Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
Integration And Automation Of Systems For
Product Identification And Segregation
Karamchedu Spandan Harithas1, Naregalkar Akshay2 , Vajanepalli Pavan Kumar3,
Gade Venkata Sai Aasish4, Akula Mounika5
1-4
Department of EIE, CVR College of Engineering, Ibrahimpatnam, R.R. Dist. – 501510 (India)
5
Department of ECE, Sri Indu College of Engineering and Technology, Ibrahimpatnam, R.R. Dist. – 501510 (India)
ABSTRACT
In this paper an automated segregated system using integrated PLC (programmable logic controller), OPC Server and National
Instruments LabVIEW technologies is proposed. The main objective of this paper is to verify different products manufactured
using the barcodes and compare the process barcodes on products with the reference barcode for identification and segregation
based on edge detection technique. This paper proposes an idea which overcomes that difficulty of using different technologies
from different vendors by introducing the integration of different technologies to monitor and control the industrial
parameters. This paper not only monitors and controls the Industrial parameters but also helps in efficient product handling
manufactured in the industries using different technologies. This paper is implemented by using LabVIEW2011 software for
control logic implementation , Allen Bradley SLC -500 PLC for interfacing sensors and actuators of system , Vision Assistant
for image processing and RSLinx OPC Server for PLC – LabVIEW communication.
Keywords: Barcode; Edge Detection; LabVIEW; OPC Server; PLC; Vision Assistant.
1. INTRODUCTION
In today’s fast moving, highly competitive industrial world, a company must be flexible, cost effective and efficient if it
wishes to survive. In Process and Manufacturing Industries, this has resulted a great demand for industrial automation
in order to stream-line operations in terms of speed, reliability and product output. Industries involve many products to
be manufactured and should be divided into different workstations which are very difficult to perform manually. In
order to overcome the difficulty, the automatic process has to be achieved [1], [2], [3]. This project aims at designing a
automated process for product identification and segregation. Identification of the product is done using the barcode
present on the product and segregation of the product is done using Edge detection technique. The Image is acquired
using an image acquisition device and the Image Processing Techniques are used to get the barcode of the object and
the dimensions of the object. After the suitable information is extracted using image processing techniques, the
mechanical systems such as Piston Actuators, Pinion and Gear Arrangement, Robotic arms which responds to the edge
detection technique are used and the segregation is done.
1.1. Problem Formulation
In a typical industry, a product is processed in different workstations. The basic means to transport them from one
workstation to the other is by implementing conveyor belts. In certain cases the product though produced using the
same raw materials are segregated to different units where they may undergo enhancements depending on the final
specification.
1.2. Solution to the Problem
This segregation of interim products into different workstations is the aim of this project. This prototype is basically
developed to customize the things automatically so that they can reduce the man-power and time. Segregation is done
by considering the properties of the object such as dimensions, colour, weight, barcode etc. Among all the properties of
the object, this prototype uses the barcode of the object and the dimensions of the object for the Segregation purpose.
The Image is acquired using a image acquisition device and the Image Processing Techniques are used to get the
barcode of the object and the dimensions of the object. After the suitable information is extracted using image
processing techniques, the mechanical systems such as Piston Actuators, Pinion and Gear Arrangement, Robotic arms
and the segregation is done.
2. PROPOSED WORK
The proposed automated system is divided into four sections, Object transportation unit, Barcode Scanning unit, Image
Processing unit and Segregation unit. The Object transportation unit is the Conveyor Belt which is made to run with
the help of DC Motors which are attached to pulleys of the Conveyor Belt. The Barcode Scanning unit compares the
product barcode with the reference barcode. The presence of the product on the belt is known with the help of the
Volume 2, Issue 4, April 2013
Page 381
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
proximity sensor which is connected to PLC [4]. After the presence is detected the image of the product barcode is
obtained using a camera. The acquired image is processed LabVIEW to extract the information of the barcode and
compare the extracted information of the product barcode with the reference barcode. All the matched barcode products
are passed on to the next stage for segregation based on edge detection. In the Segregation Unit, a camera is used to
acquire the image of the product and the image is fed as an input to LabVIEW for the processing of the image to know
the information of edges. Depending on the distance between the edges of the product, the product is segregated as
small product or the large product. The Segregation unit is connected to PLC. The communication between LabVIEW
and PLC is achieved using RS Linx OPC Server [5], [6].
