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ET 472 – Integrated Control Systems
Final Project
Control and Monitoring of a Conveyor Belt Using a PLC and LabVIEW
Due Date:
Final draft to instructor – Friday, May 2, 5:00pm.
Purpose:
The purpose of this laboratory is to allow students to plan and implement PLCbased control and LabVIEW-based monitoring of a multistage conveyor-belt
system similar to the one considered in Lab 2.
Objectives:
After completing this laboratory exercise, the student should be able to perform
the following:
1. Plan and implement control of a PLC system requiring use of concepts
learned in class including: input/output control, conditional latches, part
tracking with shift registers, delay timing, counters, math functions and
stepper motor control.
2. Plan and implement a front panel and block diagram for monitoring and
reporting of system data in a LabVIEW virtual instrument including numerical
and Boolean indicators, graphing, and data logging.
3. Work collaboratively in a multidisciplinary team.
4. Write a formal report of sufficient clarity and detail to allow fellow engineers
to understand, follow and recreate the work.
Key Terms:
Define new terms as needed.
System Requirements:
As in lab 2:
The system is activated by depressing the start switch which turns on the
conveyor motor. Parts are equally spaced by a locating fixture on the conveyor.
Parts entering the system at Zone 1 one are inspected as good (short) or bad
(tall) using an laser sensor. A counter keeps track of the total number of parts
inspected. A second counter keeps track of the number of good parts.
As the parts are processed, a second laser sensor between Zones 1 and 2
detects the transition of parts between zones. This sensor is also used to shift
the status of the part at Zone 1 into a shift register (0 = bad, 1 = good).
A third optical sensor at Zone 2 detects whether parts on the conveyor are in
position in their respective zones. If a good part is detected in Zone 1, it is
processed at each successive zone.
If a bad part is detected, processing is suspended for that part as it is tracked to
Zone 5. At Zone 5, bad parts are diverted from the conveyor and good parts
continue to processes beyond the scope of this control program. A counter
keeps track of bad parts diverted in this manner.
Processing at each zone is conducted as described below.
1. Activate the system when the start switch is depressed.
2. Detect good or bad parts at Zone 1.
3. Count the number of good parts entering the process at Zone 1.
4. Count the total number of parts entering the system at Zone 1.
5. Detect “in position” at Zone 2.
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6. Activate a cleaning mechanism at Zone 2 if a good part is present.
7. Activate a spray nozzle solenoid at Zone 3 if a good part is present.
8. Activate a heating element at Zone 4 if a good part is present.
9. Divert bad parts off of the conveyor belt by activating a solenoid diverter at
Zone 5 if a bad part is present.
10. Count the number of bad parts diverted at Zone 5.
11. Display the state of all system stations on the front panel of a well-design,
user-friendly front panel. Also include:
• Numerical or graphical displays of good/bad parts received and
discarded.
• Average production data taking into account the speed of the belt.
• Other data as would be useful to a human operator.
12. Log production data to an Excel spreadsheet.
13. Shut down the system anytime the stop switch is pressed. This should clear
the shift register.
Procedure:
1.
Specifically define all requirements of the system.
2.
Use the logical addresses shown in the table below for inputs and outputs to your system.
I/O
PLC
Address
Input
Start
I0.0
Input
Stop
I0.1
Input
Good Part Sensor
I0.2
Input
Bad Part Sensor
I0.3
Input
Zone Transition Sensor
I0.4
Input
Output
DAQ
Description
In Position Sensor
Stepper Motor Control
I0.5
Q0.0-3
Output
Clean Station ON
Q0.4
Output
Spray Station ON
Q0.5
Output
Heat Station ON
Q0.6
Output
Conveyor Motor
Q0.7
Good Part Sensor
P0.0
Input
Input
Bad Part Sensor
P0.1
Input
Zone Transition Sensor
P0.2
Input
In Position Sensor
P0.3
Input
Clean Station ON
P0.4
Input
Spray Station ON
P0.5
Input
Heat Station ON
P0.6
Input
Diverting Station ON
P0.7
3.
Using the MicroWin software, build upon your work from lab 2 to satisfy all system
requirements in light of the new system configuration.
4.
Using LabVIEW, design a monitoring program and front panel that shows the current state
of the conveyor belt system including:
• The running/idle states of each station.
• The numbers of good/bad parts received.
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•
•
Average production data taking into account belt speed.
Other data as would be useful to a human operator.
5.
After verifying that your system works as expected in a simulated (toggle-switched PLC)
environment, download your program to the system fixture. Verify that your program meets
all requirements.
6.
Demonstrate the execution of your program to your instructor and have it approved (the
instructor will sign your program verification sheet). Attach this sheet to your written report.
7.
Using the posted format, write a technical lab report including required documentation.
8.
Submit your written report by the due date.