IJCAT - International Journal of Computing and Technology

Volume 1, Issue 1, February 2014

www.IJCAT.org

1

Ropeway Conveyor and Unloading System using PLC
1
Ambily Francis,
2
Muhammad Hassan Anas KT ,
3
Ratheesh KP,
4
Vishnu G Nair

1
AP Dept.AEI, Calicut University,JECC Thrissur, Thrissur, Kerala, India

2, 3, 4
UG Scholar Dept.AEI, Calicut University, JECC Thrissur, Thrissur, Kerala, India




Abstract - In this paper the aim is to make a complete
ropeway conveyor and unloading system setup for long and
non linear transportation of materials using PLC
environment. The system is used for the transportation of raw
materials from the mines place to the production place. Since it
is difficult to transfer it through road, a rope way system is used.
The raw materials from the plant is brought through ropeway
and given to a vibrator system. From here, through conveyor it
goes to the production place. All controls are being taken place
in mines.

Keywords Bicab Ropeway, Saysaw sensor, Proximity
sensors, Load cell, Areal Ropeway.

1. Introduction

The system consists of timers, driving motors,
buckets ,counter , unloader ,conveyor,tacho and load cell.
Materials for the plants are obtained from mines which
are 8-12 Km away from plant. Path will be complicated
because of mountains. Rope cannot be connected like
simple ended connection. Directors are used to change
the path of rope way. Rope contains about 190 identical
buckets. Fixed distance should be maintained between
buckets with the use of timer in gate part of conveyor
system.Only one bucket should be filled at a time.
Another timer at the filling section will do this task. Fixed
amount should be filled in bucket, which is also
controlled by timer. The return ropeway should extend up
to the vibrator of hopper system.

High availability of rope ways, industrial plans choose
rope way. By determining the capacity of the plant
and requirement we can change the rope way design.
Market requires a great variety of types of ropeways
with numerous equipment options. There is a
considerable potential in the development of ropeways
that is not exhausted and is more likely to increase with
industrial modification. The model of rope way may be
mono or bi cable. Stations (drive tensioning device), The
central unit of rope way is the rope system: Track and


carrying rope with the units in contact with it such
as stations, towers & buckets. There will be a variable
friction contact points between rope & support or buckets.
Kernel of the program is provided with automated
input & transfers riding data to drive program. The
additional use of graphical user interfaces makes the
operation even easier. And provided better error
protection & guarantees simple data maintenance on the
other.

The simulation program used to analyze the effect of
friction between: Track rope, tower saddle of bicable
ropeway. The frictional resistance disturbs the
balancing of rope lengths between the span, leads to
an increase in the rope tension. Operations in
summer with well lubricated rope Normal ambient
temperatures produces lower frictional resistance than
operations in winter. Advantages are simple and brief
explained overview. Any apparatus for the overhead
transport of passengers or goods in carriers running
along or drawn by overhead cables supported by towers,
pylons or other similar structures, together with any
machinery, equipment or plant connected therewith.
Every part of an aerial ropeway system and its
associated equipment shall be designed with
consideration given to the safety of the passengers;
general public and operating staff, and shall be
designed in compliance with this Code of Practice.
When planning the location and route of an aerial
ropeway the following factors must be carefully
considered. An aerial ropeway including any future
extension shall be routed so that its effect on the
environment is minimal. The paper discusses in detail
about the legal and other considerations. Advantages
are exact description on planning, legal req. and design
steps.

Rules for the Construction of Installations depends on
Layout and Freeway, Maximum Speed ( For attended
cabins: 12 m/s in line and 7.5 m/s over trestles. For
IJCAT - International Journal of Computing and Technology
Volume 1, Issue 1, February 2014
www.IJCAT.org

2

unattended cabin 7 m/s in long spans Vehicles and 6
m/s over trestles.), Capacity of Vehicles, Rope
Guiding, Rescue of Passengers along the Line
Crossings, Dangerous areas, Wind action, Wire ropes,
Splices and rope termination, Testing and acceptance of
ropes, Replacement of ropes, Stations and Driving and
braking.