Figure 1. Architecture of Automated System
3. IMPLEMENTATION
The supply to the system is 230V AC, the Computer and PLC takes 230V for their operation. The other equipments
such as sensors, Rack and Pinion System work on 24V DC. Hence a Voltage Regulator is used to convert 230V AC to
24V DC supplying to field equipments. The PLC is the Central device to which the Rack and Pinion System, Proximity
sensor are connected to the input and output ports. The PLC is made to communicate with the Computer containing
LabVIEW with the help of RS Linx OPC Server.
Figure2. Block Diagram of Automated System
The Barcode Scanner is the camera which is used to capture the image of the product barcode. The image from the
camera is processed for reading the barcode using the tool called “Barcode Reader” in LabVIEW and the information of
the product barcode is obtained. The obtained barcode is given to the comparator for the comparison of the product
barcode with the reference barcode. If the product barcode is matched with the reference barcode the product is passed
to the segregation unit. In the Segregation unit, a camera is used to obtain the image of the product and the acquired
image is processed using a tool called “Edge Detection” tool in LabVIEW and the distance between the first and last
edges of the product is obtained. The information of distance between the edges of the product is used to segregate the
product into the large product or small product. The segregation into large and small products is done using a
segregation system, Rack and Pinion System. There are two such systems used each for small and large products.
Depending on the distance between the edges of the product the corresponding Rack and Pinion System is driven which
is connected to PLC.
4. COMMUNICATION BETWEEN LabVIEW and PLC
The Rack and Pinion System which is used for segregation of products into small and large products and the proximity
sensor which is used to detect the presence of the object are connected to PLC. The barcode comparison and edge
detection is done using LabVIEW. So there should be a communication between PLC and LabVIEW. The
communication between PLC and LabVIEW is established with the help of an I/O Server called RS Linx OPC Server.
OPC stands for OLE for Process Control. Using RS Linx OPC Server the input ports and output ports of the PLC are
invoked as shared variables into LabVIEW and are controlled and driven using LabVIEW Program.
Volume 2, Issue 4, April 2013
Page 382
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
Figure3. Process Flow of the system
5. SIMULATED RESULTS
Here LabVIEW is not only used HMI but also to simulate the entire process. The Process is simulated such that the
barcode obtained is shown using a variable called ‘string’, the distance between the edges of the product is shown using
a variable called ‘Numeric’ and function of the rack and pinion system corresponding to distance between the edges of
the product is shown using an LED.
5.1. Reading a Barcode
The Vision Acquisition Block is responsible for acquiring the image of the product which is present on the conveyor
Belt. The output of the Vision Acquisition Block is the image of the barcode of the product. The output of Vision
Acquisition is fed as input to the Vision Assistant which is responsible for Image Processing. The Vision Assistant
block takes the image from the Vision Acquisition Block and checks for the barcode. The information which is
obtained from the barcode is given as output of the Vision Assistant Block which the required Barcode in the form of
the String. The output from the Vision Assistant Block i.e. the information of the Barcode obtained is compared with
the reference barcode with the help of the comparator. If the obtained barcode matches with the reference barcode, only
then the product is sent for the processing of Edge Detection, otherwise the product is rejected.
Figure 4. Block Diagram for reading the barcode VI
Volume 2, Issue 4, April 2013
Page 383
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
Figure 5. Front Panel of Reading the Barcode VI
Reference Barcode: 0 to 1000
Barcode Read: 100
5.2. Edge Detection
The Image of the object is acquired with the help of the camera and Vision Acquisition Block is responsible for
acquiring the image of the product with the help of the camera. The output of Vision Acquisition Block is the image of
the product on the conveyor Belt. That image is fed as input to the Vision Assistant Block which is responsible for the
Detection of First and Last edges of the product. The Vision Assistant Block scans the edges from the image fed into it
and calculates the distance between the edges. The output of Vision Assistant Block is the information of the edges of
the product. Depending upon the output of Vision Assistant Block i.e. the distance between the edges, the products are
segregated into Small and Large Products i.e. the segregation is done with respect to size with the help of Mechanical
Plungers.
