circuit+

increase number o doub#e actin& cy#inder+ increasin& the contro# circuit+ !owercircuit and

number o directiona# va#ve to increasin& the number o sot drin'in& !roducts at the same

times with one

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9niversity o -o#o&na+ am!us o *or#P+ 1?;2;;?12

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