2. Block Diagram




Fig. 1 Block diagram

1. Rope: Main path.
2. Chain: Bucket is transferred to chain from rope
for unloading.
3. Px-1: Proximity sensor. Senses entry of bucket.
4. Gate timer: Maintains spacing between buckets.
Unload one bucket at a time for filling.
5. Px-2: Proximity sensor. Senses departure of
bucket.
6. Brake: Slows down the bucket.
7. Brake at gate: Holds bucket during spacing.
8. Hopper: A vibrator, for proper conditioning of
materials for transferring through conveyor.
9. Drive: Motors are used for driving rope, chain,
hopper, conveyor and compressor.

The bucket from the rope is dispatched to chain.
Two proximity sensors are used in the chain. One is
for entry sensing and the next is for departure
sensing. As entry sensor senses a value (high) a counter
is set to a predefined value (44). The break is applied on
the bucket till the count reaches zero which is
proportional to the definite distance between two
buckets. All units are driven by motors.
3. Flow Chart





Fig. 2 Flow chart

Each unit should be turned ON in a predefined order so
that the complete working is unaffected controversially.
So a timer is used and 10 sec delay will be provided
by the same during the turn ON of each unit. Entry
is sensed by Px-1 and departure is sensed by Px-2. The
turn OFF process is done in the reverse order of turn
ON process

IJCAT - International Journal of Computing and Technology
Volume 1, Issue 1, February 2014
www.IJCAT.org

3


4. Methodology

A programmable logic controller (PLC) or
programmable controller is a digital computer used
or automation of electromechanical process .PLC is used
in many industries and machines. Programs to control
machine operation are typically stored in battery-backed-
up or non-volatile memory. PLCs are used in many
industries and machines. PLC is designed for
multiple inputs and outputs arrangements, extended
temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. Programs to
control machine operation are typically stored in battery-
backed-up or non-volatile memory.

The system consists of timers, two belt drive system,
buckets, belt director system, unloader, conveyor and
bucket filler. Materials for the plants are obtained from
mines which are 8-12 Km away from plant. Path will
be complicated because of mountains. We are providing
up to 65 towers for leading the ropeway. The length of
each tower depends up on the path. Rope cannot be
connected like simple ended connection. Directors are
used to change the path of rope way. A dc motor of 1250
kW is used to run the ropeway. It has a driver capacity
of 1500rpm/hr. But it runs at 140rpm/hr here. Rope
contains about 190 identical bucket containers. Each
bucket has a capacity of one ton. A total of 2000
ton lime stone will be transported per a day. Fixed
distance should be maintained between buckets with
the use of timer. Only one bucket should be filled at a
time. Another timer at the filling section will do this
task. Fixed amount should be filled in bucket,
controlled by timer.

The return ropeway should extend up to the vibrator
of hopper system. The return rope way is passed through
a wheel over a rail along with a counter weight to
stretch the rope. From hear the conveyor system
bring the materials to the production part. We are
using four load cells to measure the weight of the
limes transported. Proximity sensors are used to sense the
speed and running condition of the belt. Belt saysaw
switches are used to sense the misplace of belt and to
control it. The whole process is controlled automatically
by plc software. It is an industrial computer control
system. It continuously monitors the state of input
devices and makes decisions based upon a custom
program.


5. Conclusions

Ropeway is a modest simple and efficient method for long
and nonlinear transportation and it can be simply
implemented using PLC environment. PLC
environment is 100% efficient comparing with old
relay based system.

Acknowledgments

Sincere gratitude to lord almighty. Heartfelt thanks to
our external project guide Mr. Jithesh, AE(I) who
guided us with necessary information and wholehearted
support.

References
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Muenchen, Lehrstuhl fuer Foerderwesen, 1993.


Ambily Francis Completed AMIE in Electronics and communication
engineering in the year 2007. Completed M-Tech in Applied
Electroncs from Karunya university in the year 2010, now working in
Jyothi Engineering college as assistant professor Department of
AEI.

Second Authors Final year students of B-Tech in Applied
Electronics and instrumentation in Jyothi Engineering college
cheruthuruthy, Thrissur