Table 1: Edge Detection Results
Distance Between
Small
Medium
Large
the Edges (cm)
Plunger
Plunger
Plunger
0-3
On
Off
Off
3-6
Off
On
Off
> 6
Off
Off
On
5.3. Segregation with respect to size
The information of the edges i.e. the distance between the edges is given to comparators and depending upon the
outputs of the comparators the corresponding plunger will be switched on and the object is pushed aside from the
Conveyor Belt.
Figure 6. Plunger Programming Block Diagram
Volume 2, Issue 4, April 2013
Page 384
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
6. RESULTS
6.1. Barcode Detection
Table2 Results of Barcode Comparison
Reference Barcode
Barcode Read
Result
0 to 1000
103
Barcode Matched and product forwarded to Edge
detection unit
0 to 1000
10003
Barcode Does not Match and product is rejected.
0 to 1000
5745
Barcode Does not Match and product is rejected.
0 to 1000
782
Barcode Matched and product forwarded to Edge
detection unit
0 to 1000
950
Barcode Matched and product forwarded to Edge
detection unit
0 to 1000
1008
Barcode Does not Match and product is rejected.
6.2. Edge Detection
Table3 Results of Edge Detection
Distance Between the First and
Type of Plunger Switched On
Last Edges of Product
1 cm
Plunger Corresponding to Small Size Objects is Switched on
3 cm
Plunger Corresponding to Small Size Objects is Switched on
4 cm
Plunger Corresponding to Medium Size Objects is Switched on
6 cm
Plunger Corresponding to Medium Size Objects is Switched on
7 cm
Plunger Corresponding to Large Size Objects is Switched on
9 cm
Plunger Corresponding to Large Size Objects is Switched on
7. CONCLUSION
This Project of Integrating two most powerful technologies ruling the industries lead to many new features like
acquiring data at faster rate, controlling the industrial parameters accurately and several other features. It is very
difficult to perform Image Processing with the help of PLC where as LabVIEW has good Image Processing Techniques.
In Contrast the Load driving capacity of LabVIEW is very low when compared with the load driving capacity of PLC.
Hence in order to achieve an efficient industrial process, LabVIEW is integrated with the PLC and efficient control of
Industrial Parameters is achieved.
REFERENCES
[1.] Lakshmi, A., “Experimental validation of PID based cascade control system through SCADA-PLC-OPC
interface”, India Computer Communication and Informatics (ICCCI), 2012 International Conference on pp. 1 –
4.
[2.] Jacob, M. “Real-time hardware-in-the-loop test platform for thermal power plant control systems”, Intelligent
Systems and Informatics (SISY), 2011 IEEE 9th International Symposium on, pp. 495 – 500..
[3.] Padhee. S and Singh.Y, “Data Logging and Supervisory Control of Process Using LabVIEW”, Students
Technology Symposium, IEEE 2011.
[4.] S. Aleksandrov, S. Cajetinac, Z. Jovanovic, "Internet access to PLC with integrated web server", Proceedings of the
11th International Conference Research and Development in Mechanical Industry, RaDMI 2011,September, 15.-18
,2011, Sokobanja, Serbia, pp.425- 430.
Volume 2, Issue 4, April 2013
Page 385
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
Volume 2, Issue 4, April 2013
ISSN 2319 - 4847
[5.] Kai Zhou, Xudong Wang, Chao Zhang and Jian Liu, “Data Acquisition System Based on LabVIEW ABS Dynamic
Simulation Test Stand ”, International Conference on Information and Automation, IEEE 2010.
[6.] Wenge Li, Zhenmei Li, Wei Liu, Peiyu Wei and Yayang Bur, “Remote Monitoring and Analysis System of Min
Safety Based on Virtual Instrument”, International Conference on Test and Measurement, IEEE 2009.
Volume 2, Issue 4, April 2013
Page 386